Introduction to Aluminium Channel

Aluminium channel is a type of structural component that is commonly used in various industries. It is an extruded profile made from aluminium, which is a lightweight and versatile material known for its strength and durability. In this blog post, we will discuss the different types of aluminium channels, their features, manufacturing process, and industrial uses.

Types of Aluminium Channel

There are three main types of aluminium channels:

  • U channel
  • C channel, and
  • H Channel.

Aluminium U Channel

As the name suggests, this type of channel has a shape that resembles the letter "U". It is also known as a standard or flanged Aluminium channel and is commonly used for general structural applications. The U channel comes in various sizes and can be customized to fit specific project needs.

Aluminium C Channel

The C channel has a shape that resembles the letter "C". It is also known as a structural Aluminium channel and is often used for more heavy-duty applications. This type of channel provides excellent support and strength, making it suitable for load-bearing structures. Like the U channel, the C channel also comes in various sizes and can be customized.

Aluminium H Channel

The H channel has a shape that resembles the letter "H". It is also known as a structural Aluminium channel and is often used for more heavy-duty applications. This type of channel has an "H" shaped cross-section, with two parallel flanges connected by a central web. The flanges are designed to provide structural support and stability while the web allows for easy attachment of other materials or components.

Features of Aluminium Channel

Aluminium channels offer several advantages that make them a popular choice in many industries. Here are some of their key features:

  • Lightweight: Aluminium is about one-third the weight of steel, making it easy to handle and transport.
  • Corrosion-resistant: The natural oxide layer on aluminium prevents rust and corrosion, making it ideal for outdoor applications.
  • High strength-to-weight ratio: Despite its lightweight, aluminium is incredibly strong, making it suitable for a wide range of structural applications.
  • Easy to fabricate: Aluminium can be easily cut, drilled, and welded to create custom shapes and sizes.

How Aluminium Channel is made: The Extrusion Process

Extrusion is a highly popular and cost-effective method for producing aluminium channels. It is a continuous manufacturing process in which a billet (a cylindrical piece of metal) is forced through a die to create a profile with a constant cross-section. The resulting profile can be of various shapes and sizes, including channels, angles, bars, rods, tubes, and more.

The extrusion process involves the following steps:

Billet Preparation

The first step in the extrusion process is to prepare the billet for extrusion. The billet is typically made of aluminium alloy, which is heated to a specific temperature based on the material grade and extrusion speed. Heating the billet makes it more malleable and easier to extrude.


The prepared billet is then loaded into a large press, where it is forced through a die with high pressure using a ram or screw mechanism. The die has a profile that determines the shape and size of the extruded product. The pressure applied compresses the heated metal, forcing it to flow through the die opening and taking on its shape.

Cooling and Cutting

Once the aluminium has passed through the die, it is cooled using air or water quenching to maintain its desired shape. The extruded length is then cut into smaller pieces using a saw or shear. The cut pieces are known as "billets," and they can be further processed to create final products.

Heat Treatment

After extrusion, the billets may undergo heat treatment for strengthening or hardening of the material. This process involves heating the aluminium to a specific temperature and then cooling it rapidly using water, oil, or air.

Heat treatment can improve the mechanical properties of the extruded aluminium, making it more durable and suitable for various applications.


The final step in the extrusion process is finishing, which involves any additional operations such as surface treatments, machining, or assembly. This step adds aesthetic value and functionality to the extruded product and prepares it for its intended use.

Overall, the extrusion process is crucial in creating high-quality aluminium channels. It allows for flexibility in design and produces products with consistent shapes and sizes. The versatility of this process also makes it suitable for various industries, from construction to automotive to aerospace.

Industrial Uses of Aluminium Channel

  • Electrical and Electronics

Aluminium channels are used in the electrical and electronics industry for various applications such as cable management, housing for electronic components, and heat sinks. The material's corrosion resistance properties make it a reliable choice for protecting delicate electronics from external elements.

  • Marine Industry

Due to its corrosion resistance properties, aluminium is widely used in the marine industry. Aluminium channels are used in the construction of boats, ships, and other marine vessels, providing stability and durability against harsh saltwater conditions.

  • Automotive Industry

The automotive industry is another significant application for aluminium channels. They are commonly used in vehicle frames, body panels, and other structural components to reduce overall weight and improve fuel efficiency. Additionally, aluminium's ability to be easily moulded into complex shapes makes it an ideal choice for designing sleek and aerodynamic vehicles.

  • Construction

Construction is perhaps one of the most common uses of aluminium channels. They are used in a variety of applications, such as window frames, door frames, curtain walls, and roofing systems. The material's high strength-to-weight ratio and corrosion resistance make it ideal for withstanding harsh weather conditions and heavy loads.

  • Furniture

Aluminium channels are also widely used in the furniture industry. They are commonly used to make frames for tables, chairs, shelves, and other types of furniture. Due to its lightweight properties, aluminium channels provide sturdy support while keeping the overall weight of the furniture low. This makes it easier to move and transport furniture made with aluminium channels.

  • Solar Panel Frames

Aluminium channels are widely used in the construction of solar panel frames due to their lightweight and corrosion resistance properties. These frames support the solar panels and protect them from external elements, making them an essential component in the solar energy industry.

  • Industrial Machinery

Aluminium channels are also widely used in the manufacturing of industrial machinery such as conveyors, machine frames, and assembly line equipment. The material's high strength-to-weight ratio makes it ideal for heavy-duty machinery that requires durability and stability.

Aluminium Channel Sizes

There are four dimensions for Aluminium Channels:

Aluminium Channel Sizes

A = Width
B = Height
C = Thickness
D = Leg Height





 Imperial (in) Aluminium Channel SizesImperial (in) Aluminium Channel Sizes

Metric (mm) Aluminium Channel SizesMetric (mm) Aluminium Channel Sizes

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Ross Goodwin

Ross Goodwin is a Managing Director at Aluminium Warehouse, the first online supplier of metal products in the UK, founded in 2005. Before taking on the mantle of Managing Director in 2007, he looked after all financial aspects of the company in his role of Financial Director. Ross has extensive knowledge of the metal industry and over recent years has honed his expertise in online selling, growth strategies and overseeing all marketing activities. He attended Leeds University gaining a B.A. Hons degree in Business Administration & Economics. Besides being a self-confessed workaholic, he enjoys travelling, cycling and open water swimming and is soon to compete in his first triathlon.
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