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ANSI H35.

2-2003
Revision of H35.2-2001

American National Standard Dimensional


Tolerances for Aluminum Mill Products

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Secretariat

The Aluminum Association, Inc.


900 19th St., NW
Washington, DC 20006
Approved March 10,2003

American National Standards Institute

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American National Standard
Approval of an American National Standard requires verification by ANSI that the
requirements for due process, consensus, and other criteria for approval have been met by
the standards developer.
Consensus is established when, in the judgment of the ANSI Board of Standards Review,
substantial agreement has been reached by directly and materially affected interests.
Substantial agreement means much more than a simple majority, but not necessarily
unanimity. Consensus requires that all views and objections be considered, and that a
concerted effort be made toward their resolution.
The use of American National Standards is completely voluntary; their existence does not
in any respect preclude anyone, whether he has approved the standards or not, from
manufacturing, marketing, purchasing, or using products, processes, or procedures not
conforming to the standards.
The Amencan National Standards Institute does not develop standards and will under no
circumstances give an interpretation of any American Standard. Moreover, no person shall
have the right or authorityto issue an interpretation of an American National Standard in the
name of the American National Standards Institute. Requests for interpretation should be
addressedto the secretariator sponsorwhose name appears on the title page of this standard.
CAUTION NOTICE: This Amencan National Standard may be revised or withdrawn at
any time. The procedures of the American National Standards Institute require that action
be taken to reaffirm, revise, or withdraw this standard no later than five years from the date
of approval. Purchasers of American National Standards may receive current information
on all standards by calling or writing the American National Standards Institute, 25 West
431d Street, New York, NY 10036.

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Contents
1. Definitions ................................................ 7
2. Standard Limits for Expressing Tolerances ....................... 7
3. Section Intentionally Blank
4. Section Intentionally Blank
5. Section Intentionally Blank
6. Section Intentionally Blank
7. Sheetandplate ............................................. 9
Sheetandplate-Tables 7.7a-7.18 ......................... 10
Special Finished Sheet and Plate Products - Tables 7.26 .7.43 . . . . 14
Commercial Roofing and Siding - Tables 7.26 .7.30 . . . . . . . 14
Duct Sheet - Tables 7.3 1 .7.34 ........................ 15
Tread Sheet and Plate - Tables 7.36 .7.43 . . . . . . . . . . . . . . . 15
8. FinStock ................................................ 17
Fin Stock - Tables 8.2 .8.3 ................................ 17
9. Foil ..................................................... 18
Foil - Tables 9.2 .9.24 ................................... 18
Unmounted Foil - Tables 9.2 .9.8 ..................... 18
Laminated Foil - Tables 9.9 .9.16 ..................... 19
Printed Foil - Tables 9.17 .9.24 ....................... 20
10. Wire, Rod, and Bar - Rolled or Cold Finished . . . . . . . . . . . . . . . . . . . 21
Wire, Rod and Bar - Rolled or Cold-Finished .Tables 10.5 .10.20 21
11. Wire, Rod, Bar and Profiles - Extruded ........................ 24
Wire, Rod, Bar and Profiles - Tables 11.2 .11.14 .............. 24
12. Tube and Pipe ............................................. 31
Tube and Pipe - Tables 12.2 .12.55 ......................... 32
Extruded Tube - Tables 12.2 .12.14 .................... 32
Extruded Coiled Tube - Tables 12.16 .12.18 . . . . . . . . . . . . . 36
Drawn Tube -Tables 12.20 .12.32 .................... 37
Heat Exchanger Tube - Tables 12.34 .12.39 . . . . . . . . . . . . . 40
Welded Tube - Tables 12.41 .12.47 .................... 41
Pipe - Tables 12.49 .12.55 ........................... 43
13. Structural Profiles ......................................... 46
14. Forging Stock ............................................. 47
Forging Stock - Tables 14.1 .14.4 .......................... 47
15. Forgings ................................................. 48
Hand Forgings - Table 15.3 ............................... 48
16. Electrical Conductors ....................................... 49
Electrical Conductors - Tables 16.7 .16.35 . . . . . . . . . . . . . . . . . . . 49
Wire, Rod and Bar - Rolled or Cold Finished .
Tables 16.7 .16.21 ............................ 49
Extruded Electrical Conductor - Tables 16.22 .16.29 . . . . . . 51
Pipe - Tables 16.31 .16.35 ........................... 53

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AMERICAN NATIONAL STANDARDS COMMITTEE H35
ON
ALUMINUM AND ALUMINUM ALLOYS

OFFICERS

L. Bender, Chairman
P. Pollak, Secretary

COMMITTEE MEMBERS

AEROSPACE INDUSTRIES ASSOCIATION OF AMERICA


DAVIDJOHNSON,
Aerospace Industries Association of America, Washington, D.C.

THE ALUMINUM ASSOCIATION


L. BENDER,Spectrulite Consortium, Inc., Madison, IL

ALUMiNUM EXTRUDERS COUNCIL


JO" MURPHY, Indalex Aluminum Solutions, Mountaintop, Pennsylvania

AMERICAN FOUNDRYMEN'S SOCIETY


STEVEROBISON,
American Foundrymen 's Society, Des Plaines, Illinois
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METAL SERVICE CENTER INSTITUTE


JULIES . W E , Metal Service Center Institute, Chicago, Illinois

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION


VINCEBACLAWSKI,
National Electrical ManufacturersAssociation, Rosslyn, Virginia

SOCIETY OF AUTOMOTIVE ENGINEERS INCORPORATED


KERRYTIELSCH,
Society of Automotive Engineers, Inc., Warrendale, Pennsylvania

U.S. DEPARTMENT OF THE AIR FORCE


L. R. GULLEY,US.Air Force, Wright Patterson Air Force Base, Ohio

U.S. DEPARTMENT OF COMMERCE


S . D. RIDDER,National Institute of Standards and Technology, Washington, D.C.

U.S. DEPARTMENT OF THE NAVY


CARLLEVANDUSKY,
Naval Air Warj4are Center Aircraft Division, Lakehurst, New Jersey

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Foreword
This Standard is a revision of "American National Standard Dimensional Tolerances for Aluminum Mill Products"
issued in 2001 (ANSI H35.2-2001).
The tolerances included in this Standard were developedby the Technical Committee of The Aluminum Association.
They are broadly accepted both within the aluminum industry itself and by users of the metal. They are the basis of the
dimensional tolerances specified in U.S. government, technical society, and other specifications for aluminum products.
They represent the maximum deviation from specified dimensions that may be expected in any individual piece. For most
pieces the deviation from specified dimensions will be less than the tolerance shown.
Work on the tolerances began in The Aluminum Association in 1949, five years before its Technical Committee was
established. In that year a special committee was appointed by the Association's Extruded Products Division to develop
drafting standardsfor these products. One ofthe committee's assignmentswas to develop standardtolerances for aluminum
extrusions. The committee completed its work later in 1949, and the Association issued the first edition of its Drafting
Standards for Extruded and Tubular Products, including the tolerances, in October of that year.
By 1954,the Association's technical activitieshad grown to the point that a standingTechnical Committeewas needed.
One of the first jobs undertaken by this committee was the compilation of mechanical property data for commonly used
aluminum alloys and dimensional tolerances for other aluminum mill products. This work was completed later in 1954,
and the resulting data were published in the first edition of the Association's "Standards for Aluminum Mill Products" in
June 1955. Successive editions of the "Standards for Aluminum Mill Products" have been revised to include new data and
to keep the manual abreast of industry advances. In 1968the title was changed to "Aluminum Standardsand Data" to reflect
the adoption of a revised format.
Many refinements have been made in the tolerances as experiencewas gained in their use. In addition, tolerances have
been developed for products not covered initially, and the data have been extended to embrace the larger sizes now being
produced. All of these additions and refinements have been incorporatedinto this Standard. Included also are definitions
of the various products as given in "AluminumStandards and Data" published by The Aluminum Association, and standard
limits for expressing the tolerances.
This Standard was originally developed and subsequently revised using the "canvass" method and published under
the proprietarysponsorshipof The Aluminum Association.At the request of The Aluminum Association,the establishment
of Standards Committee H35 on Aluminum and Aluminum Alloys was authorized by the American National Standards
Institute on 17 February 1970, with the Association serving as Secretariat.
The 1971revision of ANSI H35.2 was the first revision developed by Standards Committee H35, under the "Standards
Committee" procedures, and the 1972, 1975, 1978, and 1982 revisions were developed under the auspices of that
Committee.
Standards Committee H35 was transferred to an Accredited Standards Committee on December 28, 1983, and this
revision was developed under the Accredited Standards Committee method.
This latest (2003) revision consists of an expandedrange of specified diameters for round wire, rod and drawing stock,
clarification of the 5xxx alloys with special extrusion tolerances and editorial corrections.

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ANSI H35.2-2003

American National Standard


Dimensional Tolerances for Aluminum Mill Products

1, Definitions Duct Sheet-Coiled or flat sheet in specific tempers,


widths and thicknesses, suitable for duct applications.
Bar-A solid wrought product that is long in relation to
its cross section which is square or rectangular (excluding Tube-A hollow wrought product that is long in
plate and flattened wire) with sharp or rounded comers or relation to its cross section, which is symmetrical and is
edges, or is a regular hexagon or octagon, and in which at round, a regular hexagon or octagon, elliptical, or square
least one perpendicular distance between parallel faces is or rectangular with sharp or rounded comers, and that has
0.375 inch or greater. uniform wall thickness except as affected by corner radii.
Fin Stock-Coiled sheet or foil in specific alloys, Heat-Exchanger ïùbe- A tube for use in apparatus in
tempers, and thickness ranges suitable for manufacture of which fluid inside the tube will be heated or cooled by
fins for heat-exchanger applications. fluid outside the tube. The form usually is not applied to
coil tube or tubes for use in refrigerators or radiators.
Foil-A rolled product rectangular in cross section of
thickness less than 0.006 inch. In Europe, foil is equal to Welded Tube-A tube produced by forming and seam-
and less than 0.20 mm. welding sheet longitudinally.
Forging Stock-A wrought or cast rod, bar or other Wire-A solid wrought product that is long in relation
section suitable for forging. to its cross section, which is square or rectangular with
sharp or rounded comers or edges, or is round, hexagonal,
Pipe-Tube in standardized combinations of outside or octagonal, and whose diameter or greatest perpendicu-
diameter and wall thickness, commonly designated by lar distance between parallel faces is less than 0.375 inch.
"Nominal Pipe Sizes" and "ANSI Schedule Numbers."
Plate-A rolled product that is rectangular in cross
section and with thickness not less than 0.250 inch with
sheared or sawed edges. 2. Standard Limits for Expressing Tolerances
Tread P l a t e s he et or plate having a raised figured 2.1 Standard limits for expressingthetolerances dependon
pattern on one surface to provide improved traction. the type of instrument ordinarily used in measuring the
particular dimension. Where instruments permitting the
Profile-A wrought product that is long in relation to its required degree of accuracy generally are used, the
cross-sectional dimensions which is of a form other than tolerances are expressed in decimals as follows (except for
that of sheet, plate, rod, bar, tube, wire or foil. foil):
Structural Profile-A profile rolled or extruded, in Tolerance less than 0.005 in. . . . . Multiple of 0.0005
certain standard alloys, tempers, sizes, and sections, such Tolerance of 0.005 in. and greater . . . . . . . . . 0.XXX
as angles, channels, tees, zees, I-beams, and H-sections,
commonly used for structural purposes. For measurements commonly made with instruments
not permitìing such accuracy, the tolerances are expressed
Rod-A solid wrought product that is long in relation to in fractions.
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its circular cross section, which is not less than 0.375 inch
diameter. 2.2 Rounding For purposes of determiningconformance
to the dimensional tolerances, a measured value is not
Shape-This term is no longer recommended. The term rounded off. To determine applicable limits when a
"Profile" is preferred. See "Profile." dimension is specified to more decimal places than are
Sheet-A rolled product that is rectangular in cross used in these standards, it shall be rounded off to the same
section with thickness less than 0.250 inch but not less number of places in conformance with ASTM E29,
than 0.006 inch and with slit, sheared or sawed edges. StandardPractice for Using SignificantDigits in Test Data
to Determine Conformance with Specifications.
Alclad Sheet-Composite sheet comprised of an
aluminum alloy core having on both surfaces (if on one
side only, Alclad One Side Sheet) a metallurgically
bonded aluminumor aluminum alloy coatingthat is anodic
to the core, thus electrolyticallyprotecting the core against
corrosion.
Brazing Sheet-Sheet of a brazing alloy, or sheet clad
with a brazing alloy on one or both sides.

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ANSI H35.2-2003

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ANSI H35.2-2003

Aluminum Mill Products

7. Sheet and Plate

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ANSI H35.2-2003

Dimensional Tolerances for

TABLE 7.7a Sheet and Plate Thickness Tolerances 0 (Applicable to All Alloys Not Included in the
Aerospace Alloys Table 7.7b or Not Specified for Aerospace Applications)
NOTE: ALSO APPLICABLE TO ALLOYS WHEN SUPPLIED AS ALCIAD.

SPECIFIED SPECIFIED WIDMin.


THICKNESS, Upthru Over 39.37 Over 59.06 Over 78.74 Over 98.43 Over 118.11 Over 137.80 Over 157.48
in. 39.37 Thru 59.06 Thru 78.74 Thru 98.43 Thru 118.11 Thru 137.80 Thru 157.48 Thru 1ï7.17
Over Thru TOLERANCES n. plus and minu:
0.0059 0.01 o 0.0010 0.0015 .. .. .. ..
0.01o 0.016 0.001o 0.0015 .. .. .. ..
0.016 0.025 0.0015 0.0020 0.0030 0.0035 .. .. ..
0.025 0.032 0.0020 0.0025 0.0035 0.0040 .. .. .. ..
0.032 0.039 0.0020 0.0030 0.0035 0.0045 0.006 .. ..
0.039 0.047 0.0025 0.0035 0.0045 0.006 0.007 0.006 .. ..
0.047 0.063 0.0030 0.0035 0.0050 0.006 0.007 0.009 .. ..
0.063 0.079 0.0035 0.0040 0.006 0.007 0.008 0.01o .. ..
0.079 0.098 0.0035 0.0045 0.006 0.007 0.009 0.011 .. ..
0.098 0.126 0.0045 0.006 0.007 0.009 0.011 0.013 .. ..
0.126 0.158 0.006 0.007 0.009 0.01 1 0.013 0.015 .. ..
0.158 0.197 0.007 0.009 0.011 0.013 0.015 0.018 .. ..
0.197 0.248 0.009 0.011 0.013 0.015 0.018 0.022 0.027 ..
0.248 0.315 0.012 0.014 0.015 0.018 0.022 0.027 0.035 0.043
0.315 0.394 0.015 0.017 0.020 0.023 0.027 0.033 0.041 0.051
0.394 0.630 0.023 0.023 0.027 0.032 0.035 0.043 0.053 0.065
0.630 0.984 0.031 0.031 0.037 0.043 0.047 0.058 0.070 0.085
0.984 1.575 0.039 0.039 0.047 0.055 0.065 0.075 0.090 0.105
1.575 2.362 0.055 0.055 0.060 0.070 0.085 0.1O0
2.362
3.150
3.937
3.150
3.937
6.299
0.075
0.1O0
0.130
0.075
0.1O0
0.130
0.085
0.115
0.145
0.100
0.125
0.165
0.105
0.130
0.125
0.160
..
..
" I
6.300 8.000 0.160 0.160 0.160 0.165

TABLE 7.7b Sheet and Plate Thickness Tolerancesa (Applicable to All Alloys Specified for
Aerospace Appl ¡cations)
(INCLUDES AEROSPACE ALLOYS 2014,2024,2124,2219,2324,2419,7050,7075,7150,7178 and 7475)

NOTE: ALSO APPLICABLE TO ALLOYS WHEN SUPPLIED AS ALCLAD.

SPECIFIED Over Over Over Over Over Over Over Over Over Over Over
THICKNESS up 39.37 4724 55.12 59.06 70.87 78.74 86.61 98.43 118.11 137.80 157.48
thru thru
thru thru thru thru thru thru thru thru thru thru
39.37 4724 55.12 59.06 70.87 78.74 86.61 98.43 118.11 137.80 157.48 iï7.17
Over Thru
___ TOLEF K E A . pl and minu
0.0059 0.010 0.0020 0.0020 ..
0.010 0.016 0.0025 0.0025 ..
0.016 0.025 0.0025 0.0025 ..
0.025 0.032 0.0020 0.0030 0.0030
0.032 -
0.039 0.0020 0.0030 0.0030 0.0035 0.0035 0.007 .. -
0.039 0.047 0.0020 0.0030 0.0030 0.0035 0.0035 0.008 0.010 0.011
0.047 0.063 0.0030 0.0030 0.0030 0.0035 0.0035 0.009 0.011 0.013
0.063 0.079 0.0030 0.0035 0.0035 0.0035 0.0035 0.010 0.013 0.015
0.079 0.098 0.0035 0.0040 0.0040 0.0045 0.0045 0.011 0.015 0.018
0.098 0.126
- 0.0035 0.0045 0.0045 0.0045 0.0045 0.013 0.016 0.020 -
0.126 0.158 0.0045 0.007 0.007 0.009 0.009 0.015 0.018 0.W
0.158 0.197 0.007 0.009 0.009 0.011 0.011 0.018 0.022 0.026
0.197 0.248 0.012 0.017 0.017 0.021 0.021 0.025 0.029
0.248 0.315 0.015 0.019 0.019 0.024 0.024 0.029 0.033 0.041 0.051
0.315 0.394
- 0.018 0.022 0.022 0.028 0.028 0.033 0.039 0.047
- 0.059
0.394 0.630 0.023 0.028 0.028 0.033 0.033 0.039 0.047 0.059 0.070
0.630 0.984 0.031 0.037 0.037 0.043 0.043 0.051 0.060 0.070 0.085
0.984 1.575 0.039 0.047 0.047 0.055 0.055 0.065 0.075 0.090 0.105
1.575 -2.362 0.055 0.060 0.060 0.070 0.070 0.090 0.100 0.115
-
2.362 3.150 0.075 0.085 0.085 0.100 0.100 0.110 0.125
3.150 3.937 0.100 0.115 0.115 0.130 0.130 0.150 0.160
3.937 6.299
__ 0.130 0.145 0.145 0.165 0.165 .. ~

6.300 8.000 0.160 0.160 0.160 0.165 0.165 .. -


Note: Capabilityto provide tighter tolerances may vary with supplier.
@When a dimension tolerance is specified other than as equal bilateral tolerance, the value of the standard tolerance is that which applies to the mean of
the maximum and minimum dimension permissible under the tolerance for the dimension under consideration.

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ANSI H35.2-2003

Aluminum Mill Products

TABLE 7.8 Width TolerancesCheared Flat Sheet and Plate


SPECIFIED W I D T H i n .
SPECIFIED Up thru Over 6 Over 24 Over 60 Over 96 Over 132
THICKNESS 6 thru 24 thru 60 thru 96 thru 132 thru 168
in.
TOLERANCES G i n .
0.006-0.124 f l/16 IV32 fva f 1/8 fV32 ..
0.125-0.249 *Y32 *Y32 *va fV32 IV16 ..
0.250-0.499 +
1/4 +Y16 +Ys +% +7/16 +M

TABLE 7.9 Length TolerancesCheared Flat Sheet and Plate


SPECIFIED L E N G T H I n .
SPECIFIED Over 480 Over 600
up thru Over 30 Over 60 Over 120 Over 240 Over 360
THICKNESS thru 480 thru 600 thru 720
30 thru 60 thru 120 thru 240 thru 360
in.
TOLERANCES G i n .
0.006-0.1 24 f l/16 *Y32 f 1/8 IV32 +Y16 fV32 f9/32 ..
0.125-0.249 *Y32 *Y32 f 1/8 fV32 f7/32 f 1/4 IV16 ..
0.250-8.000 + 1/4 +Ys +VI8 +1/2 +g/16 +Vs +11/16 +Y4

TABLE 7.10 Width and Length Tolerances-Sawed Flat Sheet and Plate
SPECIFIED
THICKNESS
....
in
Upthru
30
I Over 30
thru 60
Over 60
thru 120
SPECIFIED WIDTH AND L E N G T H i n .
Over 120
thru 240
Over 240
thru 360
Over 360
thru 480
Over 480
thru 600
Over 600
thru 720
I TOLERANCES u n .
0.080-0.249 f VS f l/s *Y1s f 114 f 114 fV16 *Ys f7/16
0.250-6.000 + 1/4 +Y16 +Ys + v2 +9/16 +Va +Y4 +7/8

TABLE 7.1 1 Width Tolerances-lit Coiled TABLE 7.1 2 Lateral Bow Tolerances@-Coiled
Sheet Sheet
SPECIFIED WIDTH-in. SPECIFIED W I D T H i n .
Specified
Upthru Over6 Over12 Over24 Over48 Over60 1/2 Over 1 Over2 Over4
Thickness Over
thru 12 thru 24 thru 48 thru 60 thru 96 Specified thru thru thru thru
10
.n i @
TOLERANCES - plus and minus Thickness 1 2 4 10

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in. TOLERANCEin. in 6 R.
0.126-0.186 0.012 1/32 1/32 1/16 Y32 .. Allowable Deviation of a Side Edge
0.1874249 0.016 1/32 Ys4 Y32 Vs .. from a Straight Line
0.006-0.064 Y4 9/1 6 Ys 1/4 Y16
0.065-0.125 .. .. Ys 1/4 3/i 6

@Whenadimensiontolerance isspecified otherthan asan equal bilateral @ Tolerances applicable at ambient mill temperatures. A change in
tolerance, the maximum value of the standard tolerance is that which dimension of 0.013 in. per 1O0 in. per 10°F must be recognized.
applies to the mean of the maximum and minimum dimensions permissible
under the tolerance for the dimension under consideration.

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ANSI H35.2-2003

m
Dimensional Tolerances for

TABLE 7.13 Lateral Bow Tolerances-Flat Sheet and Plate -


ALLOWABLE DEVIATION OF A SIDE EDGE FROM A STRAIGHT LINE

SPECIFIED SPECIFIED
THICKNESS WIDTH A
in. in.

SPECIFIED LENGTH-In.
Up thru Over 60 Over 90 Over 120 Over 150 Over 180 Over 210
60 thru 90 thru 120 thru 150 thru 180 thru 210 thru 240
TOLERANCE-in.
Up thru 4 0.250 0.563 1.O00 1.563 2.250 3.000 4.0000
Over 4 thru 10 0.094 0.219 0.375 0.563 0.875 1.156 1.500 0
0.006-0.125
Over 1O thru 35 0.063 0.125 0.188 0.250 0.375 0.500 0.750 @
Over 35 0.032 0.063 0.125 0.188 0.250 0.375 0.500 0
Over 4 thru 15 0.063 0.125 0.250 0.375 0.563 0.750 1.O000
0.126-0.249 0.032 0.063 0.125 0.1 88 0.250 0.375 0.5000
Over 15
Upthru 10 0.250 0.563 1.O00 1.563 2.250 3.000 4.0000
0.2504.000 Over 10 thru 18 0.063 0.125 0.250 0.406 0.594 0.781 1.O000
Over 16 0.032 0.094 0.125 0.219 0.312 0.438 0.5620

TABLE 7.14 Squareness Tolerances-Flat Sheet and Plate


SPECIFIED WIDTH-ft.
Up thru 3 Over 3
ALLOWABLE DIFFERENCE IN LENGTH OF DIAGONALS @-Inches
SPECIFIED
LENGTH
ft.

Upthru 12 3/32 x width, R@ Y64 x width, li@


Over 12 9/64 x width, fi@ 7/64 x width, ft@

12
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ANSI H35.2-2003

Aluminum Mill Products

TABLE 7.15 Diameter Tolerances4heared or TABLE 7.16 Diameter Tolerances-Sawed


Blanked Sheet and Plate Circleso Sheet and Plate Circleso
SPECIFIED DIAMETER
UD thru IOver 18 I Over 36 I Over 96 I Over 132 Up thru Over 18 Over 60 Over 132
18 I thru36 I
thru96 I
thru 132 thru 168 I 18 thru 60 thru 132 thru 168
ALLOWABLE DEVIATION FROM
SPECIFIED DIAMETER
in. plus and minus

SPECIFIED SPECIFIED
THICKNESS THICKNESS
in. in.

Difference between AA a n d
specified diameter
0.006-0.249 0.080-1.000 1
/8 Vl 6 v4 1
/2
0.250-0.375 1.001-3.000 1
/4 Y8 '/2 V4
0.376-0.625 y1 6
0.626-0.875 .. VI 6 1
/4 0 When a dimension tolerance is specified other than asan equal bilateral
0.876-1.250 .. v4 Y8 v2 5/s tolerance, the maximum value of the standard tolerance is that which
applies to the mean of the maximumand minimumdimensions permissible
@When a dimensiontolerance is specified other than as an equal bilateral under the tolerance for the dimension under consideration.
tolerance, the maximum value of the standard tolerance is that which
applies to the mean of the maximum and minimum dimensions permissible
under the tolerance for the dimension under consideration.

Longitudinal or Transverse Distance (ft.)


Alloy Specified Center to Center of Buckles or Edge Waves@
(Includes Thickness UP Over 2 Over 3 Over 4
Over 6
Alclads) in. thru 2 thru 3 thru 4 thru 6
TOLERANCES. in. @ @0I

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---
1060,1100,1350,3003,3005, 0.020 thru 0.064 ve y16 y16 y1 6 Va
3105,5005,5050,5X57 0.065 thru 0.249 VfJ Vl 6 v16 V8 v2

3004,5052,5083,5086,5252, 0.020 thru 0.064 VI 6 Vi 6 vl 6 VfJ 112


5X54,5456,5652, brazing sheet, 0.065thru 0.249 y1 6 y16 Y8 1
/2 9/i6
and all heat treatable alloys

13
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TOLERANCE @ in.-Allowable Deviation from Flat
SPECIFIED THICKNESS, in.
TX51 tempers @ Other than TX51 tempers @a
0.250-3.000 Y16 in any 6 ft@ V 4 in any 6 ft or less
3.001-8.000 V a in any 6 ft or less 1/4 in any 6 ft or less

TOLERANCE @ in.-Allowable Deviation from Flat


Widths over 4 ft thru 6 ft @ Widths over 2 ft thru 4 ft Widths 2 ft and less
SPECIFIED THICKNESS, in.
Other than
Tx51 tempers@ TX51 t e m p e r s a a TX51
Other than
TX51 t e m p e r s Q 0 All tempers a
0.250-0.624 ve V2 5/1 6 va
0.625-1.500 vi 6 va Y1 6 v4 Only short-span flatness
1.501 -3.000 vl 6 v4 vi 6 Yi 6 tolerance applies
3.001-8.000 va 1/4 ve Y16

TOLERANCE (4) in.-Allowable Deviation from Flat


SPECIFIED THICKNESS, in.
TX51 tempers @ Other than TX51 t e m p e r s a a
0.250-0.624 ,100 ,125
0.625-8.000 .O75 .O90

TABLE 7.26 Thickness Tolerancesa- TABLE 7.29 Parallelness of Corrugations-


Commercial Roofing and Siding Commercial Roofing and Siding
NOMINAL NOMINAL WIDTHin. PARALLELNESSOF
PRODUCT CORRUGATIONS
THICKNESS UD thru Over 36
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

thru 54 'Ormgated roofing Capable of being lapped at either end.


and siding
TOLERANCEin. plus and minus
V-beam roofing Capable of being lapped at either end.
0.024 .O025 and siding
0.032 .O025 .O05
0.036 ,0025 .O05 Capable of being lapped at either end
0.040 .O03 .O05 Ribbed roofing and ribs are parallel to eaai other
0.050 and to edges of sheet within f V 8 in.
Ribbed siding Capable of being lapped at either end.

TABLE 7.27 Depth of Corrugation TABLE 7.30 Squareness Tolerance


Tolerances4ommerciaI Roofing Allowable difference in length of diagonals: f V z in.
and Siding
~ ~~ ~~

Allowable deviation from nominal depth of corrugation: f 1/32 in.


0 Applicable to fiat sheet prior to painting, corrugating. or embossing.
0 Applicable to lengths of 3 feet through 30 feet for all products except
ribbed siding. For ribbed siding, tolerances are applicable to lengths Of 3
TABLE 7.28 Length Tolerancesa4ommercial feet through 36% feet.

Roofing and Siding


Allowable deviation from specified length: f 1/z in.

14
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ANSI H35.2-2003

Aluminum Mill Products

TABLE 7.31 Thickness Tolerances for Duct TABLE 7.33 Width Tolerances for Coiled Duct
Sheet Sheet and Coiled Duct Sheet
Cut to Length
1 TOLERANCE-h. plus and minus
TOLERANCE-in. plus and minus
STANDARD THICKNESS
..in.. STANDARD WIDTHSin. STANDARD THICKNESS
in. I
STANDARD WIDTHS-in.
I
I 24,30,36 I 48
All l/32 Y64
0.016 ,0015 .O02
0.018,0.020,0.022,
0.025 .O025
0.032 .o02
..~ ,0025
0.040 .O025 .O03 TABLE 7.34 Length Tolerances for Coiled Duct
0.050,0.063 .O03 .O04
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

Sheet Cut to Length and


Flat Duct Sheet
TABLE 7.32 Width Tolerances for Flat Duct
STANDARD STANDARD WIDTH TOLERANCE, in.
Sheet LENGTH
All All *%
STANDARD THICKNESS

TABLE 7.38 Width Tolerances-Tread Plate


Allowable deviation from specified width: I'Y in.

THICKNESS NOMINAL WEIGHT


in. Iblsq. ft TABLE 7.39 Length Tolerances-Tread Plate
0.100 1.55
0.125 1.90 SPECIFIED LENGTH TOLERANCE
0.1 56 2.34 in.-plus
0.188 2.79 Up thru 144
0.250 3.67 Over 144 thru 240 '/l6
0.375 5.43 Over 240
0.500 7.20
0.625 8.96

TABLE 7.40 Height of Pattern Tolerance-


TABLE 7.37 Thickness Tolerances for Tread
Tread Plate
Plate
Minimum height of raised pattern: 0.040inch.
Specified Tolerancesin. (Maximum height is controlled by weight tolerance.)
Thicknessin. Plus Q Minus
0.100 ,008 .o12
0.125 .o1 o .o15
0.1 56 .o11 .o19
0.188 .O13 .O23
0.250 .o18 .O30
0.375 .O25 .o45
0.500 .O35 .O60
.o44 .O75

O Specified thickness does not include height of pattern.


@In case of dispute, allowed plus tolerance shall be determined by weight.
The allowed deviationfrom nominal weight shall not exceed plus 8 percent.

15
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ANSI H35.2-2003

DimensionalTolerances for

TABLE 7.41 Camber of Pattern Line@ TABLE 7.42 Lateral Bow Tolerances-Tread
Tolerances-Tread Plate Platea
TOLERANCE-IN.
SPECIFIED ALLOWABLE DEVIATION OF A
WIDTH SIDE EDGE FROM A STRAIGHT LINE
SPECIFIED THICKNESS-in.
0.100-0.625
Up thru 4 1 in any 10 ft.
Centerline
Over 4 thru 72 Ve in any 1O ft.

SPECIFIED TOLERANCE-in. TOLERANCE-in.


SPECIFIED LENGTH
LENGTH SPECIFIED WIDTH-in. i"
..I.
ALLOWABLE DIFFERENCE IN
LENGTH OF DIAGONALS
Up thru 48 Over 48 thru 72
Up thru 144 %
Up thru 24 Over 144 thru 240 '/l6
Over 24 thru 72 Over 240 '/2
Over 72 thru 144
Over 144 1%
@Applicable only to lengths up through 240 inches.
@ The camber of a pattern line is the maximum distance between the
center of any figure in a pattern line and a line parallel with the edge of the
plate that passes through the center of the figure in the same pattern line
nearest to the edge of the floor plate.
@ Not recquared.

16 --`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

Copyright The Aluminum Association Inc.


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ANSI H35.2-2003

Aluminum Mill Products

8. Fin Stock

TABLE 8.2 Thickness Tolerances-Fin Stock TABLE 8.3 Width and Lateral Bow
SPECIFIED THICKNESS TOLERANCE TolerancesLFin Stock
in. plus and minus Same as for coiled sheet.
0.004-0.01 04 ,0005 See Tables 7.11 and 7.12
0.0105-0.01 69 Note: The Olsen Cup and similar tests frequently used as measures of
0.017-0.030 .O015 formability are not sufficiently reproducible to permit the establishment of
standards for acceptance or rejection of material. Cup test values, when
used, are acceptable only as general guidelines for rating comparative
formability.

@Tolerances for thicknessesof 0.004-0.0059 inch are the same as those


specified for thickness of 0.006 inch.

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

17
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ANSI H35.2-2003

DimensionalTolerances for

9. Foil

SPECIFIED COVERIN A R E A - X ~ O ~sq. I. per Ib. a@ SPECIFIED COVERIN RREA-x~O~Sq. I. per lb.@@
THICKNESS THICKNESS
in. Nominal Minimum @ Maximum6 in. Nominal Minimum @ Maximum0
0.00017 54.8 67.0 0.00085 12.1 11.o 13.4
0.00020 46.6 57.0 0.00090 11.4 10.4 12.7
0.00025 37.3 45.6 0.00095 10.8 9.81 12.0
0.00030 31 .I 38.0 0.0010 10.3 9.32 1 1.4
0.00035 26.6 32.6 0.0015 6.84 6.22 7.60
0.00040 23.3 28.5 0.0020 5.13 4.66 5.70
0.00045 20.7 25.3 0.0025 4.10 3.73 4.56
0.00050 18.6 22.8 0.0030 3.42 3.11 3.80
0.00055 17.0 20.7 0.0035 2.93 2.66 3.26
0.00060 15.5 19.0 0.0040 2.56 2.33 2.85
0.00065 15.8 14.3 17.5 0.0045 2.28 2.07 2.53
0.00070 14.7 13.3 16.3 0.0050 2.05 1 .ô6 2.28
0.00075 13.7 12.4 15.2 0.0055 1 .ô6 1.70 2.07
0.00080 12.8 11.7 14.2 1
0 The nominal covering area for 0.00017inch thick foil is 60.3 x 1 O3 or @ Based on the standard thickness tolerance of plus and minus 10% per
60,300sq. in. per Ib. roll or shipment.
@ Based on a density of 0.0975Ib/cu in., the density of 1145 and 1235
aluminum. Covering area in sq. in./lb is calculated using the following Alloy Dencio/
formula:
1 1100 0.098
CoveringArea = 1145 0.0975
thickness in in. x densityin /b.íin.3 1235 0.0975
3003 0.099
5052 0.097
5056 0.095

TABLE 9.3 Roll Width-Unmounted Foil TABLE 9.5 Length and Width-Flat Sheets of
SPECIFIED TOLERANCE-in. plus and minus Unmounted Foil
WIDTH Unmounted Colored, Embossed
in. TOLERANCE-in. plus and minus

1
Foil and Coated Foil
Up thru 12 1/64 1/32 1 I T

Over 12 1/32 1/32 ROLLING


SPECIFIED
DIRECTION
LENGTH OR

TABLE 9.4 Inside Diameterxore,


WIDTH
in. -1 LENGTH -1 1

Unmounted Foil
SPECIFIED T0LERANCE-h
INSIDE DIAMETER plus and minus
in. All 1/32

15/16 1/32 0.012


3.000 1/32 0.015 --`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

18
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ANSI H35.2-2003

Aluminum Mill Products


TABLE 9.6 Spliceso -Unmounted Foil, Maximum Number Per Roll
FOIL THICKNESSin.
ROLL 0.00035-0.001 Over 0.001
DIAMETER
in. FOIL WIDTH-in.
Up thru 52% @ Over 52% Up thru 52% @ Over 52%
Up thru 9% 3 4 1 1
Over 9%-i 3% 5 7 2 3
Over 13%-18 8 11 4 5
Over 18-22 10 13 6 7
Maximum Average Number Per Roll in Total Shipment
Up thru 9% 2 2 % 'h
Over 9%-13% 3 5 1 1
Over 13%-18 5 8 2 2
Over 18-22 7 10 3 4

@ Standard splices are lap or butt made with foil or plastic tape. Other @ Maximum for 90% of shipment: remainder will not exceed maximums
types are subject to special inquiry. listed for widths over 52% inches.

TABLE 9.7 Coating Weights-Unmounted Foil TABLE 9.8 Quantity Tolerance-Unmounted


COATING TOLERANCE Foil
percent plus and minus
Heat seal, Clear
Polyethylene
20 or % lb@ SPECIFIED QUANTITY
Per Item or Order I TOLERANCE
oercent Dius and minus
Elvax All 10

@Whatever is greater.

Laminated Foil
TABLE 9.9 Roll Width-Laminated Foil TABLE 9.1 2 Coating Weights-Laminated Foil
SPECIFIED TOLERANCE-in. plus and minus COATING I TOLERANCE
WIDTH Laminated Colored, Embossed
in. Foil and Coated Foil Heat seal, Clear 20 or % lb@
Polyethylene 15
Up thru 12 1/M 1/32 Elvax 30
Over 12 1/32 1/32

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---
TABLE 9.1 O Inside Diameter-Core, TABLE 9.13 Covering Area (Yield)-
Laminated Foil Laminated Foil
SPECIFIED TOLERANCE-in. NOMINAL COVERING AREA TOLERANCEQ
INSIDE DIAMETER plus and minus sq. in. per Ib. percent plus and minus
Fiber Cores Metal Cores All 10
1/32 0.012
3.000 1/32 0.015 @ Average per roll or shipment

TABLE 9.1 1 Length and Width-Flat Sheets of TABLE 9.14 Adhesive Weight-Laminated Foil
Unmounted Foil
TOLERANCE-in. plus and minus

ROLLIh
SPECIFIED Polyethylene 15
LENGTH OR
WIDTH
in. -1 LENGTH 1-

All 1/32

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ANSI H35.2-2003

Dimensional Tolerances for

TABLE 9.15 Paper Weight-Ream Basis 0 TABLE 9.16 Quantity Tolerance-


PAPER TOLERANCE Laminated Foil
TYPE percent plus and minus
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

SPECIFIED QUANTITY TOLERANCE


Per Item or Order percent plus and minus
@Standard ream is 500 sheets 24 in. x 36 in. All 10
O Some papers may require a greater tolerance.

Printed Foil

TABLE 9.17 Border Width-Cut Labels


TYPE OF NOMINAL BORDER WIDTH TYPE LINE CYLINDER TONE OR PROCESS
CUT in., min. Relief 4 point 6 point
Rectangular Reverse 6 point 0 point
Rhomboid or Die
'h

TABLE 9.22 Quantity Tolerance@


TABLE 9.1 8 Overall Size-Cut Labels
SPECIFIED QUANTITY TOLERANCE
SPECIFIED TOLERANCE-in. plus and minus Million Sq. Inches Percent
SIZE Within a Within a up to 1 +loo, -50
in. Shipment Pack 1 to10
10to20
All '/32 1/64 20 to 35 I20
35 to 50 11 5
50 and over I 1o
TABLE 9.19 Border Variationxut Labels @ For body and neck labels ordered in equal sets and produced on
TYPE OF TOLERANCE combination cylinders see Table 9.24 for additional tolerance.
LABEL in. plus and minus
Unembossed or TABLE 9.23 Covering Area (Yield)
Full Embossed
NOMINAL COVERING AREA TOLERANCE
Embossed to
Reoicter sq. in. per Ib. percent plus and minus
All 10

TABLE 9.20 Width-Rolls TABLE 9.24 Quantity Variation Between


SPECIFIED WIDTH TOLERANCE Body and Neck Labels
in. in. plus and minus When ordered in equal sets, the allowable deviation in the number of body
All 1/32 and neck labels when produced on combination cylinders is 10 percent.

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ANSI H35.2-2003

Aluminum Mill Products

1O. Wire, Rod, and Bar-ßolled or Cold-finished

TABLE 10.5 Diameter-Round Wire and Rod TABLE 10.9 Thickness and Width-
Rectangular Wire and Bar
TOLERANCEin. plus and minus
Except as noted SPECIFIED TOLERANCE
THICKNESS OR in. plus and minus
SPECIFIED WIDTH
DIAMETER SPECIFICED DIAMETER
ALLOWABLE DEVIATION FROM
SPECIFIED THICKNESS AND WIDTH

Up thru 0.035 ,0005 ...


...
...
...
...
...
IT Drawn Wire
Rolled Bar
0.036-0.064 .o01
- Finished Bar

I I l I
0.065-0.374 ... ... ...
0.375-0.500
.o01 5
... .O015 .O20 .O20 t I+w4
Thickness Width Thickness Width
0.501-1.O00 ... .O02 .O25 .O25
1.001-1S O O ... .O025 ... ... .o01 .. .. ..
1.501-2.000 ... .O04 ... ... Up thru 0.035
2.001-3.000 ... .O06 ... ... 0.036-0.064 .O015 .. .. ..
0.065-0.500 .O02 .o02 .O06 ..
3.001-3.499 ... .O08 ... ... 0.501-0.750 .O025 .O025 .O08 .O16
3.500-5.000 ... .o12 ... ...
5.001-6.000 ... .o20 ... ... 0.751-1.000 ,0025 .O025 .O12 .O16
6.001-7.000 ... .O25 ... ... 1 .O01-1 500 .O03 .O03 .O16 .O16
7.001-8.000 ... .O30 ... ... 1.501-2.000 .O05 .O05 .O16 .O31
2.001-3.000 .o08 .O08 .O20 .O31
3.001-4.000 .. .o1o .O20 .O31
4.001-6.000 .. .. .. .o47
TABLE 10.6 Diameterxenterless Ground 6.001-10.000 .. .. .. .O62

Round Wire and Rod


I TOLERANCE
TABLE 10.1O Distance across Flats-Square
SPECIFIED DIAMETER
in. plus and minus Hexagonal and Octagonal Wire
ALLOWABLE DEVIATION
i..
1.1.

FROM SPECIFIED and Bar


DIAMETER
SPECIFIED DISTANCE
0.125-0.625 .O005 ACROSS FLATS TOLERANCE
0.6261500 .O01o in. in. plus and minus
1.501-2.000 ,0025

SPECIFIED DISTANCE

TABLE 10.7 Diameter-Rivet and Cold


Heading Wire and Rod I+ 4 Kz Finished
TOLERANCE
ALLOWABLE DEVIATION FROM Up thru 0.035 .O01 .. ..
SPECIFIED SPECIFIED DIAMETER 0.036-0.064 .o015 .. ..
DIAMETER
Rivet Wire Rivet Rod 0.065-0.374 .O02 .. ..
in.
in. in. in. in. 0.375-0.500 .. .O02 ..
plus minus plus minus
0.501-1.O00 .. ,0025 ..
1 .O01-1 500 .. .o03 ..
Up thru 0.061 ,0005 ,0005 ... ... 1.501-2.000 .. .O05 .O16
0.062-0.123 .o01 .O005 ... ... 2.001-3.000 .. .O08 .O20
0.124-0.154 .o01 .O01 ... ... 3.0014.000 .. .. .O20
0.155-0.374 .O02 .O01 ... ...
0.375-0.500 ... ... .O02 .o01
0.501-1.000 ... ... .O03 .O01

TABLE 10.8 Diameter-Drawing Stock


SPECIFIED TOLERANCEin. plus and minus
DIAMETER ALLOWABLE DEVIATION
FROM SPECIFIED DIAMETER
0.375- 0.500 .o20
0.501 - 1.000 .O25

21 --`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

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ANSI H35.2-2003

Dimensional Tolerances for

TABLE 10.11 Thickness and Width-Flattened TABLE 10.12 Thickness and Width-Flattened
Wire (Round Edge) and Slit Wire
SPECIFIED TOLERANCE TOLERANCE
TOLERANCE WIDTH TOLERANCE in. in.
THICKNESS in. In. plus and plus and
in. plus and plus and minus minus
SPECIFIED SPECIFIED
minus minus THICKNESS ALLOWABLE WIDTH ALLOWABLE
in. DEVIATION in. DEVIATION
ALLOWABLE ALLOWABLE FROM FROM
DEVIATION DEVIATION SPECIFIED SPECIFIED
THICKNESS WIDTH
FROM
SPECIFIED *I It FROM
SPECIFIED 0.01&0.020 .O01 0.500-0.625 ,0025
THICKNESS WIDTH 0.021-0.060 .O015 0.626-1.500 .O04
0.061-0.080 .O02 1.501-4.750 .O06

1 ,
Up thru 0.020 Up thru 0.875 .O07
0.021-0.060 0.876-2.000 .o1 o
0.061-0.187
TABLE 10.13 Lengthdpecific and Multiple

I I
TOLERANCE@-in. plus
SPECIFIEDDIAMETER, 12 ALLOWABLE DEVIATION050er
WIDTH OR DISTANCE FROM SPECIFIED LENGTH
ACROSS FLATS SPECIFIED LENGTH-fi.
in.
Up thru Over 12 Over 30
thru 30 thru 50
UD thru 2.999 I ve I 114 I ve I 1
3.000-7.999 vi 6 Y16 '/i6 1
8.000 and over v4 ve 1/2 1

TABLE 10.14 TwistLBar and Straight Lengths


TOLERANCEm G D E G R E E S

ALLOWABLE DEVIATION FROM STRAIGHT

SPECIFIED WIDTii
(RECTANGLES):

SPECIFIED DISTANCE
PRODUCT TEMPER ACROSS FLATS:
(SQUARES, HEXAGONS
AND OCTAGONS)

in.
Y (max.) in degrees
IN TOTAL LENGTH OR IN
MAXIMUM
ANY MEASURED SEGMENT
FOR TOTAL
OF ONE FT. DR MORE
LENGTH
OF TOTAL LENGTH
All except Up thru 1.499 1 x Measured length, ft
1.500-2.999 Yi x Measured length, ft
Square, Rectangular 3.000 and over
and Octagonal Bar
0.500-2.999 1Yi x Measured length, ft
TX51@
3.000 and over
Up thru 1.499 1 x Measured length, ft 7
Hexagonal Bar All except O 1,500-2.999 Yi x Measured length, f i
3.000 and over 3

@ For TX51 tempers, tolerance is applicable only to thicknesses of 0.500 Tolerance,


Maximum allowable
in. and over. linear deviation
degrees inch per inch of width
@TX51 is a general designation for the following stress-relievedtempers:
T351, T451, T651, T851, and l7351. % 0.004
@When weight of piece on flat surface minimizes deviation. Yi 0.009
@Twist is normally measured by placing the bar on a flat surface and at 1 0.017
any point along its length measuring the maximum distance between the 1% 0.026
bottomsurface of the bar and the flat surface. From this measurement, the 3 0.052
actual deviation from straightness of the bar at that point is subtracted. The 5 0.087
remainder is the twist. To convert the standard twist tolerance (degrees) to 7 0.122
an equivalent linear value, the sine of the standard tolerance is multiplied 9 0.1 56
by the width of the surface of the section that is on the flat surface. The 15 0.259
followingvalues are used to convert angular tolerances to linear deviation: 21 0.358
@ For wire, rod and bar ordered as standard screw machine stock, Me
length tolerance is plus VE in.

22 --`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

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Aluminum Mill Products

TABLE 10.15 Strai! itness-Rod and Bar in Straight Lengtt Other than Screw Machine Stock
TOLERANCE @-in.
SPECIFIED DIAMETER ALLOWABLE DEVIATION (D) FROM STRAIGHT
(ROD):
SPECIFIED DISTANCE
ACROSS FLATS:
(SQUARES, HEXAGONS
PRODUCT TEMPER
AND OCTAGONS)
SPECIFIED THICKNESS
(RECTANGLES)

I in. IN TOTAL LENGTH OR IN ANY


MEASURED SEGMENT OF ONE FT.
OR MORE OF TOTAL LENGTH
ROLLED
Rod and All except O All 0.050 x Measured length, it.
Hexagonal,
Square, Rectangular
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

and Octagonal Bar


COLD FINISHED
All except All 0.025 x Measured length, it
Rod and O and TX51@
Hexagonal Bar
TX51@ 0.500 and over 0.025 x Measured length, it
All except All 0.025 x Measured length, ft
Square, Rectangular O and TX51@
and Octagonal Bar
TX51@ 0.500 and over 0.050 x Measured length, it

SPECIFIED DIAMETER, TOLERANCEO in.


(ROD);
SPECIFIED DISTANCE LLOWABLE DEVIATION
TEMPER A FROM STRAIGHT
ACROSS FLATS
(HEXAGONAL BAR)
in.
All Except TX51 @
In any foot or
less of length In
0.0125
’*
feet
0.100 Allowable deviation from nominal angle: i1 degree
All
0.500 and over TX51@ 0.0125 0.1 O0

TABLE 10.17 Flatness-Flat Surfaces


TOLERANCE, in.
TABLE 10.19 Squareness of Saw Cuts
~~

Allowable deviation from square: 1 degree

SURFACE WIDTH
in.

1YcW-I
Thickness, inches Corner Radii
Maximum Allowable Deviation D inches, max.
Up thru 1 Up thru 0.500 0.016
Over 1 0.004x W (inches) 0.501-2.000 0.032
Inany1 in.
of width 0.004 2.001 and thicker 0.050

w h e n weight of piece on flat surface minimizes deviation.


m 5 1 is a general designation for the following stress-relieved tempers:
T351, T451, T851, and l7351.

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Dimensional Tolerances for

11. Wire, Rod, Bar, and Profiles-Extruded

TABLE 11.2 Cross-Sectional Dimension Tolerancesbrofiles@


EXCEPT FOR T3510, T4510,T6510,T73510,i76510 AND TE510 TEMPERSO

COIS.

col. 2 -e

TOLERANCE@&in. plus and minus


I

, ,
METAL DIMENSIONS SPACE DIMENSIONS
ALLOWABLE DEVIATION FROM ALLOWABLE DEVIATION FROM SPECIFIED
SPECIFIED DIMENSION WHERE DIMENSION WHERE MORE THAN 25 PERCENT OF
THE DIMENSION IS SPACE@@

in. At At At At At At
A,l
Wall Thickness@ Dimensioned Dimensioned Dimensioned Dimensioned Dimensioned Dimensioned

ExgteEr Compieteiy @
Enclosing Space
0.11 sq. in. and
Points Points Points
0.250-0.624 0.625-1.249 1.250-2.499
Points Points Points
2.500-3.999 4.000-5.999 6.000-8.000
inches from inches from inches from inches from inches from inches from

1 I
by Column Over (Eccentricity) Base of Leg Base of Leg Base of Leg Base of Leg
I I Base of Leg Base of Leg
Col. 2 Col. 3I Col. 4 Col. 6 COI. 7 Col. 8
5 m 5 m 5m

1 ii1i i
Other Other 24.0 Other 24.0 Other 24.0 Other
Alloys nominal Alloys nominal Alloys nominal Alloys nominal Alloys nominal Alloys nominal Alloys nominal Alloys

1 i I 1 1 1 1; i i ;i 1
Mg QD Mg Qp Mg QD Mg QD Mg QD
-- .- ._

::
Up thru 0.124 .o09 .O06 5 .O13 .O10 .o15 .O12
::
C

0.125-0.249 .o11 .O07


._
O
g .s .i .O16 .O12 .O18 .O14 .O20 .Ois 1:
.1 :.
E
.MO .O16 .O22 .O20
0.250-0.499 .o12 .O08
EE .O18 .O14 .O18 .O24
0.500-0.749 .O14 .O09 54 ,021 ,016 .O23 ,018 .O25
:: ::.O20 .O27 .O22 .. ..

t
.o1o
0.750-0.999 -.o15 - ;
.- 2 .- 9
u
.
,023 .O18 .O25
.O29
.O20
.O23
.O27
.O32 .O26
.O30
.O36
.O25
.O30
:û3: .O30
.O35
1 .ooo-1.499 .O18 .o12 ,027 .O21
Co # L

1.500-1.999 .o21 .O14


2.000-3.999 .O36 ,024 E o€
o m
g
8:
.O31
.o46
.O24
.O34
.O33
.O50
.O26
.O38
.O38
.O60 .o48
.o43
.o69
.O36
.O57
.o49
.O80
.O42
.O68
.O57
.O92
.O50
.O80
4.000-5.999 .O51 .o34 ’0 .O61 .o44 ,067 .O50 .O81 .O64 .O95 .O78 .I 1 1 .O94 .I 27 .1 1 O
6.000-7.999 .O66 .o44
8.000-9.999 -.O81 054
$2
F
02
7
,076
.o91 .o64
,054 ,084
.1 O1
.I 27
.O62
.O74
.I 04 .O82
.I O0
.I 21
.I 47
.O99
.I 20
,142
,182
,120
,145
,162
.197
,140
.I 70
U U
NG CI
- -- --LE S ES la CHE N -
DIAMETER AND O’ R -
Up thru 0.124 .O21 .O14 .O25 .o18
.O27 .O20 .. ..
0.125-0.249 .O22 .O15 .O26 .o19
.o29 .o22 .. ..
0.250-0.499 .O24 .O16 .O28 .o20 .O32 .O24 .O58 .O50 .. ..
0.500-0.749 .O25 .O17 .O30 .o22 .O35 .O27 .O68 .O60 .. ..
0.750-0.999 .O27 .O18 -
.O31 .O23 -
- .O39 .O30
~ -
.O79 -
.O70 .o99 .O90 -
.. -
..
1.000-1.499 .O28 .o19 .O33 .O24 .o43 .o34 .O89 .O80 ,109 .loo .. ..
1.500-1.999 .O36 .O24 .o46 .O34 .O56 ,044 .IO2 .O90 ,122 .110 .182 .170
2.000-3.999 .O51 .O34 .O61 .o44 .O71 .O54 ,117 ,100 ,137 .I20 ,197 ,180
4.000-5.999 .O66 .o44 .O76 .O54 .O86 .O64 ,132 ,110 ,152 ,130 ,212 ,190
6.000-7.999
8.000-9.999
.O81
.O96
.O54
.O64
-
.o91
,106
.o64 -
- ,101 .O74
-
.O74 ,116 .o84
-
,147
,162
-
,120 ,167 .140 -
,227 ,200
,130 ,182 .I50 242 .210
-
10.000-11.99: ,111 .O74 ,121 .o84 ,131 .o94 .177 .140 ,197 .160 ,257 ,220
12.000-13.99s ,126 .O84 .I 36 .O94 .146 ,104 ,192 ,150 ,212 .I70 ,272 230
14.000-15.99s ,141 .O94 ,151 ,104 ,161 ,114 ,207 ,160 ,227 ,180 ,287 ,240
16.000-17.99! ,156 ,104 ,166
- ,114
~
,176
- ,124
- ,222
- ,302 ,250
,170 ,242 ,190 -
- -
18.000-19.99s .171 ,114 ,181 ,124 .I91 ,134 ,237 ,180 ,257 200 .317 260
20.000-21.99s .I86 ,124 ,196 ,134 206 ,144 252 ,190 ,272 .210 ,332 ,270
22.000-24.00( .201 ,134 -
2 11 -
,144 -
,221 -
,154 -
267 -
,200 ,287 .EO -.347 ,280 _L

@These Standard Tolerances are applicable to the average profile; wider @Where dimensions specified are outside and inside, rather than Wall
tolerances may be required for some profilesand closer tolerances may be thickness itself, the allowable deviation (eccentriciiy) given in Column 3
possible for others. applies to mean wall thickness. (Mean wall thickness is the average of two
@ The tolerance applicable to a dimension composed of two or more wall thickness measurements taken at opposite sides of the void.)
component dimensions is the sum of the tolerances of the component @ In the case of Class 1 Hollow Profiles the standard wall thickness
dimensions if all of the component dimensions are indicated. tolerance for extruded round tube is applicable. (A Class 1 Hollow Profile
@Whena dimension tolerance is specifiedother than asan equal bilateral is one whose void is round and one inch or more in diameter and whose
tolerance, the value of the standard tolerance is that which applies to the weight is equally distributed on opposite sides of two or more equab
mean of the maximum and minimum dimensions permissible under the spaced axes.)
tolerance for the dimension under consideration. (Continued on bottom of next page)

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---
24
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Aluminum Mill Products


Examples Illustrating Use of Table 11.2, previous page
Closed-Space Dimensions
x (Col. 4)

iyL (7 xcc9i. 4)

x (COI. Y4)( Col. 2)


r
p d4) +l
.

4, Y (Col. 2)

All dimensions designated "Y" are classed as "metal dimensions," and tolerances are determined
from column 2.
L x (COI. 4)
COI. 4)

Dimensions designated "n'are classed as "space dimensions through an enclosed void," and the
tolerances applicable are determined from column 4 unless 75 percent or more of the dimension
is metal, in which case column 2 applies.

Open-Space Dimensions
? X i

Tolerances aDplicable to dimensions 'X" are


determined asfoiiows:

L a
1. Locate dimension ' X in column 1
2. Determinewhich of columns 4-9 is
applicable, dependent on distance "A."
3. Locate proper tolerance in column 4,5,6, 7,
Y
8 or 9 in the same line as dimension "X."

Dimensions 'Y" are "metal dimensions"; tolerances are determined from column 2.
Distances 'C" are shown merely to indicate incorrect values for determining which of columns 4-9

'B'
Tolerances applicable to dimensions ' X are determined as follows: Tolerances applicable to dimensions "X" are not determined from Table
1. Locate distance "8" in column 1. 11.2; tolerances are determined by standard tolerances applicable to
2. Determine which of columns 4-9 is applicable, dependent on angles "A."
distance 'A."
3. Locate proper tolerance in column 4, 5,6,7,8 or 9 in the same line
as value chosen in column 1.

Footnotes for previous page (Continued)


@At points less than 0.250 inch from base of leg the tolerances in Col. 2 8 These tolerances do not appiy to space
are applicable. dimensions such as dimensions 'X" and
@ Tolerances for extruded profiles in T3510, T4510, T6510, T73510, "2" of the example (right), even when
77651O and TE51O tempers shall be as agreed upon between purchaser 'Y" is 75 percent or more of 'X." For the
and vendor at the time the contract or order is entered. tolerance applicable to dimensions 'n'
z x I
@The following tolerances apply where the
space iscompletelyenclosed (hollow profiles);
For the width (A), the balance is the value
---=--
and '2,"use Col. 4, 5, 6, 7, 8 or 9, de-
pendent on distance "A." I
I
I
l
l
shown in Col. 4 for the depth dimension (D). hD ! I
For the depth (D), the tolerance is the value 31 or Greater
shown in Col. 4 for the width dimension (A). In k--A-.(
no case is the tolerance for either width or @The wall thickness tolerance for hollow or
depth less than the metal dimensions (Col. 2) semihollow profiles shall be as agreed
at the comeffi. upon between purchaser and vendor at
Example-Alloy 6061 hollow profile having 1 the time the contract or order is entered
x 3 rectangularoutside dimensions;width tolerance is Io.021 inch and when the nominal thickness of one wall is
depth tolerance 1.034 inch. (Tolerances at corners, Col. 2, metal k /LA three times or greater than that of the
dimensions, are 10.024 inch for the width and 10.012 inch for the opposite wall.
depth.) Note that the Col. 4 tolerance of 0.021 inch must be adjusted to ~ r ~ ~@Tolerancesapplyto
t e r 5malloyswith 14.0%
0.024 inch so that it is not less than the Col. 2 tolerance. nominal Mg.

25
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

Copyright The Aluminum Association Inc.


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ANSI H35.2-2003

DimensionalTolerances for

TABLE 11.3 Diameter or Distance Across Flats-Round Wire and Rod Square, Hexagonal -
and Octagonal Wire and Bar
TOLERANCE-in. plus and minus -
ALLOWABLE DEVIATION FROM SPECIFIEO IIMENSIONACROSS FLAT 3R DIAMETER
SPECIFIED ROUND SQUARE HEXA INAL OCTA' INAL
DIMENSION 3 ROD WIRE A D BAR WIRE b D BAR WIRE b D BAR
IN 5- 5ux 5- 1
24.0 Other 24.0 Other 24.0 Other 24.0
nominal Alloys nominal Alloys nominal Alloys nominal Alloys
Mg @ Mg 0 Mg @ Mg @
Up thru 0.124 0.009 0.006 0.009 0.006 0.009 0.006 0.009 0.006
0.125-0.249 0.011 0.007 0.011 0.007 0.011 0.007 0.011 0.007
0.250-0.499 0.012 0.008 0.012 0.008 0.012 0.008 0.012 0.008
0.500-0.749 0.014 0.009 0.014 0.009 0.014 0.009 0.014 0.009
0.750-0.999 0.015 0.010 0.015 0.010 0.015 0.010 0.015 0.010
1.000-1.499 0.018 0.012 0.018 0.012 0.018 0.012 0.018 0.012
1.500-1.999 0.021 0.014 0.021 0.014 0.021 0.014 0.021 0.014
2.000-3.999 0.036 0.024 0.036 0.024 0.036 0.024 0.036 0.024
4.000-5.999 0.051 0.034 0.051 0.034 0.051 0.034 0.051 0.034
6.000-7.070 0.066 0.044 I 0.066 0.066 0.044 0.066 0.044
7.071-7.999 0.066
I 0.066 0.044 0.066 0.044

I
8.000-8.659 0.081 0.054 0.081 0.054
8.660-8.999 0.081 0.054 0.081 0.054
9.000-9.238 0.081 0.054
9.239-9.999 I 0.081 0.054
10.000-11.999
12.000-13.999
14.000-15.999
Note: Shaded tolerancesdenote products with a circumscribing circle size of 10 inches in diameter and over.

TABLE 11.4 Thickness or Width (Distance Across Flats)-


Rectangular Wire and Bar
TC ERANCEin. plus and minus
ALLOW BLE DEVIATION FROM SPECIFIED
WIDT OR THICKNESS ACROSS FLATS

II II
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

SPECIFIED 5ux
DIMENSION 24.0 Other Other
IN. nominal AIIOYS I nominal AIIOYS
Mg @
Up thru 0.124 0.009 0.006
O.125-0.249 0.011 0.007
0.250-0.499 0.012 0.008
0.500-0.749 0.014 0.009
0.750-0.999 0.015 0.01o
1.000-1.499 0.018 0.012
1.500-1.999 0.021 0.014
2.000-3.999 0.036 0.024
4.000-5.999 0.051 0.034
6.000-7.999 0.066 0.044
8.000-9.999 0.081 0.054
10.000-11.999 .. ..
12.000-13.999 .. ..
14.000-15.999 .. ..
16.000-17.999 .. ..
18.000-19.999 .. ..
20.000-21.999 .. ..
22.000-24.000 ..
Note: Shaded tolerances denote products with a circumscribing circle size of 10 inches in diameter and over.

For all numbered footnotes,see two precedingpages.

26
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ANSI H35.2-2003

TOLERANCEin. plus
SPECIFIED DIAMETER (WIRE AND ROD): ALLOWABLE DEVIATION FROM SPECIFIED LENGTH
SPECIFIED WIDTH (BAR):
CIRCUMSCRIBING SPECIFIED LENGTH-ft.
CIRCLE DIAMETER @. Over Over
(PROFILES (SHAPES)) UP 12 30 Over
in. thru thru thru 50
12
30 50
Up thru 2.999 1/8 v4 % 1
3.000-7.999 Yi 6 5/,6 '/i 6 1
8.000 and over '/4 YB '/2 1

TABLE 11.6 Straightnessa -Rod, Bar and Profiles


TOLERANCE @-in.
SPECIFIED DIAMETER ALLOWABLE DEVIATION (D) FROM STRAIGHT@
(ROD): SPECIFIED
THICKNESS
SPECIFIED WIDTH (RECTANGLES):
(BAR):
PRODUCT TEMPER MINIMUM
CIRCUMSCRIBING THICKNESS
CIRCLE DIAMETER@
(PROFILES):
(PROFILES): I
TOTALLENGTH OR IN ANY
~ ~

in. IN
in. MEASURED
SEGMENT OF ONE FT.
OR MORE OF TOTAL LENGTH
All except O
TX5100 All .. ,0125 x Measured length, ft
Rod and Square, TX5110
Hexagonal
and Octagonal O 0.500 and over .. .O50 x Measured length, fl.
Bar TX51O 0 0.500 and over .. .O50 x Measured length, ft.
TX5110 0.500 and over .. ,0125 x Measured length, fl.
All except O Up thru 1.499 Up thru 0.0940 .O50x Measured length, ft.
TX51O O 0.095 and over ,0125 x Measured length, ft.
TX5110 1.500 and over All ,0125 x Measured length, ft.
Rectangular
Bar O Over 0.500 0.500 and over .O50x Measured length, ft.
TX51O O Over 0.500 0.500 and over .O50x Measured length, fl.
TX5110 Over 0.500 0.500 and over ,0125 x Measured length, ft.
All except O Up thru 1.499 Up thru 0.0940 .O50 x Measured length, ft.
TX51000 0.095 and over ,0125 x Measured length, fl.
TX511O 1.500 and over All ,0125 x Measured length, fl.
Profiles O 0.500 and over Up thru 0.0940 ,200 x Measured length, fl.
0.095 and over .O50x Measured length, ft.
TX511O 0.500 and over Up thru 0.0940 .O50x Measured length, ft.
0.095 and over .O125 x Measured length, fl.

Footnotes for this page and the following page


@These Standard Tolerances are applicable to the average profile; wider Maximum allowable
Tolerance, linear deviation
tolerances may be required for some profiles, and closer tolerances may degrees
be possible for others. inch per inch of width
0 TX510 and TX511 are general designations for the following stress % 0.004
relieved tempers:T3510,T4510,T61510,T6510,T8510,T73510,T76510 % 0.009
and T3511, T4511, T61511, T6511, T8511, T73511,T76511, respectively. 1 0.017
0 When weight of piece on the flat surface minimizes deviation. 1% 0.026
@The circumscribing circle diameter is the diameter of the smallest circle 3 0.052
that will completely enclose the cross section of the extruded product. 5 0.087
6)Tolerances for T3510, T4510, T6510, T73510, T76510, and TE510 7 0.122
tempers shall be as agreed upon between purchaser and vendor at the 9 0.156
time the contract or order is entered. 15 0.259
@ Twist is normally measured by placing the extruded section on a flat 21 0.358
surfaceand at any point along its length measuring the maximum distance
between the bottom surface of the extruded section and the flat surface. 0 Applies only if the thickness along at least V 3 of the total perimeter is
From this measurement, the actual deviation from straightness of the 0.094 or less. Otherwise use the tolerance shown for 0.095 and over.
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

extruded section at that point is subtracted. The remainder is the twist. To @Tolerancefor "O" temper material is four times the standard tolerances
convert the standard twist tolerance (degrees) to an equivalent linear value, shown.
the sine of the standard tolerance is multiplied by the width of the surface @Straightnessmust be met in all orientations, including orientations which
of the section that is on the flat surface. The following values are used to are not self-supporting.
convert angular tolerances to linear deviation:

27
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ANSI H35.2-2003
Dimensional Tolerances for

TABLE 11.7 Twist-Bar and Profiles


TOLERANCE &Degrees
ALLOWABLE DEVIATION FROM STRAIGHT
SPECIFIED SPECIFIED
WIDTH THICKNESS
(BAR): (RECTANGLES):

PRODUCT TEMPER CIRCUMSCRIBING MINIMUM


CIRCLE DIAMETER@ THICKNESS
(PROFILES): (PROFILES):

in. in. IN TOTAL LENGTH OR IN


I,!!!iZ'!
1
ANY MEASURED SEGMENT
run I u I n L
OF ONE FT. OR MORE LENGTH
OF TOTAL LENGTH
All except O Up thru 1.499 All 1 x Measured length, ft. 7
TX51O O 1.500-2.999 All K x Measured length, it. 5
TX511 O 3.000 and over All % x Measured length, ft. 3
0.500-1.499 0.500 and over 3 x Measured length, ft. 21
O 1.500-2.999 0.500 and over 1%x Measured length, it. 15
Bar 3.000 and over 0.500 and over % x Measured length, ft. 9
TX510O 0.500-2.999 0.500 and over 1K x Measured length, ft. 7
3.000 and over 0.500 and over K x Measured length, it. 5
0.500-1.499 0.500 and over 1 x Measured length, ft. 7
TX511 O 1,500-2.999 0.500 and over K x Measured length, ft. 5
3.000 and over 0.500 and over % x Measured length, it. 3

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---
All exceot O UDthru 1.499 All 1 x Measured length, ft. 7
TX5106@ 1,500-2.999 All K x Measured length, ft. 5
TX511 O 3.000 and over All % x Measured length, ft. 3
0.500 and over Up thru 0.094 0 3 x Measured length, ft. 21
O 0.500-1.499 0.095 and over 3 x Measured length, ft. 21
Profiles 1.500-2.999 0.095 and over 1Y5 x Measured length, it. 15
3.000 and over 0.095 and over 34 x Measured length, it. 9
0.500 and over Up thru 0.094 0 1x Measured length, ft. 7
TX511 O 0.500-1.499 0.095 and over 1x Measured length, ft. 7
1.500-2.999 0.095 and over Kx Measured length, it. 5
0.095 and over %x Measured length, R. 3

TABLE 11.8 Flatness (Flat Surfaces)@-Bar, Solid Profiles and Semihollow Profiles
EXCEPT FOR PROFILES IN O@, T3510, T4510, T6510,l73510, T76510 and T8510 TEMPERSO

SURFACES WIDTHS UP THRU 1 INCH OR ANY 1 INCH INCREMENT OF


WIDER SURFACES
Maximum Allowable Deviation D = TOLERANCE (in.)

WIDTHS OVER 1 INCH


Maximum Allowable Deviation D = TOLERANCE x W (in.)

0.500-0.749 .O04 .O04 .O06 .O06 .O08 .O08 .O08 .O08 .O10 .O10 .o12
0.750-0.999 .O04 .O04 ,006 .O06 .O08 .O08 .O08 .O08 .O08 .O08 .o10
1.000-1.499 ,004 ,004 ,004 ,006 .O06 ,008 ,008 .O08 .O08 ,008 .O08
1.500-1.999 ,004 ,004 ,004 ,004 .O06 .O06 .O06 .O08 .O08 .O08 .O08
2.000 and up ,004 .O04 ,004 .O04 ,004 ,006 ,006 .O06 .O08 .O08 .O08
For all numbered footnotes, see previous page.

28
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Aluminum Mill Products


HOLLOW PROFILES EXCEPT FOR PROFILES IN O@, T3510, T4510, T6510, T73510,
TABLE 11.9 Flatness (Flat Surfaces)o l76510 and T8510TEMPERS@

SURFACES WIDTHS UP THRU 1 INCH OR ANY 1 INCH INCREMENT OF WIDER SURFACES


Maximum Allowable Deviation D = TOLERANCE (in.)
WIDTHS OVER 1 INCH
Maximum Allowable Deviation D = TOLERANCE x W (in.)

0.500-0.749 ,004 .O04 ,006 ,008 ,008 ,008 .O1O .O1O .O12 .O12 .O14
0.750-0.999 .O04 .O04 ,006 ,006 ,008 .O08 .O08 .O08 .O1 O .O1 O .O12
1.O00and up ,004 ,004 ,004 ,006 ,006 .O08 .O08 .O08 .O08 .O08 .O08

TABLE 11.1 O Surface Roughnessm-Wire TABLE 11.13 Corner and Fillet Radia-
Rod, Bar & Profiles Bar and Profiles
ALLOWABLE DEPTH TOLERANCE-in.
SPECIFIED SECTION THICKNESS OF CONDITIONS @
in. in. max. FROM SPECIFIED RADIUS
Up thru 0.063 .O015
0.064-0.125 .o02
0.126-0.188 ,0025 SPECIFIED RADIUS@
0.189-0.250 .O03 in.
0.251-0.500 .O04
0.501- and over .O08

Difference between radius


TABLE 11.1 1 Contour (Curved S u r f a c e s p A and specified radius
Profiles
Sham corners I +1/64
Temper 0.01?6-0.187 f l/64
0.188 and over i 10%

inch of chord length; 0.005inch minimum. Not applicable to

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---
TOLERANCE
Allowable deviation from specified contour: 0.015 inch per Degrees plus and minus
inch of chord length; 0.015 inch minimum. Not applicable to ALLOWABLE DEVIATION FROM
SPECIFIED ANGLE
ILCOL. 3
TABLE 11.12 Sauareness of Cut Ends@
~~ ~
MINIMUM \*COL.
Allowable deviation from square: 1 degree SPECIFIED
30
TEMPER LEG Y.
THICKNESS
?
in.

RATIO: @@)LEG OR SURFACE


LENGTH TO LEG OR METAL
THICKNESS

_I--
1 and less Over 1thru 40
COI. 1 COL2 C01.3
Up thru 0.187
All except
0.188-0.749
O, TX510G
1.750 and over

O
Up thru 0.187
0.1884.749
1.750 and over
3 I %
:

For all numbered footnotes, see following page.

29
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ANSI H35.2-2003

Dimensional Tolerances for

Footnotes for previous page


0 These Standard Tolerances are applicable to the average profile; O Mgles are measuredwith protractors or with gauges.
wider tolerances may be required for some profiles, and closer toler- As illustrated, a four-point contact system is used, two
ances may be possible for others. contact points being as dose to the angle vertex as prao
@ Conditions include die lines and handling marks. -1, and the others near the ends of the recpective
O As measured with a contour gauge whose surface is limitedto a maximum surfaces foming me angle. Between these points of
subtended angle of 90 degrees. Extruded wived surfaces comprising more measurementsurface flahess is the controlling tolerance.
than a M e g r e e subtended angle are ched<ed by sliding the gauge aaocs @When the area between the surface fotming an angle is ail metal, vaiues in
the surface, thus checking two or more %degree portions of the surface. column 2 apply if the larger surface length to metal thickness ratio is 1 or less.
Extruded profilesurfaces comprising ans fomed by two or more radii require @ When two legs are involved the one having the larger ratio detemines the
the use of a separate contour gauge for each portion of the surface fomed by applicable column.
an inddual radius. @ Not applicable to 2219 alloy exbusions. Most profiles in 2219 alloy will have
@TolerancesforT3510,T4510,T6610,l73510,T76510andT8510 die lines about twice the depth shown in the table; however, for each profilethe
tempers shall be as agreed upon between the purchaser and vendor and at supplier should be contacted for the roughnessvalue to apply.
the time the contract or order is entered. 63If unspecified, the radius shall be 1/32 in. maximum induding tolerances.
@ Tolerance for "(Y' temper material is four times the standard tolerancec
shown.
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

30
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Aluminum Mill Products

12. Extruded Tube


--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

31
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DimensionalTolerances for

TABLE 12.2
~~ Diameter-Round Tube
EXCEPT FOR T3510, T4510, T6510,i73510,i76510 AND T8510 TEMPERSO

I ALLOWABLE DEVIATION OF MEAN DIAMETER@


FROM SPECIFIED DIAMETER (Size)
I
TOLERANCE Qin. plus and minus
ALLOWABLE DEVIATION OF DIAMETER AT ANY POINT
FROM SPECIFIED DIAMETER @

SPECIFIED
DIAMETERQ

In.
I B
A@ A

Differencebetween H (AA+BB)
B
and specified diameter Difference between AA or BB and specified diameter
Col. 2 Col. 3
Col. 1 5 x u 24.0 S a u 24.0
Other Alloys Other Alloys
nominal Mg@ nominal Mg @
0.500-0.999 .o15 .o1 o .O30 .O20
1.000-1.999 .o18 .o1 2 .O38 .O25
2.000-3.999 .O23 .o15 .o45 .O30
4.000-5.999 .O38 .O25 .O75 .O50
6.000-7.999 .O53 .O35 ,113 .O75
8.000-9.999 .O68 .o45 ,150 ,100
10.000-1 1.999 .O83 .O55 .188 ,125
12.000-1 3.999 .O98 .O65 .225 ,150
14.000-15.999 ,113 .O75 .263 .175
16.000-17.999 ,128 .O85 .300 ,200
18.000-19.999 ,143 .O95 .338 225
20.000-21.999 ,158 .lo5 ,375 ,250
22.000-23.999 ,173 ,115 ,413 ,275

I NOT AT CORNERS FROM SPECIFIED WIDTH OR DEPTH@

SPECIFIED
WIDTH
OR
DEPTH

in.
I A A A
AT CORNERS FROM SPECIFIED WIDTH OR
DEPTHDifference between AA and specified Difference between AA and specified
width or depth width, depth, or distance across flats
SQUARE RECTANGULAR
SQUARE, RECTANGULAR
HEXAGONAL, OCTAGONAL
Col. 2 Col. 3 Col. 4
Col. 1 5- >4.0 Other 5- >4.Q Other All
nominal Mg @ Alloys nominal Mg @ Alloys Alloys
0.500-0.749 .o18 .o12 .O30 .O20
0.750-0.999 .o21 .o14 .O30 .O20 The tolerance for the width is
1.000-1.999 .O27 .O18 .O38 .O25 the value in the previous column
2.000-3.999 .O38 .O25 .O53 .O35 for a dimension equal to the
4.0004.999 .O53 .O35 .O68 .o45 depth, and conversely, but in no
5.000-5.999 .O68 .o45 .O83 case is the tolerance less than
6.000-6.999 .O83 .O55 .O98 .O65 at the corners.
7.000-7.999 .O98 .O65 ,108
8.000-8.999 ,113 .O75 Examp1e:Thewidthtoleranceof
,123 ‘Oa5 a 1 x 3 inch alloy 6061 rectan-
9.000-9.999 ,128 .O85 ,143 ‘Og5
gular tube is Io.025 inch and
10.000-1 0.999 ,143 .O95 ,158 ,105 the depth tolerance 10.035 inch.
11.000-12.999 ,158 ,105 ,173 ,115

@When outside diameter, inside diameter, and wall thickness (or their @Mean diameter is the average of two diameter measurements taken at
equivalent dimensions in other than round tube) are all specified, standard right angles to each other at any point along the length.
tolerances are applicable to any two of these dimensions, but not to all @Not applicable in the annealed (O) temper of if wall thickness is less than
three. When both outside and inside diameters or inside diameter and wall 2% percent of outside diameter of a circle having a circumference equal to
thickness are specified, the tolerance applicable to the specified or the perimeter of the tube.
calculated O.D. dimension shall also apply to the I.D. dimension. 0 Tolerances for T3510, T4510, T6510, l73510, i76510 and T8510
@When a dimension tolerance is specified other than as an equal bilateral tempers shall be as agreed upon between purchaser and vendor at the
tolerance, the value of the standard tolerance is that which applied to the time the contract or order is entered.
mean of the maximum and minimum dimensions permissible under the @Tolerances apply to 5xxx alloys with 24.0% Mg.
tolerance for the dimension under consideration.

32
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

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Aluminum Mill Products

TABLE 12.4

ALLOWABLE DEVIATION OF MEAN WALL THICKNESS8 FROM ALLOWABLE DEVIATION


SPECIFIED WALL THICKNESS OF WALL THICKNESS
AT ANY POINT FROM
SPECIFIED MEAN WALL THICKNESS 8

@i#P
WALL (Eccentricity)
THICKNESS@

in.
\B
Difference between H (AA + BB) and specified wall thickness
HETER-IN. Difference between AA and
Under 1.250 3.000-4.999 5.000 and over mean wall thickness
Ca 2 Col. 3 CI 4 Col. 5 Col. 6
5ux 5 m 5-
Col. 1 24.0 Other 24.0 Other 24.0 Other Other
All Alloys
nominal Alloys nominal Alloys nominal Alloys
Mg @ Mg @ Mg @
Under 0.047 .O09 .O06 .. .. .. ..

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---
0.047-0.061 .o11 .O07 .o12 .o08 .o12 .O08 Plus and
0.062-0.077 .o12 .O08 .o12 .O08 .o14 .O09 minus
0.078-0.124 .O14 .O09 .O14 .O09 .o15 .O10 10% of
O.125-0.249 .O14 .O09 .O14 .O09 .O20 .O13 .O30 .O20 mean
0.250-0.374 .O17 .o11 .o17 .o1 1 .O24 .O16 .O25 wall
0.375-0.499 .. .. .O23 .o15 .O32 .o21 .O53 .O35 thickness
0.500-0.749 .. .O30 .O20 .o42 .O28 .O68 .o45
0.750.999 .. .. .. .O53 .O35 .O83 max 10.060
1.000-1.499 .. .. .. .O68 .o45 .O98 min iO.010
1.500-2.000 .. .. .. .. ..
2.001-2.499 .. .. .. .. ..
2.500-2.999 .. .. .. .. .. io.1 20
3.000-3.499 .. .. .. .. .. ,105
3.500-4.000 .. .. .. .. .. ,173 ,115

TABLE 12.5 Wall Thickness-ûther-Than-Round Extruded Tube


TOLERANCE awn.plus and minus
ALLOWABLE DEVIATION OF MEAN WALL ALLOWABLE DEVIATION OF WALL THICKNESS
THICKNESS@FROM SPECIFIED WALL THICKNESS AT ANY POINT FROM MEAN WALL

67
THICKNESS 8 (Eccentricity)
SPECIFIED
WALL
THICKNESS@
A+ A' @ A - g i g
in.
Difference between 'h (AA + BB) and
speciïied wall thickness Difference between AA and mean wall thickness
CIRCUMSCRIBING CIRCLE DIAMETER @-in.
Under 5.000 5.000 and over Under 5.000 5.000 and over
Col. 2 Col. 3 Col. 4 Col. 5
Col. 1 5 u x 24.0 Other 5- 24.0 Other All All
nominal Mg@ Alloys nominal Mg @ Alloys Alloys Alloys
Under 0.047 .O08 .O05 .o12 .O08 .O05
0.047-0.061 .O09 .O06 .o14 .O09 .O07 Plus and
0.062-0.124 .o11 .O07 .o15 .o1o .o1o minus
0.125-0.249 .o12 .O08 .O23 .o15 .o15 10% of
0.250-0.374 .o17 .o11 .O30 .O20 .O25 mean
wall
0.375-0.499 .o21 .O14 .o45 .O30 .O30 thickness
0.500-0.749 .O38 ,025 .O60 .o40 .o40
0.750.999 .O53 .O35 .O75 .O50 .O50 max 4.060
1.000-1.499 .O68 .o45 .O90 .O60 .O60 min iO.010
1.500-2.000 .. .. .I 05 .O70 ..
@ When outside diameter, inside diameter, and wall thickness (or their ments taken opposite each other. The mean wall thickness of other-than-
equivalent dimensions in other than round tube) are all specified, standard round tube is the average of two measurements taken opposite each other
tolerances are applicable to any two of these dimensions, but not to all at approximate center line of tube and perpendicular to the longitudinal axis
three. When both outside and inside diameters or inside diameter and wall of the cross section.
thickness are specified, the tolerance applicable to the specified or @ When dimensions specified are outside and inside, rather than wall
calculated O.D. dimension shall also apply to the I.D. dimension. thickness itself, allowable deviation at any point (eccentricity) applies to
@When a dimension tolerance is specified other than asan equal bilateral mean wall thickness.
tolerance, the value of the standard tolerance is that which applied to the @The circumscribing circle diameter is the diameter of the smallest circle
mean of the maximum and minimum dimensions permissible under the that will completely enclose the cross section of the extruded product.
tolerance for the dimension under consideration. @Tolerancesapply to 5xxx alloys with 24.0% Mg.
6) The mean wall thickness of round tube is the average of two measure-

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Dimensional Tolerances for

TOLERANCE-in. plus excepted as noted


ALLOWABLE DEVIATION FROM SPECIFIED LENGTH
SPECIFIED OUTSIDE STRAIGHT COILED
DIAMETER OR WIDTH SPECIFIED LENGTH-ft.
in. Over Over Over Over
UP 12 30 Over UP 1O0 250 Over
thru thru
thru thru 50 thru thru 500
12 1O0
30 50 250 500
0.500-1.249 .1/8 V'4 Y8 1 +5%, -0% I 10% 11 5% &O%
1.250-2.999 '/a %4' Y8 1 .. .. .. ..
3.000-7.999 YI 6 vi6 7/i6 1 .. .. .. ..
8.000and over '/4 Y8 712 1 .. .. .. ..

TABLE 12.7 Twist-ther than Round Tube


TOLERANCE @&Degrees
ALLOWABLE DEVIATION FROM STRAIGHT

SPECIFIED
TEMPER WIDTH
in. in. I
Y (max.) in degrees

IN ANY SEGMENT OF
FOR TOTAL
ONE Fí. OR MORE
LENGTH
OF TOTAL LENGTH
All except O, 0.500 thru 1.499 All 1 x Measured length, ft. 7
TX51O, TX511 @ 1,500-2.999 All W x Measured length, ft. 5
3.000 and over All % x Measured length, ft. 3
TX51O @ 0.500 and over 0.095 and over o o
TX511 @ 0.500-1.499 0.095 and over 1 x Measured length, ft. 7
1.500-2.999 0.095 and over H x Measured length, ft. 5
3.000 and over 0.095 and over % x Measured length, ft. 3

Maximum allowable
Tolerance,
linear deviation
degrees

1 0.017
1% 0.026
3 0.052
5 0.087
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

7 0.122
9 0.1 56
15 0.259
21 0.358

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Aluminum Mill Products


TABLE 12.8 Straightness-Tube in Straight TABLE 12.11 Corner and Fillet Radii
Lengths TOLERANCE-in.
TOLERANCE a w n . ALLOWABLE DEVIATION
FROM SPECIFIED
ALLOWABLE DEVIATION (D) RADIUS
FROM STRAIGHT

SPECIFIED RADIUS
TEMPER in.@
in. d
IN TOTAL LENGTH OR
IN ANY SEGMENT OF J
ONE FT. OR MORE
OF TOTAL LENGTH Differencebetween radius
A and specified radius
All except 0.500-5.999 .O1O x Measured length, it.
O, TX51O @ Sharp corners i'/64
0.016-0.187 I'/64
0.500 0.1 88 and over I 10%
TX51O @
and over

TABLE 12.12 Angularity


TABLE 12.9 Flatness (Flat Surfaces) Allowable deviation from square: 12 degrees.
EXCEPT FOR O, T3510, T4510, T6510, T73510, T76510 AND TE510
TEMPERSO
TOLERANCE-in.

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---
Specified Specified Allowable
Outside Wall Depth of
Diameter Thickness Conditions@
in. in. in., max.
MINIMUM THICKNESS
OF METAL FORMING Up thru 0.063 0.0025
THE SURFACE 0.0644.125 0.003
in. Up thru 0.126-0.188 0.0035
12.750 0.189-0.250 0.004
Maximum Allowable Deviation Y 0.251-0.500 0.005
0.501 and over 0.008
1 IN. OR ANY 1 12.751-1 5.000 Up thru 0.500 0.010
IN. INCREMENT 0.501 and over 0.012
15.001-20.000 Up thru 0.500 0.012
Up thru 0.187 0.006 0.006 x W (inches) 0.501 and over 0.015
0.188and over 0.01 5
Up thru 0.500
20.001 and over 0.501 and over 0.020

TABLE 12.1O Squareness of Cut Ends TABLE 12.14 Dents @


Allowable deviation from square: 1 degree. Depth of dents shall not exceedtwice the tolerances specified in Table 12.1
for diameter at any point from specified diameter, except for tube having a
wall thickness less than 2.5 percent of the outside diameter, in which case
the following multipliersapply:

2% to 2%% exclusive-2.5 x tolerance (max.)


1%% to 2% exclusive-3.0 x tolerance (max.)
1% to 1%% exclusive-4.0 x tolerance (max.)

0 Tolerances for T351O, T4510, T6510, T7351O, T7651O and TE510 @ Conditions include die lines, mandrel lines and handling marks.
tempers shall be as agreed upon between purchaser and vendor at the @For tube over 12.750 in. O.D. the 2000 and 7000 series alloys and 5000
time the contract or order is entered. series alloys with nominal magnesium content of 3 percent or more are
@ TX510 and TX511 are general designations for the following stress- excluded.
relieved tempers: T3510, T4510, T6510, T8510, T73510, T76510; and @Not applicable to O temper tube.
T3511, T4511, T6511, T8511,T73511, E'6511, respectively. @Not applicableto 2219 alloy tube. Most tubes in 2219 alloy will have die
@When weight of piece on flat surface minimizes deviation. lines about twice the depth shown in the table; however, for each tube size
@TolerancesnotapplicabletoTX510,orTX511 tempertubehavingawall the supplier should be contacted for the roughness value to apply.
thickness less than 0.095 in. @If unspecified, the radius shall be '/y in. maximum including tolerances.

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Dimensional Tolerances for

TABLE 12.16 Outside Diameter-Extruded Coil Tube


SPECIFIED TOLERANCE-in. plus and minus
OUTSIDE DIAMETER ALLOWABLE DEVIATION OF MEAN ALLOWABLE DEVIATION OF DIAMETER
in. DIAMETER FROM SPECIFIED DIAMETER AT ANY POINT FROM SPECIFIED DIAMETER
0.250-0.625 0.004 0.006

TABLE 12.17 Wall Thickness-Extruded Coil Tube


TOLERANCEin. plus and minus
SPECIFIED WALL ALLOWABLE DEVIATION OF MEAN WALL ALLOWABLE DEVIATION OF WALL THICKNESS
THICKNESS, in. THICKNESS FROM SPECIFIEDWALL AT ANY POINT FROM SPECIFIED WALL
THICKNESS THICKNESS
0.032-0.050 0.003 0.004

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---
PERCENT OF COILS IN SHIPMENT RANGE OF LENGTH
70 min. 80 to 120 percent of nominal
30 m a . 60 to 80 percent of nominal

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Aluminum Mill Products

TABLE 12.20 Diameter-ürawn Round Tube


1 TOLERANCE &in. plus and minus

/
ALLOWABLE DEVIATION OF MEAN DIAMETER @ ALLOWABLE DEVIATION OF DIAMETER AT ANY POINT
FROM SPECIFIED DIAMETER (Si=) FROM SPECIFIED DIAMETER@

SPECIFIED
DIAMETER A+ O
in.
4
Am@ B
B
Difference between AA or BB and specified diameter

Difference between H (AA + BB) AND


NON-HEAT-TREATED HEAT-TREATED ANNEALED
and specified diameter TUBE O TUBE
TUBE
Col. 1 Col. 2 Col. 3 Col. 4 Col. 5
Up thru 0.500 .O03 .O03 .O06 .o18
0.501-1.O00 .O04 .O04 .O08 .O24
1.001-2.000 .O05 .O05 .O10 .O30
2.001-3.000 .O06 .O06 .o12 .O36
3.001-5.000 .O08 .O08 .O16 .o48
5.001-6.000 .o1o .O10 .O20 .O60
6.001-8.000 .o15 .o15 .O30 .O90
8.001-10.000 .O20 .O20 .O40 ,120
10.001-12.000 .O25 .O25 050 150

TABLE 12.21 Width and Depth-Drawn Square, Rectangular, Hexagonal and Octagonal Tube
TOLERANCE &-n
i. plus and minus
ALLOWABLE DEVIATION OF WIDTH OR DEPTH ALLOWABLE DEVIATION OF WIDTH OR DEPTH
AT CORNERS FROM SPECIFIED WIDTH OR DEPTH NOT AT CORNERS
FROM SPECIFIED WIDTH OR DEPTH OB)

SPECIFIED
WIDTH
OR
DEPTH a
in.
A A A

Difference between AA and specified Difference between AA and specified


width or depth width, depth, or distance across flats
SQUARE, RECTANGULAR
SQUARE, RECTANGULAR
HEXAGONAL, OCTAGONAL
Col. 1 Col. 2 Col. 3 Col. 4
Up thru 0.500 .O03 ,006
0.501-1.000 ,004 .o08
1 .O01-2.000 .o05 .o1o The tolerance for the width is the
.O06 .o12 value in Col. 3 for the dimension
2.001-3.000
3.001-5.000 .O08 .O16 equal to the depth, and conversely,
5.001-6.000 .o1o .o20 but in no case is the tolerance less
than at the comers. @
6.001-8.000 .o15 .O30
8.001-10.000 .O20 .o40
10.001-1 2.000 .o25 .O50

0 When outside diameter, inside diameter, and wall thickness (or their
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

@Not applicable to coiled tube or tube having a wall thickness less than
equivalent dimensions in other than round tube) are all specified, standard 2% percent of the specified outside diameter. The tolerance for tube with
tolerances are applicable to any two of these dimensions, but not to all wall thickness less than 2% percent of the specified outside diameter is
three. When both outside and inside diameters or inside diameter and wall determined by multiplyingthe applicable tolerance in columns 3 thru 5 as
thickness are specified, the tolerance applicable to the specified or calcu- follows:
lated O.D. dimension shall also apply to the I.D. dimension. 2% to 2%% exclusivc+l.5 x tolerance
@When a dimension tolerance is specified other than asan equal bilateral 1 %% to 2% exclusive-2.0 x tolerance
tolerance, the value of the standard tolerance is that which applies to the 1 % to 1%% exclucive3.0 x tolerance
mean of the maximum and minimum dimensions permissible under the %% to 1 % exclusive-4.0 x tolerance
tolerance of the dimension under consideration. @ For the T8 tempers of 6063 the tolerances in Column 3 apply.
@ Mean diameter is the average of two diameter measurements taken at @Example:The width tolerance of 1 x 3 inch rectangular tube is plus and
right angles to each other at the same longitudinal location on the tube. minus 0.008 inch, and the depth tolerance is plus and minus 0.012in.
0 Not applicable to annealed (O temper) tube.

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DimensionalTolerances for

TABLE 12.22 Diameter-Drawn Oval, Eliptical TABLE 12.23 Corner Radii-Drawn Tube
and Streamline Tube TOLERANCE @L n
i.
TOLERAN i@ U n . ALLOWABLE DEVIATION FROM
SPECIFIED RADIUS
LENGTH OF LENGTH OF
MAJOR AXIS, in. MAJOR AXIS, in.

EQUIVALENT SPECIFIED~
ROUND RADIUS
DIAMETER 8
in. in.

Difference between Difference between


AA and AA and
specified length specified length
Col. 1 Col. 2 Col. 3 Difference between radius A and
specified radius
Up thru 2.500
2.501-4.250 Sharp Corners +l/64
4.251-6.000 0.016-0.187 I
l/64
6.001-8.000 0.188 and over *lo%
8.001-10.000

TABLE 12.24 Wall Thickness-Drawn Round and Other-Than-Round Tube


TO :RANCE@&in. plus and minus
ALLOWABLE DEVIATION OF MEAN WALL ALLOWABLE DEVIATION OF WALL THICKNESS
THICKNESS@ FROM SPECIFIED AT ANY POINT FROM SPECIFIED WALL THICKNESS
WALL THICKNESS (Eccentricity)
ROUND, NON-HEAT- ROUND, HEAT-TREATABLE ALLOYS AND
TREATABLEALLOYS@ OTHER THAN ROUND. ALL ALLOYS
SPECIFIED
THICKNESS @

in

Difference between H(AA+BB) and


specified wall thickness

Col. 1 Col. 2 Col. 3 Col. 4


0.010-0.035 .O02 .O02
0.036-0.049 .O03 .O03
0.050-0.083 .o04 .O04
0.084-0.1 20 .O05 .O06 Plus and minus 10% of specified
0.1 21-0.203 .O06 .O08 wall thickness, min 10.003
0.204-0.300 .O08 .o12
0.301-0.375 .o15 .O20
0.376-0.500 .O30
0 When outside diameter, inside diameter, and wall thickness (or their than-round tube is the average of two measurementstaken opposite each
equivalent dimensions in other-than-roundtube) are all specified, standard other at approximate center line of tube and perpendicular to the longitudi-
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

tolerances are applicable to any two of these dimensions, but not to all nal axis of the cross section.
three. When both outcide and inside diameters or inside diameter and wall @ When dimensions specified are outside and inside, rather than wall
thickness are specified, the tolerance applicable to the specified or thickness itself, allowable deviation at any point (eccentricity) is plus and
calculated O.D. dimension shall also apply to the I.D. dimension. minus 10 percent of the mean wall thickness but not less than 10.003 inch.
@When a dimension tolerance is specifiedother than as an equal bilateral @ Equivalent round diameter is the diameter of the circle having a
tolerance, the value of the standard tolerance is that which applies to the circumference equal to the perimeter of the tube.
mean of the maximum and minimum dimensions permissible under the @ I tube, values in Column 4 apply.
For coiled
tolerance for the dimension under consideration. 0 If unspecified, the radius shall be 1/32 in. maximum including tolerances.
@ The mean wall thickness of round tube is the average of two mea-
surements taken opposite each other. The mean wall thickness of other-

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Aluminum Mill Products

TABLE 12.25 Straightness-ürawn Tube TABLE 12.26 TwistbDrawn Tube


TOLERANCE @&in. TOLERANCE Q@-Degree
ALLOWABLE DEVIATION FROM STRAIGHT ALLOWABLE DEVIATION FROM STRAIGHT

SPECIFIED
OUTSIDE
DIAMETER
OR WIDTH
in.
in.
D(mW Y ( m a ) in degrees
IN TOTAL LENGTH OR IN ANY IN TOTAL LENGTH OR
MAXIMUM
MEASURED SEGMENT OF ONE FT. IN ANY MEASURED
OR MORE OF TOTAL LENGTH SEGMENT OF ONE Fi.OR
Up thru 0.374 ,500 x Measured length, ft. MORE OF TOTAL LENGTH LENGTH
0.375-5.999 .O10 x Measured length, ft. Up thru 1.499 1 x Measured length, ft. 7
6.000 and over .O20x Measured length, ft. 1.500-2.999 Y2 x Measured length, ft. 5
3.000 and over % x Measured length, ft. 3

TABLE 12.27 Length-Drawn Tube


TOLERANCE-in. plus except as noted
SPECIFIED ALLOWABLE DEVIATION FROM SPECIFIED LENGTH
OUTSIDE DIAMETER STRAIGHT COILED
OR WIDTH SPECIFIED LENGTH-fi.
in. UP Over12 Over30 Over
Up thru Over 100 250 500 and
thru thru thru
12 30 50 50 1O0 to 250 to 500 over
Up thru 0.249 1/4 Y8 v2 .. +5%, -0% I 10% I 15% &O%
0.250-1.249 V8 1/4 Y8 1 +5%, -0% I 10% I 15% &O%
1.250-2.999 1 .. .. .. ..
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

'/8 v4 Y8
3.000-7.999 Y16 Y1 6 '/i6 1 .. .. .. ..
8.000 and over v4 Y8 1/2 1 .. .. .. ..

TABLE 12.28 Flatness (Flat Sutfacesk TABLE 12.30 Anqularity-Drawn


- Tube
Other-Than-Round Drawn Tube Allowable deviation from specified angle: i2 degrees
I TOLERANCE u n .
1 ALLOWABLE DEVIATION FROM FLAT

@Tolerance is applicable when weight of tube on flat surface minimizes


SPECIFIED deviation.
WIDTH OR DEPTH @ Not applicable to annealed (O temper) tube.
@ Not applicable to annealed (O temper) tube, wiled tube, or tube
in. having a wall thickness less than 0.020inch or less than 2H% of the
equivalent round diameter. Equivalent round diameter is the diameter of
a circle having a circumference equal to the perimeter of the tube.
@Twist is normally measured by placing the drawn tube on a flat surface
and at any point along its lengthmeasuring the maximum distance between
allowable distance Y the bottom surface of the drawn tube and the flat surface. From this
measurement, the actual deviation from straightness of the drawn tube at
Up thru 0.500 .O03
that point is subtracted. The remainder is the twist. To convert the standard
0.501-1.000 .O04
twist tolerance (degrees) to an equivalent linear value, the sine of the
1.001-2.000 .O05 standard tolerance is multiplied by the width of the surface of the section
.O06 that is on the flat surface. The following values are used to convert angular
3.001-5.000 .O08 tolerances to linear deviation:
5.001-6.000 .o1o
6.001-8.000 .o15 Maximum allowable
8.001-10.000 .O20 Tolerance,
linear deviation
10.001-12.000 .O25 degrees
inch per inch of width
x 0.004
Y2 0.009
TABLE 12.29 Squareness of Cut Ends- 1 0.017
1% 0.026
Drawn Tube 3 0.052
5 0.087
Allowable deviation from square: 1 degree 7 0.122
9 0.156
15 0.259
21 0.358

39
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ANSI H35.2-2003
Dimensional Tolerances for

TABLE 12.31 Surface RoughnessQ TABLE 12.36 Wall Thickness-Heat Exchanger


Drawn Tube Tube
Depth of surface conditions shall not exceed 10% of the smaller (or TOLERANCEin. plus
nominal) wall thickness or 0.005 inch, whichever is smaller. SPECIFIED
WALL
ALLOWABLE DEVIA- I ALLOWABLE DEVIATION
TION OF MEAN @ OF WALL THICKNESS AT
@ Not applicable to annealed (O temper) tube THICKNESS, WALL THICKNESS ANY POINT FROM
in. FROM SPECIFIED SPECIFIED WALL
WALL THICKNESS THICKNESS (Eccentricity)
TABLE 12.32 Dents-ûrawn Tube Up thru 0.035 .O04 .O06
0.036-0.049 .O06 .O09
TOLERANCESin. 0.050-0.058 .O07 .O10
SPECIFIED 0.059-0.065 .O08 .o12
DIAMETER NON-ANNEALED AND HEAT-TREATED ANNEALED 0.066-0.072 .O09 .o1 3
in. NON-HEAT-TREATED TUBE 8
TUBE
TUBE 0.073-0.083 .o1o .o15
0.084-0.095 .o11 .O17
Col. 1 Col. 2 Col. 3 Col. 4 0.096-0.109 .o13 .O20
Up thru 0.500 ,006 .o12 .O36 0.110-0.120 .o14 .O22
0.501-1.000 .O08 .O16 .O48 0.121-0.1 34 .O16 .O24
1.001-2.000 .o1o .o20 .O60 0.135-0.145 .O17 .O26
2.001-3.000 .o12 .O24 .O72 0.1 46-0.1 54 .o18 .O28
3.001-5.000 .O16 .O32 .O96 0.1 55-0.1 79 .o21 .O32
5.001-6.000 .O20 .O40 .120 0.1 80-0.200 .O24 .O36
6.001-8.000 .O30 .O60 ,180
8.001-1 0.000 .O40 .O80 ,240
10.001-1 2.000 .O50 ,100 ,300 TABLE 12.37 Length-Heat Exchanger Tube
SPECIFIED LENGTH TOLERANCE-in. plus
Up thru 15 y32
Over 15-20 '/e
Over 20-30 y16
Over 30-60 '/4

TABLE 12.38 Straightness-Heat Exchanger


Tube
TOLERANCE @-in.
ALLOWABLE DEVIATION FROM STRAIGHT

TABLE 12.34 Outside Diameter-


SPECIFIED
Heat-Treatable OUTSIDE
Heat Exchanger Tube DIAMETER
in.
SPECIFIED OUTSIDE TOLERANCE in.
DIAMETER, in. plus and minus D(mW
Up thru 0.500 IN TOTAL LENGTH OR IN ANY
0.501-1.000 MEASURED SEGMENT OF ONE Fi.
1.001-1 500 .O05 OR MORE OF TOTAL LENGTH
1.501-2.000 0.375-2.000 .O10 x Measured length, ft.

TABLE 12.35 Outside Diameter- TABLE 12.39 Squareness of Cut Ends-


Non-Heat-Treatable Heat Exchanger Tube
Heat Exchanger Tube Allowable deviation from square: 1 degree
SPECIFIED OUTSIDE TOLERANCE 6 in.
DIAMETER, in.
Up thru 0.500 0 As measured by use of 'go" or "no go" ring gages.
0.501-0.749 ,0025 @ Mean wall thickness is the average of h o measurements taken
0.750-1 .O00 opposite each other.
1.001-1.250 ,0035 @Tolerance is applicable when weight of tube on flat surface minimizes
1.251-2.000 ,004 deviation.

40
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

Copyright The Aluminum Association Inc.


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ANSI H35.2-2003

Aluminum Mill Products

Welded Tube

ALLOWABLE DEVIATION OF MEAN DIAMETER@ ALLOWABLE DEVIATION OF DIAMETER AT ANY POINT


FROM SPECIFIED DIAMETER (Size) FROM SPECIFIED DIAMETER

SPECIFIED
DIAMETER @

in.

B A +
Difference between H (AA+BB) B
and specified diameter Difference between AA or BB and specified diameter
Col. 1 Col. 2 Col. 3
0.500-1 .O00 .O04 .O08
1.001-2.000 .O05 .o1o

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---
TABLE 12.42 Width and Depth Tolerances- TABLE 12.43 Wall Thickness Tolerances-
Welded Square Tube Welded Round and Square Tube
TOLERANCE &h. plus and minus TOLERANCE @-in. plus
ALLOWABLE DEVIATION OF WALL
DEVIATION OF DEVIATION OF THICKNESS AT ANY POINT FROM
WIDTH OR DEPTH WIDTH OR DEPTH SPECIFIED WALL THICKNESS
AT CORNERS NOT AT CORNERS
FROM SPECIFIED FROM SPECIFIED SPECIFIED
WIDTH OR DEPTH WIDTH OR DEPTH THICKNESS
SPECIFIED
WIDTH OR
in.
DEPTH
in.

A 0.025-0.041 .O04
Difference between Ditference between 0.042-0.071 .O05
AA and specified AA and specified
width or depth width or depth
Col. 1 Col. 2 Col. 3
0.501-1.000 .O05 .O08
1.001-2.000 .O06 .o1o

@When adimension tolerance is specified other than asan equal bilateral @ Mean diameter is the average of two diameter measurements taken at
tolerance, the value of the standard tolerance is that which applies to the right angle to each other at any point along the length.
mean of the maximum and minimum dimension permissible under the @ Not applicable to the weld area or to embossed tube.
tolerance for the dimension under consideration.

41
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Dimensional Tolerances for

TABLE 12.44 Length Tolerances- TABLE 12.46 Twist0 Tolerances-


Welded Tube Welded Tube
TOLERANCEin. TOLERANCE @-Degrees
ALLOWABLE DEVIATION FROM SPECIFIED LENGTH ALLOWABLE DEVIATION FROM STRAIGHT
OUTSIDE SPECIFIED LENGTH-.
DIAMETER Over 12
..' ....
UP Over 20
OR WIDTH thru thru thru
in. 12 20 40 SPECIFIED
Plus( Minus Plus Minus Plus Minus I I WIDTH
in.
Up thru 2.000 1 O % I O Ya 1 0
Y (rnax) in degrees
TABLE 12.45 Straightness Tolerances- IN TOTAL LENGTH OR IN ANY
MEASURED SEGMENT OF ONE FT.
Welded Tube OR MORE OF TOTAL LENGTH
Up thru 1.500 1 x Measured length, ft.
TOLERANCE G i n . 1.501-2.000 % x Measured length, ft.
ALLOWABLE DEVIATION FROM STRAIGHT

SPECIFIED
OUTSIDE
TABLE 12.47 Squareness of Cut Ends-
DIAMETER Welded Tube
OR WIDTH
Allowable deviation from square: 1 degree

IN TOTAL LENGTH OR IN ANY


MEASURED SEGMENT OF ONE FT.
OR MORE OF TOTAL LENGTH
0 Tolerance is applicable when weight of tube on flat surface minimizes
deviation.
0.501-1 .O00 .O30x Measured length, ft. @Twist is normally measured by placing the welded tube on a flat surface
1.001-2.000 .O40 x Measured length, ft. and at any point along its length measuringthe maximum distance between
the bottom surface of the welded tube and the flat surface. From this
measurement, the actual deviation from straightness of the welded tube at
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

that point is subtracted. The remainder is the twist. To convert the standard
twist tolerance (degrees) to an equivalent linear value, the sine of the
standard tolerance is multiplied by the width of the surface of the section
that is on the flat surface. The followingvalues are used to convert angular
tolerances to linear deviation:

Maximum allowable
Tolerance,
linear deviation
degrees
inch per inch of width
% 0.004
'h 0.009
1 0.01 7
1% 0.026
3 0.052
5 0.087
7 0.122
9 0.156
15 0.259
21 0.358

42
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ANSI H35.2-2003

Aluminum Mill Products

Pipe-EHruded and Drawn


TABLE 12.49 Outside Diameter Tolerances- TABLE 12.52 Length Tolerances-Extruded
Extruded and Drawn Pipe and Drawn Pipe
TOLERAI E-ln. SPECIFIED TOLERANCE
Allowable deviation Allowable deviation
LENGTH in. plus
of mean @diameter of diameter at ALLOWABLE DEVIATION
from nominal any point from FROM SPECIFIED LENGTH

#
diameter nominal diameter Q Up thru 20
Over 20 thru 40
PIPE
SIZE
A B
TABLE 12.53 Straightness Tolerances-
in.
A A
Extruded and Drawn Pipe
TOLERANCE a n .
Difference between Ditference between
H(AA+BB) and AA and nominal ALLOWABLE DEVIATION FROM STRAIGHT
nominal diameter diameter
SCHEDULE 20
SCHEDULES 5 AND 10
AND GREATER
PIPE
Under 2 +.015-.O31 +.015-.O31 SIZE
2 4 +.031-.O31 +I %-I %
5-7 +.062-.O31 +I %-I % in.
a
12 +.093-.O31 +I %-I %
Dlmaxì
IN TOTAL LENGTH OR IN ANY
TABLE 12.50 Wall Thickness Tolerances- MEASURED SEGMENT OF ONE FT.
Extruded and Drawn Pipe OR MORE OF TOTAL LENGTH
Under 6 .O10x Measured length, ft.
TOLERANCE 6 12 .O20x Measured length, ft.
SCHEDULE ALLOWABLE DEVIATION OF
NUMBER WALL THICKNESS AT ANY POINT
FROM NOMINALQ WALL THICKNESS TABLE 12.54 Standard Welding Bevels-
5 and 10 112H%, 1.012 in. min.
20 and greater -12E%@ Extruded and Drawn Pipe
DOUBLE LEVEL STRAIGHT BEVEL
For Wall Thickness For Wall Thickness
TABLE 12.51 Weight Tolerances-Extruded Over 0.750 in. 0.750 in. and Less
and Drawn Pipe 37H" i 21/28.

--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---
TOLERANCE
SCHEDULE 37%" f 2H"
NUMBER
FROM THEORETICAL WEIGHT
A A
+8% @ 7

@ Nominal diameter and wall thickness are those listed in Table 12.55. @ For schedule 5 and IO, only diameter, wall thickness and length
@ Mean diameter is the average of any two diameter measurementstaken tolerances apply.
at right angles to each other at any point along the length. @ Minimum weight is controlled by tolerances for outside diameter and
@Maximum wall thickness is controlled by weight tolerance. wall thickness.
@When weight of pipe on flat surface minimizes deviation.

43
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ANSI H35.2-2003

Dimensional Tolerances for

TABLE 12.55 Diameters, Wall Thicknesses, Weights-Pipe


NOMINAL INSIDE WALL THICKNESS WEIGHT PER FOOT
OUTSIDE DIAMETER
PIPE SCHEDULE IAMETER in. Ib.
in.
SIZE a NUMBER in.
IN. Nom. @ Min@@ uax.@@ Nom. Nom.0 Min@ Max. @ Nom. 0 Max. @@
'/a 40 0.405 0.374 0.420 0.269 0.068 0.060 .. 0.085 0.091
80 0.405 0.374 0.420 0.215 0.095 0.083 .. 0.1o9 0.118
40 0.540 0.509 0.555 0.364 0.088 0.077 .. 0.147 0.159
80 0.540 0.509 0.555 0.302 0.119 0.104 .. 0.185 0.200
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

40 0.675 0.644 0.690 0.493 0.091 0.080 .. 0.196 0.212


80 0.675 0.644 0.690 0.423 0.126 0.11 o .. 0.256 0.276
?4 5 0.840 0.809 0.855 0.710 0.065 0.053 0.077 0.186 ..
10 0.840 0.809 0.855 0.674 0.083 0.071 0.095 0.232 ..
40 0.840 0.809 0.855 0.622 0.1o9 0.095 .. 0.294 0.318
80 0.840 0.809 0.855 0.546 0.147 0.129 0.376 0.406
160 0.840 0.809 0.855 0.464 0.188 0.164 0.453 0.489
5 1 .O50 1.019 1 .O65 0.920 0.065 0.053 0.077 0.237 ..
10 1 .O50 1.019 1 .O65 0.884 0.083 0.071 0.095 0.297 ..
40 1 .O50 1.019 1 .O65 0.824 0.113 0.099 .. 0.391 0.422
80 1 .O50 1 .o19 1 .O65 0.742 0.154 0.135 .. 0.510 0.551
160 1 .O50 1 .o19 1 .O65 0.612 0.219 0.192 .. 0.672 0.726
1 5 1.315 1.284 1.330 1.185 0.065 0.053 0.077 0.300 ..
10 1.315 1.284 1.330 1 .O97 0.1o9 0.095 0.123 0.486 ..
40 1.315 1.284 1.330 1 .O49 0.133 0.116 .. 0.581 0.627
80 1.315 1.284 1.330 0.957 0.179 0.157 .. 0.751 0.811
160 1.315 1.284 1.330 0.815 0.250 0.219 .. 0.984 1 .O62
1% 5 1.660 1.629 1.675 1.530 0.065 0.053 0.077 0.383 ..
10 1.660 1.629 1.675 1.442 0.109 0.095 0.123 0.625 ..
40 1.660 1.629 1.675 1.380 0.140 0.122 .. 0.786 0.849
80 1.660 1.629 1.675 1.278 0.191 0.167 .. 1 .O37 1.120
160 1.660 1.629 1.675 1.160 0.250 0.219 .. 1.302 1.407
1 Y' 2 5 1.900 1.869 1.915 1.770 0.065 0.053 0.077 0.441 ..
10 1.900 1.869 1.915 1.682 0.109 0.095 0.123 0.721 ..
40 1.900 1.869 1.915 1.610 0.145 0.127 .. 0.940 1 .O15
80 1.900 1.869 1.915 1.500 0.200 0.175 .. 1.256 1.357
160 1 .goo 1 .E69 1.915 1.338 0.281 0.246 1.681 1.815
2 5 2.375 2.344 2.406 2.245 0.065 0.053 0.077 0.555 ..
10 2.375 2.344 2.406 2.157 0.109 0.095 0.123 0.913 ..
40 2.375 2.351 2.399 2.067 0.154 0.135 .. 1.264 1.365
80 2.375 2.351 2.399 1.939 0.218 0.191 .. 1.737 1 .876
160 2.375 2.351 2.399 1.687 0.344 0.301 .. 2.581 2.788
2% 5 2.875 2.844 2.906 2.709 0.083 0.071 0.095 0.856 ..
10 2.875 2.844 2.906 2.635 0.120 0.105 0.135 1.221 ..
40 2.875 2.846 2.904 2.469 0.203 0.178 .. 2.004 2.164
80 2.875 2.846 2.904 2.323 0.276 0.242 .. 2.650 2.862
160 2.875 2.846 2.904 2.125 0.375 0.328 .. 3.464 3.741
3 5 3.500 3.469 3.531 3.334 0.083 0.071 0.095 1 .o48 ..
10 3.500 3.469 3.531 3.260 0.120 0.105 0.135 1.498 ..
40 3.500 3.465 3.535 3.068 0.216 0.189 2.621 2.830
80 3.500 3.465 3.535 2.900 0.300 0.262 3.547 3.830
160 3.500 3.465 3.535 2.624 0.438 0.383 4.955 5.351
3% 5 4.000 3.969 4.031 3.834 0.083 0.071 0.095 1.201 ..
10 4.000 3.969 4.031 3.760 0.120 0.105 0.135 1.720 ..
40 4.000 3.960 4.040 3.548 0.226 0.198 .. 3.151 3.403
80 4.000 3.960 4.040 3.364 0.318 0.278 .. 4.326 4.672

For all numbered footnotes,see following page.

44
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ANSI H35.2-2003

Aluminum Mill Products


TABLE 12.55 Diameters, Wall Thicknesses, Weights (concluded)
NOMINAL INSIDE WALL THICKNESS WEIGHT PER FOOT
OUTSIDE DIAMETER iIAMETER
PIPE SCHEDULE in. in. Ib.
SIZE a NUMBER in.
IN. Nom. a Min Q@ Max. QO Nom. Nom. a MinQ ax. Q Nom.@ Max. QQ
4 5 4.500 4.469 4.531 4.334 0.083 0.071 0.095 1.354 ..
10 4.500 4.469 4.531 4.260 0.120 0.105 0.135 1.942 ..
40 4.500 4.455 4.545 4.026 0.237 0.207 .. 3.733 4.031
80 4.500 4.455 4.545 3.826 0.337 0.295 .. 5.1 83 5.598
120 4.500 4.455 4.545 3.624 0.438 0.383 .. 6.573 7.099
160 4.500 4.455 4.545 3.438 0.531 0.465 .. 7.786 8.409
5 5.563 5.532 5.625 5.345 0.109 0.095 0.123 2.1 96 ..
10 5.563 5.532 5.625 5.295 0.1 34 0.117 0.1 51 2.688 ..
40 5.563 5.507 5.61 9 5.047 0.258 0.226 .. 5.057 5.461
80 5.563 5.507 5.619 4.81 3 0.375 0.328 .. 7.188 7.763
120 5.563 5.507 5.61 9 4.563 0.500 0.438 .. 9.353 10.10
160 5.563 5.507 5.61 9 4.313 0.625 0.547 11.40 12.31
5 6.625 6.594 6.687 6.407 0.1 o9 0.095 0.123 2.624 ..
10 6.625 6.594 6.687 6.357 0.134 0.117 0.1 51 3.213 ..
40 6.625 6.559 6.691 6.065 0.280 0.245 .. 6.564 7.089
80 6.625 6.559 6.691 5.761 0.432 0.378 .. 9.884 10.67
120 6.625 6.559 6.691 5.501 0.562 0.492 .. 12.59 13.60
160 6.625 6.559 6.691 5.187 0.719 0.629 .. 15.69 16.94
8 5 8.625 8.594 8.718 8.407 0.1 o9 0.095 0.123 3.429 ..
10 8.625 8.594 8.718 8.329 0.148 0.130 0.1 66 4.635 ..
20 8.625 8.539 8.71 1 8.125 0.250 0.219 .. 7.735 8.354
30 8.625 8.539 8.71 1 8.071 0.277 0.242 .. 8.543 9.227
40 8.625 8.539 8.71 1 7.981 0.322 0.282 .. 9.878 10.67
60 8.625 8.539 8.71 1 7.813 0.406 0.355 12.33 13.31
80 8.625 8.539 8.71 1 7.625 0.500 0.438 15.01 16.21
1O0 8.625 8.539 8.71 1 7.437 0.594 0.520 .. 17.62 19.03
120 8.625 8.539 8.71 1 7.187 0.719 0.629 .. 21 .o0 22.68
140 8.625 8.539 8.71 1 7.001 0.812 0.71O .. 23.44 25.31
160 8.625 8.539 8.71 1 6.813 0.906 0.793 .. 25.84 27.90
10 5 10.750 10.719 10.843 10.482 0.134 0.117 0.1 51 5.256 ..
10 10.750 10.719 10.843 10.420 0.165 0.144 0.186 6.453 ..
20 10.750 10.642 10.858 10.250 0.250 0.21 9 .. 9.698 10.47
30 10.750 10.642 10.858 10.136 0.307 0.269 .. 11.84 12.79
40 10.750 10.642 10.858 10.020 0.365 0.319 .. 14.00 15.12
60 10.750 10.642 10.858 9.750 0.500 0.438 .. 18.93 20.45
80 10.750 10.642 10.858 9.562 0.594 0.520 .. 22.29 24.07
1O0 10.750 10.642 10.858 9.312 0.719 0.629 .. 26.65 28.78
12 5 12.750 12.719 12.843 12.438 0.1 56 0.136 0.1 76 7.258 ..
10 12.750 12.719 12.843 12.390 0.180 0.158 0.202 8.359 ..
20 12.750 12.622 12.878 12.250 0.250 0.21 9 .. 11.55 12.47
30 12.750 12.622 12.878 12.090 0.330 0.289 .. 15.14 16.35
40 12.750 12.622 12.878 11.938 0.406 0.355 .. 18.52 20.00
60 12.750 12.622 12.878 11.626 0.562 0.492 .. 25.31 27.33
80 12.750 12.622 12.878 11.374 0.688 0.602 30.66 33.11

@ln accordance with ANSVASME Standards B36.10M and B36.19M CU in., the density of 6061 alloy. For alloy 6063 multiplyby 0.99
and for alloy
@Based on standard tolerancesfor outside diameter,wall thickness and 3003 multiply by 1.O1 1.
weight shown earlier in this section. 0For schedules 5 and 10 these values apply to mean outside diameters.
@Based on nominaldimensions, plain ends, and a density of 0.098 Ib per
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

45
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ANSI H35.2-2003

Dimensional Tolerances for

13. Structured Profiles


Tolerance limits for aluminum alloy structural profiles are identical with those for other extruded
profiles as shown in Section 11.
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

46
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ANSI H35.2-2003

Aluminum Mill Products

14. Forging Stock


TABLE 14.1 DiameteP-Round Forging Stock
CLASS 1. FORGING STOCK CLASS 2. FORGING STOCK
TOLERANCE TOLERANCE
in. plus and minus in. plus and minus
SPECIFIED ALLOWABLE SPECIFIED ALLOWABLE
DIAMETER DEVIATION CONDI- DIAMETER DEVIATION
in. FROM TIONING in. FROM
SPECIFIED ALLOWANCE @ SPECIFIED
DIAMETER DIAMETER
0.375-0.500 .o15 -l/32 0.375-0.500 ,0015
0.501-1.000 .o15 -'/32 0.501-1 .O00 .O02
1.001-1.500 .o15 -l/32 1.O01-1 S O O .O025
1SOI-3.000 .o15 -l/32 1 SOI-3.000 .O08
3.001-5.000 .O31 -l/16 ..
5.001-8.000 .O63 -l/16

TABLE 14.2 Distance Across Flatso-Square Forging Stock


CLASS 1. FORGING STOCK CLASS 2. FORGING STOCK

v
-
1
SPECIFIED DISTANCE SPECIFIED DISTANCE
ACROSS FLATS TOLERANCE ACROSS FLATS TOLERANCE

fl*
in. in. plus and minus in. in. plus and minus

CONDITIONING

-4 I+ SPECIFIED ALLOWANCE@ +I I+ SPECIFIED


DISTANCE ACROSS DISTANCE ACROSS
FLATS FLATS
0.375-0.500 .o1o -1/3z on face 0.375-0.500 .o02
0.501-1 .O00 .o15 -Va2 on face 0.501-1.000 ,0025
1.001-2.000 .o18 -li32 on face 1.001-1 S O O .O03
2.001-3.000 .o20 -1/3z on face 1.501-4.000 .O05
3.001-4.000 .O32 - 1 h on face .. ..

TABLE 14.3 Thickness and Width-ectangular Forging Stock


CLASS 1. Fi GING STOCK CLASS 2. FORGING STOCK
SPECIFIED SPECIFIED SPECIFIED
THICKNESS TOLERANCE WIDTH TOLERANCE THICKNESS
in. plus and minus in. in. plus and minus
in.

L7
~~ I

ALLOWABLE ALLOWABLE
CONDITIONING
SPECIFIED SPECIFIED ALLowANcE@ r u I SPECIFIED
THICKNESS WIDTH

0.375-0.500 - 1/32 on face Up thru 1.500 -VI6 on face 0.375-0.500


0.501-1.000 - 1/32 on face 1S01-4.000 -1/16 on face 0.501-1.000
1.001-2.000 - 1/32 on face 4.001-6.000 -1116 on face 1.001-1.500
2.001 -3.000 - 1/32 on face 6.001-10.000 -1116 on face 1 S01-4.000

0 These tolerances are applicable for forging stock in rod and bar form.
TABLE 14.4 Length-pecific and Multiple Standard tolerances for foroina stock in sheet and olate form are as
indicated in the section on Sheet and Plate.
TOLERANCEin. plus
@ Conditioning allowance is an additional tolerance at localized areas to
SPECIFIED DIAMETER, ALLOWABLE DEVIATION permit removal of possible surface conditions.
WIDTH OR DISTANCE FROM SPECIFIED LENGTH
ACROSS FLATS SPECIFIED LENGTH-ft.
in.

Up thru 2.999
3.000-7.999 3/16 5/,6 '/i6
8.000 and over 114 3/8 V2

47
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ANSI H35.2-2003

Dimensional Tolerances for

15. Hand Forgings

DIMENSIONALTOLERANCES
ORDERED LENGTH STRAIGHTNESS@
in. in. THICKNESS WIDTH @ LENGTH
in., max. in., max. in., max.
up thru 71.99 0.250 0.250 0.375 1 .O00
72.00-149.99 0.375 0.250 0.500 1 .O00
150.00and over 0.500 0.375 0.750 1 .O00

@ Comer radii may vary from O to 0.500 inch. @ Measured exclusive of edge bulges typically present on compression
@ A s measuredwith the hand forging resting on a flat surface. cold work forgings.

48
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ANSI H35.2-2003

Aluminum Mill Products

16. Electrical Conductors


16. Wire, Rod, and Bar-Rolled or Cold-finished

TABLE 16.7 Diameterxold-Finished Wire TABLE 16.11 Width-Rolled Bar


I TOLERANCE
SPECIFIED in. plus and minus or percent SPECIFIED
DIAMETER TOLERANCE
ALLOWABLE DEVIATION WIDTH in. plus and minus
in. OF MEAN@ DIAMETER in.
FROM SPECIFIED DIAMETER

r 3
0.0100-0.0359 ,0005 ALLOWABLE DEVIATION
0.0360-0.0999 .o010 FROM SPECIFIED
0.1000-0.2600 1% WIDTH
I- 4

TABLE 16.8 Diameter-Drawing Stock 0.500-1.500


1.501-4.000
.O1 6
.O32
SPECIFIED TOLERANCEin. plus and minus 4.001-6.000 .o47
6.001-12.000 .O63
DIAMETER ALLOWABLE DEVIATION
in. FROM SPECIFIED DIAMETER
0.375-0.500
0.501-1 .O00
.O20
.O25
TABLE 16.12 Length-Rolled Bar and
Sawed-Plate Bar
TABLE 16.9 Diameter-Maanetic Wire TOLERANCE-in. plus
SPECIFIED I TOLERANCEin. olus and minus
SPECIFIED WIDTH
in. Up thru Over
DIAMETER ALLOWABLE DEVIATION OF MEANO 18 ít. 18ft.
in. DIAMETER FROM SPECIFIED DIAMETER Up thru 3.499 /'a %
0.010 .o001 3.500 and over ?h %
0.011-0.020 .o002
0.021-0.030 .o003
0.031-0.040 .o004 TABLE 16.13 Straightness-Rolled Bar and
0.041-0.050 .O005
0.051-0.060 .O006 Sawed-Plate Bar
0.061-0.080 .O008
0.081 -0.150 .O01o TOLERANCE @@n -i.
0.151 -0.260 .o01 5 Maximum Curvature (Depth of Arc)

TABLE 16.1O Thickness-Rolled Bar


SPECIFIED THICK- TOLERANCE
NESS in. plus and minus
in.

ALLOWABLE DEVIATION D (max.) = % inch in any 5 feet of bar length


f FROM SPECIFIED
THICKNESS
TABLE 16.14 Flatness (Flat Suríaces)-Rolled
Bar and Sawed-Plate Bar
~

0.125-0.500 .O06
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

0.501-0.750 .O08
0.751-1.000 .o12 TOLERANCEin,
1 .o01-2.000 .O20

SPECIFIED WIDTH

@ Mean diameter is the average of two measurements taken at right in.


angles to each other at any point along the length. At least three such
measurements are made, one near each end and one near the middle of
the coil.
@ Straightness shall be measured by placing the bar on a level table so
that the arc or departure from straightness is horizontal. Measure the Maximum Allowable Deviation D
maximum depth of arc to the nearest 3/32 inch using a steel scale and a Up thru 1 ,004
straightedge. Over 1 .O04x W (inches)
@When weight of piece on flat surface minimizes deviation. In any 1 in. of width .O04

49
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ANSI H35.2-2003

DimensionalTolerances for

TABLE 16.15 Angularity-Rolled Bar TABLE 16.16 Squareness of Saw Cuts-


Rolled Bar
Allowable deviation from square: 1 degree.

Allowable deviation from nominal angle: f 1 degree.

TABLE 16.17 Corner and Edge Radii of Rolled Bar


SPECIFIED EDGE CONTOUR
I SPECIFIED BAR
THICKNESS
in.
NOMINAL
RADIUS
RADIUS
TOLERANCE

Square
Comers O 0.125-1.000
1.O01 and over
..
..
+l/32
+1/16
Round 0.125-0.1 88 1/32 f l/64
Corners 0.189-1 .o00 l/16 f l/64
ve

I
1 .O01 and over f l/64
Radiussr *
1 0.125andover 1I4 x Bar thickness f% x Bar thickness
L Blended Corners
Full
Rounded All ih x Bar thickness +25%
Edge

TABLE 16.20 Width-Sawed-Plate Bar


TOLERANCE TOLERANCE
SPECIFIED THICKNESS in. plus and minus SPECIFIED WIDTH in. plus and minus
in. ALLOWABLE DEVIATION ALLOWABLE DEVIATION
FROM SPECIFIED THICKNESS FROM SPECIFIED WIDTH
0.250-0.320 .o13 2.000-6.000
0.321-0.430 .o19 6.001-14.000 ,125
0.439-0.625 .O25
0.6260.875 .O30
0.876-1.125 .O35 TABLE 16.21 Corners and Edges-
1.1261.375 .O40
1.376-1.625 .O45 Sawed-Plate Bar
1.626-1.875 .O52
Edge surfaces and rough, showing saw marks, and comers are substan-
1.876-2.250 .O60
tially square, with a slight burr.
2.251-2.750 .O75
2.751-3.000 .O90

0 Twist is normally measured by placing the bar on a flat surface and at


any point along its length measuring the maximum distance between the
bottom surface of the bar and the flat surface. From this measurement,the
actual deviation from straightness of the bar at that point is subtracted. The
remainder is the twist. To convert the standard twist tolerance (degrees) to
TOLERANCEQDEGREES an equivalent linear value, the sine of the standard tolerance is multiplied
Allowable Deviation from Straight by the width of the surface of the section that is on the flat surface. The
following values are used to convert angular tolerances to linear deviation:
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

Maximum allowable
Tolerance,
linear deviation
degrees
inch per inch of width
SPECIFIED
WIDTH I4 0.004
in. ?4 0.009
1 0.017
1% 0.026
Y (max.) in degrees 3 0.052
IN TOTAL LENGTH OR MAXIMUM 5 0.087
IN ANY MEASURED 7 0.122
SEGMENT OF ONE FT.OR
MORE OF TOTAL LENGTH
FyE"AL 15
9 0.1 56
0.259
Up thru 1.499 1 x Measured length, ft. 7 21 0.358
1SOO-2.999 ih x Measured length, ft. 5
3.000 and over % x Measured length, ft. 3 w h e n weight of bar on flat surface minimizes deviation.

50
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,
ANSI H35.2-2003

Aluminum Mill Products

Extruded Rod and Bar


TABLE 16.22 Thickness, Width, Diameter- TABLE 16.23 Length-Extruded Rod and Bar
Extruded Rod and Bar
SPECIFIED THICKNESS
OR DIAMETER

0.1254.249
0.500-0.749
0.250-0.499
T O L ERANCEWn . plus and minus
ALLOWABLE DEVIATION FROM
SPECIFIED DIMENSION
SPECIFIED WIDTH
in.

Up thru 2.999
3.000-7.999
c
I

~
TOLERANCEin. olus
ALLOWABLE DEVIATION
FROM SPECIFIED LENGTH
SPECIFIED LENGTH-ft.
Up thru 12
'18
Yi 6
Over 12 thru 30
114
Y16
.O08
.O09
0.750-0.999 .o1o 8.000and over 114 Y8

I,000-1.499
1.500-1.999
2.000-3.999
4.000-5.999
6.000-7.999
8.000-9.999
10.000-12.000 .O74

@For some items of relatively thin wide bar greater thickness tolerances
are required as follows:
a. Specified bar thickness less than 0.500 in.; corner radii 1/16 in. or
less; width to thickness ratio 24 to 1 and greater.
Tolerance per Table 16.22 except for distance M in. from each
edge where plus tolerance of Table 16.22applies and minus
tolerance of 2 x Table 16.22tolerance applies.
Example:

-
i i p
to.008" to.008"
-0.016" * 0.008"
7 ---I
-0.018"

9.500"= 0.064"

b. Specified bar thickness 0.500 in. and greater; comer radii 3/16 in.
or less; width to thickness ratio 10 to 1 and greater. Thickness
tolerance per Table 16.22except for distance 'h in. from edge
where plus tolerance of Table 16.22 applies and minus tolerance
2 x Table 16.22 applies.

51
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ANSI H35.2-2003

Dimensional Tolerances for

TABLE 16.24 Flatness (Flat Surfaces)- TABLE 16.26 Straightness 0 @-Extruded


Extruded Bar Rod and Bar
I TOLERANCE-h. BAR ROD

TOLERANCE TOLERANCE
DIAMETER
in. in any 10 ft. in in.
SPECIFIED WIDTH

in.

Maximum Allowable Deviation D


Up thru 1 .O04
Over 1 thru 5.999 .O04 x W (inches)

1 1 1
In any 1 in. of width .O04 I
1 IN TOTAL LENGTH OR
IN ANY MEASURED
Flatwise Edgewise (max')
TABLE 16.25 Twist@-Extruded Bar SEGMENT OF ONE FT. OR
MORE OF TOTAL LENGTH
. TOLERANCE @DEGREES 0.375-5.999 .O10 x Measured length, ft.
ALLOWABLE DEVIATION D(max.) = % D (max.) = '18 6.000 and .O20x Measured length, ft.
over
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

FROM STRAIGHT

TABLE 16.27 Angularity-Extruded Bar


SPECIFIED
WIDTH
in.

Y (max.) in degrees
IN TOTAL LENGTH OR MAXIMUM
IN ANY MEASURED
SEGMENT OF ONE FT. OR Allowable deviation from nominal angle: I1 degree.
F~~~~~~
MORE OF TOTAL LENGTH
Up thru 1.499 1 x Measured length, ft. 7
1.500-2.999 'h x Measured length, R. 5
3.000 and over % x Measured length, ft. 3 TABLE 16.28 Squareness of Cut Ends-
Extruded Rod and Bar
Allowable deviation from square: 1 degree.
0 Deviation from straightness shall be checked as follows: Place the bar Maximum allowable
Tolerance,
or rod on a level surface so that the departure from straightness is linear deviation
horizontal. Measure the maximurn depth of arc to the nearest 1/32 inch degrees
inch per inch of width
using a steel scale and a 120-inch-long straightedge. % 0.004
@When weight of piece on flat surface minimizes deviation. 'h 0.009
@Twist is normally measured by placing the bar on a flat surface and at 1 0.01 7
any point along its length measuring the maximum distance between the 1% 0.026
bottom surface of the bar and the flat surface. From this measurement, the 3 0.052
actual deviation from straightness of the bar at that point is subtracted. The 5 0.087
remainder is the twist. To convert the standard twist tolerance (degrees) to 7 0.122
an equivalent linear value, the sine of the standard tolerance is multiplied 9 0.1 56
by the width of the surface of the section that is on the flat surface. The 15 0.259
following values are used to convert angular tolerances to linear deviation: 21 0.358

TABLE 16.29 Corner and Edge Radii-Extruded Bar


SPECIFIED BAR
NOMINAL RADIUS
SPECIFIED EDGE CONTOUR THICKNESS RADIUS TOLERANCE
in.
Square
Comers O 0.125-1 .o00
1.O01 and over
..
..
+ 1/32 in.
+l/16 in.

Round 0.125-0.188 l/32 I'/M in.


Corners 0.1 89-1 .O00 l/16 11/64 in.
1 .O01 and over 1/8 f1/64 in.

D
Radius-
Rounded Up thru 0.149 1% x Bar thickness f1/64 in.
Edge 0.1 50 and over 1% x Bar thickness I 10%
2 Blended Comers
Full
Rounded Up thru 0.374 % x Bar thickness f1/64 in.
Edge 0.375 and over 'h x Bar thickness +I 0%

52
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ANSI H35.2-2003

Aluminum Mill Products

Pipe
TABLE 16.31 Outside Diameter-Pipe TABLE 16.33 Straightness-Pipe
I
~~~~ ~

I
TOLERANCE-in. or percent TOLERANCE @-in.
~~~

ALLOWABLE DEVIATION OF DIAMETER AT ALLOWABLE DEVIATION FROM


ANY POINT FROM NOMINAL DIAMETER @@ STRAIGHT

PIPE SIZE
in.

D (max.)
IN TOTAL LENGTH OR IN ANY
Difference between AA MEASURED SEGMENT OF ONE FT.

1
and nominal diameter OR MORE OF TOTAL LENGTH
SCHEDULE 40 or 80 Under 6 0.010x Measured length, ft.
Under 2 +.o15 -.O31
2-4 +i% -1 Yo
5-7 +1% -1 %
8-1 2 +i% -1%
TABLE 16.34 Length-Pipe
--`,``,,,`,``,,,`,`,``,-`-`,,`,,`,`,,`---

~~~

Allowable deviation from specified length: plus Ya in. Applies only in


lengths 20 ft. and under.
TABLE 16.32 Wall Thickness-Pipe
Allowable deviation of wall thickness at any point from nominal wall
thickness@ minus 12%percent. (Maximum wall thickness is controlled TABLE 16.35 Weight-Pipe
by weight tolerance.)
Allowable deviation from theoretical weight: plus 8 percent. (Minimum
0 Nominal diameter and wall thickness are those listed in Table 12.55. weight iscontrolled by tolerances for outside diameter and wall thickness.)
@ Not applicable to annealed (O temper) pipe.
@When weight of piece on flat surface minimizes deviation.

53
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