Aluminum Frame Sizes: Standard Profile, Window & Screen Dimensions

Standard aluminum frame sizes depend on the use. Industrial profiles come in 20 to 100 mm, with 40×40 mm the most common. Window frames and screen frames use inches.

Wall thickness runs 1.2 to 3.0 mm, depending on the job. This guide covers profile sizes, window and screen frames, measuring steps and common questions.

Aluminum Frame Size Chart

Measure an Aluminum Frame

How do you measure an aluminum screen frame? Measure the width and height at three points: top, middle and bottom, or left, center and right. Use the smallest number.

For the window channel, measure from the deeper groove side and deduct 5/16 inch for clearance. Round to the nearest 1/16 inch.

For a replacement window, measure the structural opening. Make the new unit 1/2 to 3/4 inch (10 to 15 mm) smaller. That leaves room for shims, leveling and sealing.

Standard Aluminum Profile and Extrusion Sizes

Profile Dimensions

Industrial modular profiles come in 20, 30, 40, 45, 60, 80 and 100 mm. The 40×40 mm profile is the most widespread.

Wall Thickness

Industrial structural frames use walls of 1.5 to 3.0 mm. Architectural doors and windows use 1.2 to 2.5 mm, based on wind load needs.

Alloy Grades

6063-T5 suits architectural finishes and windows. 6061-T6 suits high-strength structural uses.

Cross-Section Types

Extrusions come solid, semi-hollow or hollow. Preferred circumscribing circle diameters (CCD) stay under 203 mm.

Aluminum Window and Screen Frame Sizes

What are the standard sizes for aluminum windows? Common units measure 32×48, 36×36, 60×36 and 72×48 inches. Many makers use these as stock sizes.

Aluminum Window Frame Sizes

Residential window and sliding door frames typically use 1.2 to 1.6 mm walls. Commercial and high-rise profiles scale up to 1.8 to 2.5 mm.

Aluminum Screen Frame Sizes

Screen frame thickness is commonly 3/8 inch or 7/16 inch. 3/8 inch often suits tight channel fits.

Screen assemblies range from 24×36 up to 48×72 inches. Sliding screens span wider tracks.

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Questions

What are the standard sizes of aluminum frames?

Aluminum frame sizes depend on their application. Industrial framing systems commonly use profile dimensions from 20 to 100 mm. Common nominal residential window sizes include 32 × 48, 36 × 36, 60 × 36, and 72 × 48 inches, although availability varies by manufacturer.

What are the standard sizes of aluminum profiles?

Common modular aluminum profile sizes include 20, 30, 40, 45, 60, 80, and 100 mm. The 40 × 40 mm profile is widely used in modular framing and industrial applications. The best size depends on the load, application, and profile series.

Can you still buy aluminum frame windows?

Yes. Aluminum frame windows are still manufactured and sold for residential and commercial buildings. Available styles, colors, finishes, and energy-efficiency features vary by region and manufacturer.

What are the standard sizes for aluminum windows?

Common nominal aluminum window sizes include 32 × 48, 36 × 36, 60 × 36, and 72 × 48 inches. Actual dimensions and available sizes vary by window style and manufacturer, so confirm the product measurements before ordering.

What are the disadvantages of aluminum windows?

Aluminum conducts heat and cold more readily than many insulating frame materials, so standard frames can be less energy-efficient. Thermal-break designs improve insulation. Aluminum may also corrode in harsh or salty environments if the alloy, coating, and maintenance are unsuitable.

How much do aluminum frames cost?

There is no single price for aluminum frames. Cost depends on dimensions, profile design, wall thickness, alloy, finish, and intended use. For an accurate estimate, compare supplier quotes using the same specifications and measurements.