Alustar (Perfis & Secções)

ALU-STAR Profile System Product Overview
Profiles and Sections

Extruded aluminum profiles and sections service-proven over many years for do-ityourself assembly of support, frame and guard constructions of all types. All the profiles and sections feature apertures for standard threads and connectors and can be variously combined to suit your specific requirements. If required, we will perform the preparation/machining work for you and deliver the elements ready sawn, drilled and tapped.
Connectors
All profile and section connections are bolted. The connectors are designed to produce perfectly fitting, rigid constructions of exceptional strength. By planning your system carefully in advance, incorporating a sufficient number of disassembly joints, you will be able to adapt it to changing situations. The grooves on the Tee head underside penetrate the anodized layer of the profile, thus producing an equipotential bond between profiles.
Accessories
A comprehensive range of accessories ideally supplements the ALU-STAR Profile System. Stirrup-type handles Adjustable steel footpads Wheels, hinges, closers Compressed air ducting system Panels
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Tools
Drills Profile drilling jigs Thread reducer insert drivers
Guideways
Various guideways from the Cam Roller Guide and Ball Rail Systems ranges, as well as Linear Bushings and Shafts, with optimized mounting accessories
Adaption of Linear Motion Systems
Easy mounting of Linear Motion Systems to frame constructions
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ALU-STAR Profile System Technical Data

Size Basic Profile Planar moments of inertia lX [cm ] 100 x 200 PB 50
4
Torsion moment l [cm ]

4
Section moduli WX [cm ] WY [cm ]

3 3
Area
Profile mass
Page
lY [cm ]
A [cm2]
q [kg/m]
706.4
2522.0
141.3
252.2
57.35
15.49
62
100 x 100
PB 50
305.15
305.15
187.30
61.03
61.03
30.85
8.40
63
50 x 100
PB 50
146.50
42.50
34.80
29.30
17.00
16.52
4.47
64
50 x 50
PB 50
19.41
19.41
6.00
7.76
7.76
8.54
2.30
65
50 x 50 with four guide slots
PB 50
18.77
X
20.63
7.58
8.25
9.00
2.43
66
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Size
Basic Profile Planar moments of inertia lX [cm ]

4

4

3 3
Area
Profile mass
Page
lY [cm ]
A [cm2]
q [kg/m]
12 x 100
PB 50
X Y
1.06
67.47
1.75
13.49
6.59
1.80
67
40 x 200
PB 50
X Y
48.7
1054.3
24.4
105.4
26.10
7.05
68
40 x 150
PB 50
X Y
35.8
476.3
17.9
63.5
20.67
5.58
69
40 x 100
PB 50
X Y
26.1
156.2
13.1
31.2
15.46
4.17
70
80 x 160
PB 40
238.4
Y
887.5
59.6
110.9
33.25
8.99
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Size Basic Profile Planar moments of inertia lX [cm ] 80 x 80 PB 40
4

4

3 3
Area
Profile mass
Page
lY [cm ]
A [cm2]
q [kg/m]
131.89
131.89
30.48
30.48
15.58
4.43
72
40 x 80
PB 40
65.12
17.06
16.28
8.53
9.83
2.65
73
40 x 40
PB 40
9.51
Y
9.51
4.76
4.76
5.79
1.56
74
40 x 40 closed
PB 40
11.1
X
11.1
5.6
5.6
6.51
1.76
75
35 x 35
PB 35
5.05
Y
5.05
1.00
2.88
2.88
4.26
1.12
76
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Size
Basic Profile Planar moments of inertia lX [cm ]

4

4

3 3
Area
Profile mass
Page
lY [cm ]
A [cm2]
q [kg/m]
35 x 40 with three guide slots
PB 35
6.63
X
5.63
3.29
3.22
5.02
1.32
77
35 x 35, quadrant profile

X
PB 35 4.37 4.37 2.66 2.66 4.13 1.09 78
25 x 50
X Y
PB 25 3.1 9.8 2.5 3.9 4.21 1.14 79
25 x 25
X Y
PB 25 1.3 2.0 1.0 1.6 2.38 0.64 80
6 x 50
X
0.09
Y
6.25
0.3
2.5
3.0
0.81
81
10 x 50
X
0.42
Y
10.42
0.83
4.17
5.0
1.35
81
98 x 98, gusseted angle section 147.92

X
147.92
46.54
46.54
19.64
5.31
82
48 x 48, angle section
14.06
X
14.06
9.44
9.44
7.10
1.91
83
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Deflection of Profiles and Sections
Profile and section deflection subdivides into two distinct types: Deflection caused by external forces. Deflection caused by the profile's or section's own weight. Both these types can further be categorized according to a variety of conceivable load cases that depend largely on the way the profiles and sections are fixed in place. The most commonly encountered load cases are listed below. For other load cases, please consult us.
Deflection and bending stresses caused by external forces
Deflection f [mm] Load case 1: F
Bending stress [N/mm2]
f=
F L3 3 E I 104
FL W 103
max
Load case 2:
L/2 F L
f=
F L3 48 E I 104
FL 4 W 103
max
Load case 3:
F
f
f=
a b
F a2 b2 3 E I L 104
Fab W L 103
max
Load case 4: F
f=
L
F L3 192 E I 104
FL 8 W 103
max
F = load [N] L = profile length [mm]
I = planar moment of inertia [cm4] E = elastic modulus = 70,000 [N/mm2]
W = section modulus [cm3]
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Deflection and bending stresses caused by profile's own weight

Deflection f [mm] Load case 5: Bending stress [N/mm2]
Load case 6:
f=
9.81 q L4 8 E I 107
9.81 q L2 2 W 106
max
q L
f=
49.05 q L4 384 E I 107
9.81 q L2 8 W 106
max
Load case 7:
q
f=
L
9.81 q L4 384 E I 107
9.81 q L2 max 12 W 106
q = profile mass [kg/m] L = profile length [mm]
I = planar moment of inertia [cm4] E = elastic modulus = 70,000 [N/mm2]
W = section modulus [cm3]
The maximum permissible deflection f depends on the customers application and must therefore be specified individually.
Irrespective of the load case, the permissible bending stress must never exceed the maximum specified for the material. Maximum permissible bending stress max = 130 N/mm2 (or 110 N/mm2 for a 100 x 100 profile) This value includes a safety factor = 1.5.
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Tolerances for precisionstraightened profiles and sections
Permissible dimensional tolerances for profiles and sections Deviations in outer dimensions from one profile bar to the next are attributable to the accuracy of the extrusion dies and to fluctuations in manufacturing. Within a batch, the variation in dimensional accuracy between the individual profiles lies within a close tolerance range.
b
a [mm] 25 35/40 0.3 50 0.4 100 0.6
Tolerance T [mm] 0.2
b [mm]
10
Tolerance T [mm] +0.4
c [mm]
5.2
5.5
14 +0.1 -0.3
32 +0.3 -0.2
Tolerance T [mm] 0.15 0.1
Shape tolerances to DIN 17615 Part 3

Straightness of longitudinal edges
L2 = 300
Length L [mm] Tolerance h1 max [mm]
0 to 1000 up to 2000 up to 3000 up to 4000 up to 5000 up to 6000 0.7 1.3 1.8 2.2 2.6 3.0
te pla ing r asu h1 Me

L1
h2
>3 00
In addition to the above, the deviation h2 may not at any point exceed 0.3 mm over a length l2 = 300.
Warping
Width b [mm] over L
Warping tolerance v [mm] for profile lengths [mm] 0 to 1000 up to 2000 up to 3000 up to 4000 up to 5000 up to 6000 1.0 1.0 1.0 1.0 1.5 1.2 1.2 1.2 1.5 1.5 1.2 1.5 2.0 1.8 1.5 2.0 2.0 2.0 2.0 2.2 2.0 2.0 2.0 2.5
up to 25 50 75 100
25 50
Rectangularity and inclination

w
b
v
75
Width of shorter side [mm] Tolerance w [mm]
up to 40 up to 100 up to 300
0.3
0.6
0.8
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Material Properties
Profiles and sections:
extruded precision profile to DIN 17 615
Material:
Al Mg Si 0.5 F25 Material number Al Mg Si 0.5 F22 Material number
3.3206.72 3.3206.71 (profile 100 x 100, rectangular profile 6 x 50 and 10 x 50)
Heat treatment:
artificially aged
Surface finish:
anodized to E6/EV1 (pickled and anodized, color neutral) Layer thickness: 12 m
Elastic modulus:
E = 70,000 N/mm2
Shear modulus:
G = 26,000 N/mm2
Density:
= 2.7 g/cm3
Hardness:
75 HB 2.5/62.5 Brinell 70 HB 2.5/62.5
(for Al Mg Si 0.5 F25) (for Al Mg Si 0.5 F22)
Minimum tensile strength in extrusion direction:
Rm = 245 N/mm2
(for Al Mg Si 0.5 F22 Rm = 215 N/mm2)
Proof stress in extrusion direction:
Rp 0.2 = 195 N/mm2
(for Al Mg Si 0.5 F22 Rp 0.2 = 160 N/mm2)
Elongation after fracture:
A5 = 10% A5 = 12%
A10 = 8% A10 = 10%
(for Al Mg Si 0.5 F25) (for Al Mg Si 0.5 F22)
Linear expansion coefficient:
= 23.38 10-6 1/K
(at 0 to 100C)
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Connection Options
Basic Variable Linear Side Parallel Threaded Connection Angle Variable connector connector angle connector connector connector connector, connector bracket connector (arbitrary cross (90) connecting connector angle) (0 and 90) Page 90 Page 92 Page 94 Page 96 Page 97 Page 98 Page 99 Page 100 Page 110
The remaining connectors serve to mount attachments/components to the profiles and sections.
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Tool Data
Drilling the profiles 16 mm diameter holes for profile connectors Drill speed ........................................ n = 2800 rpm Lubricant .......................................... Shell Dromus B or Micro 3000-S
16
For ordering data see Tools
Cutting the profiles Profile cuts performed with precision saw blade Cutting speed .................................. 4000 m/min Number of teeth .............................. 108 Saw blade ........................................ 350 mm dia. Rake angle ....................................... negative Precision saw blade .......................... carbide-tipped Lubricant .......................................... Shell Dromus B or Micro 3000-S
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ALU-STAR Profile System Profile Ends, Drilling, Tapping

0106-122-02 0106-122-05 0106-122-08 0106-122-03 0106-122-10 100 X 200 100 X 100 50 X 100 12 X 100 40 X 200
Part number Options
* for flat profiles and sections
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 21 22 23 24 25 26 27 99
Square-sawn to length L Square-sawn to length L 1 hole for connector Square-sawn to length L 1 hole for connector, turned 90 Square-sawn to length L 2 holes for connector (on wide face)* Square-sawn to length L 2 holes for connector (on narrow face)* Square-sawn to length L 4 holes for connector (on narrow face)* Square-sawn to length L 1 central M16x100 thread Square-sawn to length L 2 M16x100 threads Square-sawn to length L 4 M16x100 threads Square-sawn to length L 1 M8x30 thread Sawn bevel 1 hole for connector Sawn bevel 2 holes for connector (on wide face)* Sawn bevel 2 holes for connector (on narrow face)* Sawn bevel 4 holes for connector (on narrow face)* Sawn bevel (on wide face)* Sawn bevel on narrow face Square-sawn to length L 8 M16x100 threads Sawn bevel 1 hole for connector, turned 90 Square-sawn to length L 3 holes for connector on wide face Sawn bevel 3 holes for connector on wide face Square-sawn to length L 4 holes for connector on wide face Sawn bevel 4 holes for connector on wide face Square-sawn to length L 3 M16x100 threads Square-sawn to length L 8 holes for connector on wide face Sawn bevel 8 holes for connector on wide face to customer drawing
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40 X 150
50 X 50F
50 X 50
Profiles/Sections
0106-122-01
0106-122-04
0106-122-07
Overview
40 X 100 0106-122-06 80 X 160 0106-124-05 80 X 80 0106-124-01 40 X 80 0106-124-02 40 X 40 0106-124-03 40 X 40G 0106-124-06 35 X 35 0106-126-01 35 X 40F 0106-126-02 35 X 35S 0106-126-03 25 X 50 0106-127-02 25 X 25 0106-127-01 98 X 98 0106-128-01 48 X 48 0106-128-02
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Dimensions
The following connectors are provided for connecting profiles and sections to each other or to other elements: basic connector angle connector linear connector variable connector threaded connector variable angle connector
Options 15 - 16 -
To accommodate these connectors, the profile ends require to be prepared as given below.
Size All sizes 100 x 200 80 x 160 50 x 100 40 x 80 40 x 200 40 x 150 40 x 100 25 x 50
Options Square-cut 01 Square-sawn to length L
Bevel-cut Sawn bevel (on wide face)* Sawn bevel (on narrow face)*
02 50 x 40 x 35 x 35 x 50 40 35 40
1 hole for connector
11 -
1 hole for connector
16
25 PB35 28 PB40 33 PB50
25
16
25 PB35 28 PB40 33 PB50
25
32
1 hole for connector, turned 90
16 25
34 (standard angle 45)

18 - 1 hole for connector, turned 90
03 50 x50F 35 x 40 Sektor
32
16
25 PB35 28 PB40 33 PB50
25
34
(standard angle 45) 2 holes for connector (on wide face)* 16 28 PB40 33 PB50 2 holes for connector (on wide face)* 16 28 PB40 33 PB50
04
12 -
50 x 100 40 x 80 40 x 100 32 21
34 (standard angle 45) 3 holes for connector (on wide face)* 22 - 3 holes for connector (on wide face)* 16 28
16
40 x 150
28
34
32
* for flat profiles
(standard angle 45)
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Dimensions
Size Options 23 16 Square-cut 4 holes for connector (on wide face)* 28 Options 24 - Bevel-cut 4 holes for connector (on wide face)* 16
28
40 x 200
32 26 8 holes for connector (on wide face)*
34
(standard angle 45) 27 - 8 holes for connector (on wide face)*

16 28 PB40 33 PB50
16
28 PB40 33 PB50
100 x 200 80 x 160
32
05 50 x 100 40 x 80 40 x 200 40 x 150 40 x 100
16
34
(standard angle 45) 2 holes for connector (on narrow face)*

28 PB40 33 PB50
13 -
16
2 holes for connector (on narrow face)*

28 PB40 33 PB50
32
34
(standard angle 45) 06 16 4 holes for connector (on narrow face)* 28 PB40 33 PB50 14 - 4 holes for connector (on narrow face)*
16
100 x 200 100 x 100 80 x 160 80 x 80 32
28 PB40 33 PB50
34
(standard angle 45)
* for flat profiles
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Dimensions
The following end machining operations are required for bolting to other elements such as
Size Options 07 100 x 200 100 x 100 80 x 160 50 x 50 40 x 40 35 x 35 35 x 40 40 x 150
M16
panels, footpads,
swivel and fixed castors.

Size Options 08 Bevel-cut 2 M16x100 threads
Square-cut 1 central M16x100 thread
M16
100
50 x 100 40 x 80 40 x 100
M16
M16
100
100
09
M16
4 M16x100 threads
25 M16
3 M16x100 threads
100 x 200 100 x 100 40 x 200 80 x 160 80 x 80
M16
100
M16 1 M8x30 thread 17

M16
M16 100
40 x 150
M16
100
10
8 M16x100 threads
M8
98 x 98 48 x 48
M8
30
M16
30
M16 M16
100 x 200 80 x 160
100
Special machining options

All sizes 99 to customer drawing
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Tolerances for profile end machining Profiles and sections

Basic profile PB 25 PB 35 PB 40 25 x 25 35 x 40 with three guide slots 40 x 40 closed 50 x 50 with four guide slots 25 x 50 35 x 35 quadrant 40 X 40 50 x 50 35 x 35 40 x 80 80 x 80 80 X 160 40 x 100 40 x 150 40 x 200 Size
PB 50
50 x 100 100 x 100 100 x 200 12 x 100
Length tolerance Length L of profile (= greatest length) Tolerance limit up to 400 mm 0.2 mm over 400 mm up to 1000 mm 0.3 mm over 1000 mm up to 2000 mm 0.4 mm over 2000 mm up to 4000 mm 0.5 mm over 4000 mm 0.7 mm
Rectangularity to ISO 1101 Profile height Tolerance zone up to 40 mm 0.1 over 40 mm up to 50 mm 0.15 over 50 mm up to 80 mm 0.2 over 80 mm over 100 mm over 150 mm up to 100 mm up to 150 mm up to 200 mm 0.25 0.4 0.6
Angularity of bevel cuts
= 0.2
Angle definition for bevel cuts

left side
135
45
45
135
right side
Closer tolerances available on request.
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ALU-STAR Profile System Frame Construction Recommendations

Concentrated load
Long profiles, braced
Short profiles, braced
Distributed load
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ALU-STAR Profile System Frames

Frame A1
14
Short profiles, braced
Frame A2
Frame B1
Frame B2
Frame C1
Frame C2
For simplified ordering of the above standard frames, see 14 . The frames can be supplied complete with options such as twist locks, worktops, adjustable footpads, or fixed and swivel castors.
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ALU-STAR Profile System Profile Ordering Data

Ordering Example Ordering Data
Profile part number
0106 - 122 - 01, 1000/
01/ 14-75
Aluminum profile 100 x 100 0106-122-01
Profile length L
L
L = 1000 mm
Left-hand profile end Option

01
Right-hand profile end Option

14
with 75 bevel
The left and right-hand profile ends can be combined as required. The available profile end Options are listed alongside the data for each profile. For details of profile end machining options, see Profile Ends, Drilling, Tapping.
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This chapter contains further information relating to product pages marked with this symbol and a cross reference number .
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Information
Adaption of Linear Motion Systems
Guideways
Accessories Tools
Connectors
Profiles & Sections
ALU-STAR Profile System Profiles / based on the size PB 50 section

Aluminum Profile 100 x 200
Planar moment of inertia Section modulus Area Mass lX ly WX Wy A q = = = = = = 706.4 2522.0 141.3 252.2 57.35 15.49 cm4 cm4 cm3 cm3 cm2 kg /m
Ordering data 0106-112-09, length 4 m 0106-112-10, length 5.8 m No preparation

6.5 3.7 200 170
14 mm core diameter for M16 thread 5.5 mm core diameter for M6 self-tapping screws
X
0106-122-10, length in mm / .. / .. Length as specified End machining options, see selection table
6.5 4.2 50 20
10 25 50 70 100
10
Ordering example ALU-STAR Profile Profile part number Profile length L in mm 0106 - 122 - 10, 1000/ 01/ 27-75
Angle definition for bevel

135 45
left side
45 135
Left-hand profile end Right-hand profile end
01 27 with 75 bevel right side
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 06 07 09 17 26 Description Square-cut Square-sawn to length L 4 holes for connector on narrow face 1 central M16x100 thread 4 M16x100 threads 8 M16x100 threads 8 holes for connector on wide face 62 99 to customer drawing Profile end Options 15 16 14 27 Description Bevel-cut Sawn bevel on wide face Sawn bevel on narrow face 4 holes for connector on narrow face 8 holes for connector on wide face
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Torsion moment l = 187.3 cm4 Planar moment of inertia lx = ly = 305.15 cm4 Section modulus Wx = Wy = 61.03 cm3 Area A = 30.85 cm2 Mass q = 8.4 kg /m
Ordering data 0106-112-01 Length 6 m, no preparation
3.7
100
6.5
4.2 10 50 100 20 14 mm core diameter for M16 thread 25
X
32
Y
135
45
left side
45 135
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 06 07 09 99 Description Square-cut Square-sawn to length L 4 holes for connector 1 central M16x100 thread 4 M16x100 threads to customer drawing Profile end Options 15 14 Description Bevel-cut Sawn bevel 4 holes for connector
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Profiles & Sections

11
Torsion moment Planar moment of inertia Section modulus Area Mass
l lX ly WX Wy A q
= 34.8 = 146.5 = 42.5 = 29.3 = 17.0 = 16.52 = 4.47
cm4 cm4 cm4 cm3 cm3 cm2 kg /m
3.7
50
6.5
4.2 10 50 100 20 25 14 mm core diameter for M16 thread
X
32
Y
135
45
left side
45 135
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 04 05 08 99 Description Square-cut Square-sawn to length L 2 holes for connector on wide face 2 holes for connector on narrow face 2 M16x100 threads to customer drawing Profile end Options 15 16 12 13 Description Bevel-cut Sawn bevel on wide face Sawn bevel on narrow face 2 holes for connector on wide face 2 holes for connector on narrow face
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Torsion moment l = 6.0 cm4 Planar moment of inertia lx = ly = 19.41 cm4 Section modulus Wx = Wy = 7.76 cm3 Area A = 8.54 cm2 Mass q = 2.3 kg /m

50 6.5 3.7 4.2
X
14 mm core diameter for M16 thread
10 20
50

135 45
left side
45 135
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 02 07 Description Square-cut Square-sawn to length L 1 hole for connector 1 central M16x100 thread Profile end Options 15 11 Description Bevel-cut Sawn bevel 1 hole for connector
99
to customer drawing
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Profiles & Sections

Aluminum Guide Profile 50 x 50
Planar moment of inertia Section modulus Area Mass lX ly WX Wy A q =18.77 =20.63 =7.58 =8.25 =9.00 =2.43 cm4 cm4 cm3 cm3 cm2 kg /m

50 8.6 13
X
10 20 4.2
50
6.5
3.7

135 45
left side
45 135
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 02 03 07 99 Description Square-cut Square-sawn to length L 1 hole for connector 1 hole for connector, turned 90 1 central M16x100 thread to customer drawing Profile end Options 15 11 18 Description Bevel-cut Sawn bevel 1 hole for connector 1 hole for connector, turned 90
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4
Planar moment of inertia Section modulus Area Mass lX = 1.06 cm4 ly = 67.47 cm4 WX = 1.75 cm3 Wy = 13.49 cm3 A = 6.59 cm2 q = 1.80 kg /m

6.5 12 100 50 4.2 6.5
X
6 10 20
3.7
Ordering example ALU-STAR Profile Profile part number Profile length L in mm 0106 - 122 - 05, 1000/ 01/ 15

135 45
left side
45 135
01 15 right side
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 Description Square-cut Square-sawn to length L Profile end Options 15 Description Bevel-cut Sawn bevel on wide face
99
to customer drawing
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Profiles & Sections

Planar moment of inertia Section modulus Area Mass lX ly WX Wy A q = 48.7 cm4 = 1054.3 cm4 = 24.4 cm3 = 105.4 cm3 = 26.10 cm2 = 7.05 kg /m
11
This profile is particularly suited as a carriage profile for Cam Roller Guides.
200 185 20 10 50
4.2
70
30 6.5 5.5 mm core diameter for M6 self-tapping screws
32
40 3.7

135 45
left side
45 135
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 05 09 23 99 Description Square-cut Square-sawn to length L 2 holes for connector on narrow face 4 M16x100 threads 4 holes for connector on wide face to customer drawing Profile end Options 15 16 13 24 Description Bevel-cut Sawn bevel on wide face sawn bevel on narrow face 2 holes for connector on narrow face 4 holes for connector on wide face
Options 23 and 24 require PB 40 or universal connectors.
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1
Planar moment of inertia Section modulus Area Mass lX ly WX Wy A q = 35.8 cm4 = 476.3 cm4 = 17.9 cm3 = 63.5 cm3 = 20.67 cm2 = 5.58 kg /m
11
Profiles & Sections
L
150 135 50 25
X
4.2 20 30
10
20 40
Y
6.5
5.5 mm core diameter for M6 self-tapping screws
3.7

135 45
left side
45 135
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 05 07 21 25 Description Square-cut Square-sawn to length L 2 holes for connector on narrow face 1 central M16x100 thread 3 holes for connector on wide face 3 M16x100 threads Profile end Options 15 16 13 22 99 Description Bevel-cut Sawn bevel on wide face Sawn bevel on narrow face 2 holes for connector on narrow face 3 holes for connector on wide face to customer drawing
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Planar moment of inertia Section modulus Area Mass lX ly WX Wy A q = 26.1 = 156.2 = 13.1 = 31.2 = 15.46 = 4.17 cm4 cm4 cm3 cm3 cm2 kg /m
11

25
100 85 50
Y
32
X
4.2 20
10 3.7 6.5
20 40
30
5.5 mm core diameter for M6 self-tapping screws

135 45
left side
45 135
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Profiles / based on the size PB 40 section

Planar moment of inertia Section modulus Area Mass lX ly WX Wy A q = 238.4 = 887.5 = 59.6 = 110.9 = 33.25 = 8.99 cm4 cm4 cm3 cm3 cm2 kg /m
2
Profiles & Sections
L
Ordering data 0106-114-04, length 4 m 0106-114-05, length 5.8 m No preparation

160 150 3.7 6.5
14 mm core diameter for M16 thread 5.5 mm core diameter for M6 self-tapping screws
10 20 40 70 80
6.5 4
40
20
10

135 45
left side
45 135
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 06 07 09 17 26 Description Square-cut Square-sawn to length L 4 holes for connector on narrow face 1 central M16x100 thread 4 M16x100 threads 8 M16x100 threads 8 holes for connector on wide face 99 to customer drawing Profile end Options 15 16 14 27 Description Bevel-cut Sawn bevel on wide face Sawn bevel on narrow face 4 holes for connector on narrow face 8 holes for connector on wide face
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71

Planar moment of inertia Section modulus Area Mass
lx = ly =131.89 cm4 Wx = Wy= 30.48 cm3 A = 15.58 cm2 q = 4.43 kg /m
Ordering data
3.7
80
6.5
0106-114-01 Length 6 m, no preparation

4 10
X
20
40
80
20
Y
135
45
left side
45 135
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 06 09 Description Square-cut Square-sawn to length L 4 holes for connector 4 M16x100 threads Profile end Options 15 14 Description Bevel-cut Sawn bevel 4 holes for connector
99
to customer drawing
72
RE 82 801/10.99
1
3
Profiles & Sections
L
3.7
40
6.5
4 2 10 40 80 20
X
20
Y
135
45
left side
45 135
RE 82 801/10.99
73

lx = ly = Wx = Wy= A = q =
9.51 cm4 4.76 cm3 5.79 cm2 1.56 kg /m

3.7 4
40
X
6.5
10
20 40

135 45
left side
45 135
99
to customer drawing
74
RE 82 801/10.99
1
Aluminum Profile 40 x 40, Closed
3
Profiles & Sections
L
This profile is particularly suited for use in the food and packaging industries. Ordering data 0106-114-06 Length 6 m, no preparation
3.7 4
40
X
6.5
10
20 40

135 45
left side
45 135
99
to customer drawing
RE 82 801/10.99
75

Torsion moment l = Planar moment of inertia lx = ly = Section modulus Wx = Wy= Area A = Mass q = 1.0 cm4
5.05 cm4 2.88 cm3 4.26 cm2 1.12 kg /m
Ordering data
35

6.2
2 4.2
3.9
X
14 mm core diameter for M16 thread 5.2
10 19.5 35

135 45
left side
45 135
99
to customer drawing
76
RE 82 801/10.99
Aluminum Guide Profile 35 x 40

Ordering data
6.2
35 8.6 2.3
10.75
X
14 mm core diameter for M16 thread 5.2
4.2
10
19.5 40
Y
2 3.9 Angle definition for bevel
Ordering example ALU-STAR Profile Profile part number Profile length L in mm 0106 - 126- 02, 1000/ 01/ 11-75
135
45
left side
45 135
RE 82 801/10.99
77
Profiles & Sections

Aluminum Quadrant Profile 35 x 35
lx = ly = 4.37 cm4 Wx = Wy= 2.66 cm3 A = 4.13 cm2 q = 1.09 kg /m

L
Ordering data
3.9 6.2

35 19.5 10
Y
R 31.1
X
4.2
5.2 2 35

135 45
left side
45 135
78
RE 82 801/10.99
Profiles / based on the size PB 25 section

3
Profiles & Sections
L

2 4.2
50 20 10 9 6.2
5.5 mm core diameter for M6 thread
25
Y
135
45
left side
45 135
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 Description Square-cut Square-sawn to length L Profile end Options 15 16 Description Bevel-cut Sawn bevel on wide face Sawn bevel on narrow face
99
to customer drawing
RE 82 801/10.99
79


6.2
25 20 10 9 2 4.2
5.5 mm core diameter for M6 thread
X Y
25

135 45
left side
45 135
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 Description Square-cut Square-sawn to length L Profile end Options 15 Description Bevel-cut Sawn bevel
99
to customer drawing
80
RE 82 801/10.99
6
Aluminum Profile, Flat
Flat Profile 6 x 50 Planar moment of inertia Section modulus Area Mass lX ly WX Wy A q = = = = = = 0.09 6.25 0.30 2.50 3.00 0.81 cm4 cm4 cm3 cm3 cm2 kg /m
Flat Profile 10 x 50 Planar moment lX of inertia ly Section WX modulus Wy Area A Mass q
= 0.42 cm4 = 10.42 cm4 = 0.83 cm3 = 4.17 cm3 = 5.00 cm2 = 1.35 kg /m
These profiles can be inserted into the slots of aluminum profiles to serve as a support for panel-type elements. Ordering data 6 x 50 0106-118-05 10 x 50 0106-118-06 Length 3 m, no preparation
6
50 50
6 x 50 10 x 50
10
0106-128-05, length in mm / .. / .. 0106-128-06, length in mm / .. / .. Length as specified End machining options, see selection table

135 45
left side
45 135
01 15 right side
RE 82 801/10.99
81
Profiles & Sections
ALU-STAR Profile System Profiles

Gusseted Aluminum Angle Section 98 x 98
lx = ly =147.92 cm4 Wx = Wy= 46.54 cm3 A = 19.64 cm2 q = 5.31 kg /m

L
Detail Z
8
98
X
6.4 Z 8.5 63 98 45 7
Core diameter for M8 thread

135 45
left side
45 135
01 10 right side
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 10 Description Square-cut Square-sawn to length L 1 M8x30 thread Profile end Options 15 Description Bevel-cut Sawn bevel
99
to customer drawing
82
RE 82 801/10.99
Profiles
Aluminum Angle Section 48 x 48
lx = ly = 14.06 cm4 Wx = Wy= 9.44 cm3 A = 7.10 cm2 q = 1.91 kg /m
Detail Z 8
8
48
7.
Z 6.4 Core diameter for M8 thread 8.5

135 45
left side
45 135
01 10 right side
Profile end selection table (left and right-hand profile ends given in the table can be combined as required) Profile end Options 01 10 Description Square-cut Square-sawn to length L 1 M8x30 thread Profile end Options 15 Description Bevel-cut Sawn bevel
99
to customer drawing
RE 82 801/10.99
83
Profiles & Sections

Aluminum Slot Closure Profile Plastic Slot Closure Profile
Material Al slot closure profile Plastic slot closure profile Finish/color Al slot closure profile Plastic slot closure profile
Al Mg Si 0.5 F 22 PVC anodized 12 m black
Aluminum slot closure profile to seal off profile slots. The tight-fitting U-profile snaps into place. Particularly suited for: Dusty and dirty environments Design enhancement As covers for data cables The plastic slot closure profile is available in other colors on request (minimum order quantity).
PB 25 / PB 35 B A
11.75
0.9
PB 40 / PB 50
11.1
1 2.2
3.9 7.7
Description Fig. A B Al slot closure profile, length 3 m Plastic slot closure profile, length 2 m
Part number 0106-118-03 0106-210-10
84
RE 82 801/10.99
Slot Profile
Material PVC, black
The slot profile can be employed as a: glazing/panel rail screen surround slot liner or slot closer As a glazing/panel rail, it is suitable for element thicknesses of 6 mm and 8 mm. Panels of 10 mm in thickness can be directly inserted into the aluminum profile slot. Please note that the location depth in the slot will vary according to panel thickness. The slot profile retains cables ducted along the slots.
PB 35
PB 40 / PB 50
4 7
9 6 6.5 8
6.2 8.2 11
Description Slot profile, length 2 m
Part number 0106-210-01
RE 82 801/10.99
85
Profiles & Sections

Cheek Profile
Material Weight PB 50 PB 40 PB 40 slimline PB 35 PE-HD black q = 0.52 kg /m q = 0.45 kg /m q = 0.32 kg /m q = 0.39 kg /m
L
Cheek profiles with good sliding properties for easy insertion into the profile slot. The extra-wide versions (PB 50, PB 40, PB 35) protect the structure on three sides against abrasion or damage. The PB 40 slimline cheek profile is slightly narrower than the profile it slots into. The profiles have a drilling groove as a centering aid for drilling holes. Ordering data PB 50 PB 40 PB 40 slimline PB 35 0106-210-03
PB 50
51
PB 40
41
17.5
8
19
0106-210-07 0106-210-09 0106-210-04

4
19
Length 3 m, no preparation 0106-220-03, length in mm / .. / .. 0106-220-07, length in mm / .. / .. 0106-220-09, length in mm / .. / .. 0106-220-04, length in mm / .. / .. Length as specified End machining options, see selection table
Ordering example ALU-STAR Profile Profile part number Profile length L in mm
PB 40 slimline
39
Drilling groove
PB 35
36
14.5
8
19
4 2.1 15.5
19
Angle definition for bevel 0106 - 220 - 04, 1000/ 01/ 15 left side
45 135 135 45
01 15 right side
86
17.5
RE 82 801/10.99
Protective Panel Profile

Basic material Sealing lips PVC, black, hard PVC, black, soft
This protective panel profile can be employed as a: glazing/panel rail screen surround protective panel frame As a protective panel frame, it is suitable for element thicknesses of 4 mm to 8 mm. Panes or panels of 10 mm in thickness can be directly inserted into the aluminum profile slot.
17 to 21
8.5
4 to 8
6.5 PB 40/PB 50
12
approx.16
PB 25/PB 35
Description Protective panel profile, length 2 m
Part number 0106-210-02
RE 82 801/10.99
87
Profiles & Sections

Plastic Guide Profile 3 slots PB 50 / PB 40 / PB 35
Material PVC, black
Plastic round bar Material Bar diameter Finish Color Steel round bar Material Bar diameter Finish Color
PE-HD 8 mm smooth/wear and oil resistant black silver steel 8.2 mm polished shiny
Guide profile with 3 guide slots. Snap-fits into all profile slots. The round bars guarantee good sliding properties while the guides support the panel elements. Particularly suitable for sliding doors with overlaps.
2.1 8.6 34 8 2
H = h - 29 h 8(8.2)
23.4
Description Plastic guide profile, 3 slots, length 2 m Round bar, plastic, 8 mm dia., length 2 m Round bar, steel, 8.2 mm dia., length 2 m
Part number 0106-210-05 0106-210-06 0106-310-01
88
RE 82 801/10.99

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ALU-STAR Profile System Product Overview

Profiles and Sections

Drills Profile drilling jigs Thread reducer insert drivers

Adaption of Linear Motion Systems

Easy mounting of Linear Motion Systems to frame constructions

ALU-STAR Profile System Technical Data

Torsion moment l [cm ]

Section moduli WX [cm ] WY [cm ]

50 x 50 with four guide slots

Basic Profile Planar moments of inertia lX [cm ]

Torsion moment l [cm ]

Section moduli WX [cm ] WY [cm ]

ALU-STAR Profile System Technical Data

Torsion moment l [cm ]

Section moduli WX [cm ] WY [cm ]

Basic Profile Planar moments of inertia lX [cm ]

Torsion moment l [cm ]

Section moduli WX [cm ] WY [cm ]

35 x 40 with three guide slots

35 x 35, quadrant profile

PB 35 4.37 4.37 2.66 2.66 4.13 1.09 78

PB 25 3.1 9.8 2.5 3.9 4.21 1.14 79

PB 25 1.3 2.0 1.0 1.6 2.38 0.64 80

98 x 98, gusseted angle section 147.92

48 x 48, angle section

ALU-STAR Profile System Technical Data

Deflection and bending stresses caused by external forces

Deflection f [mm] Load case 1: F

Bending stress [N/mm2]

F = load [N] L = profile length [mm]

I = planar moment of inertia [cm4] E = elastic modulus = 70,000 [N/mm2]

W = section modulus [cm3]

Deflection and bending stresses caused by profile's own weight

49.05 q L4 384 E I 107

9.81 q L4 384 E I 107

9.81 q L2 max 12 W 106

q = profile mass [kg/m] L = profile length [mm]

I = planar moment of inertia [cm4] E = elastic modulus = 70,000 [N/mm2]

W = section modulus [cm3]

ALU-STAR Profile System Technical Data

Tolerance T [mm] 0.2

Tolerance T [mm] +0.4

Tolerance T [mm] 0.15 0.1

Shape tolerances to DIN 17615 Part 3

Length L [mm] Tolerance h1 max [mm]

te pla ing r asu h1 Me

Rectangularity and inclination

Width of shorter side [mm] Tolerance w [mm]

Profiles and sections:

extruded precision profile to DIN 17 615

Al Mg Si 0.5 F25 Material number Al Mg Si 0.5 F22 Material number

3.3206.72 3.3206.71 (profile 100 x 100, rectangular profile 6 x 50 and 10 x 50)

anodized to E6/EV1 (pickled and anodized, color neutral) Layer thickness: 12 m

75 HB 2.5/62.5 Brinell 70 HB 2.5/62.5

(for Al Mg Si 0.5 F25) (for Al Mg Si 0.5 F22)

Minimum tensile strength in extrusion direction:

(for Al Mg Si 0.5 F22 Rm = 215 N/mm2)

Proof stress in extrusion direction:

Rp 0.2 = 195 N/mm2