ALUMINUM ANGLE

The Aluminum Angle 40×40 is a universal L-profile structural component for building custom PV substructures, tilt frames, and connection elements where standard rail-based mounting systems do not fit the project geometry. Extruded from EN AW-6060 T6 aluminum alloy in a 40×40 mm equal-leg L-profile, this aluminum angle for PV applications provides the raw material for solar installers, fabricators, and project engineers who need to design bespoke mounting solutions for non-standard roof geometries, custom tilt angles, parapet clearance brackets, and ground-mount substructures. Available in 3 mm and 4 mm wall thicknesses and a standard supply length of 6,000 mm (6 m), the angle can be cut, drilled, and assembled on site to solve unique structural challenges that prefabricated profile systems cannot address. ULAMEX supplies the Aluminum Angle 40×40 at B2B wholesale conditions from stock in Poland with European-wide delivery, making it the practical building block for all-aluminum PV fabrication projects.

Technical Specifications

The Aluminum Angle 40×40 is manufactured from EN AW-6060 T6 (AlMgSi alloy, solution heat-treated and artificially aged), an aluminum grade with a minimum tensile strength of 190 MPa, minimum yield strength of 150 MPa, and minimum elongation of 8%. The T6 temper condition delivers the best combination of strength, formability, and corrosion resistance within the 6060 alloy family, making it suitable for outdoor structural applications exposed to weather, UV radiation, and temperature cycling over the full service life of a photovoltaic installation (typically 25–30 years).

The equal-leg L-profile geometry (40 mm × 40 mm) provides symmetrical load-bearing capacity in both axes, simplifying structural calculations and allowing the angle to be oriented in whichever direction best serves the design. The two available wall thicknesses serve different structural roles:

• 3 mm wall thickness — suited for lightweight auxiliary frames, spacer elements, edge supports, and non-primary structural connections where moderate loads govern the design.
• 4 mm wall thickness — suited for primary load-bearing elements, tilt frame legs, ground-mount post brackets, and connections that must resist significant wind uplift or cantilever loads.

Both variants are supplied in mill-finish (natural silver) aluminum with the inherent aluminium oxide surface layer that provides maintenance-free corrosion protection in outdoor environments classified as corrosivity categories C1–C3 per EN ISO 9223.

Fabrication and Connection Methods

Unlike dedicated PV mounting rails with integrated T-slot channels, the Aluminum Angle 40×40 is deliberately designed as an open structural profile without built-in fastening channels. This means all connections are made through conventional through-bolting using standard metric hardware — M8 or M10 bolts, nuts, washers, and lock washers from our fasteners and accessories range.

This open design is the angle’s greatest strength in custom applications: it imposes no constraints on hole position, bolt pattern, or connection geometry. The installer or fabricator drills holes exactly where they are needed, at whatever spacing the structural design requires. Typical fabrication operations include:

• Cutting to length — the 6 m supply length can be cut on site using standard aluminum cutting tools (mitre saw, circular saw with non-ferrous blade, or reciprocating saw). The EN AW-6060 T6 alloy machines cleanly without burring.
• Drilling — standard HSS or cobalt drill bits produce clean holes in the 3 mm or 4 mm wall sections. Pre-drilling and counter-sinking for flush-head bolts is straightforward.
• Bolting — through-bolt connections using M8 or M10 stainless steel or galvanized hardware. For aluminum-to-aluminum joints, standard metric hardware is sufficient. For aluminum-to-steel connections, use appropriate bi-metal or stainless steel fasteners to prevent galvanic corrosion.
• Bending and forming — the EN AW-6060 T6 alloy allows moderate cold bending for custom bracket shapes, though sharp bends should be avoided to prevent cracking at the bend radius.

Installation Applications

The Aluminum Angle 40×40 serves as the universal structural building block for PV installation scenarios that cannot be solved with off-the-shelf profile-and-clamp systems:

• Custom tilt frames for flat roofs — where the required panel tilt angle does not match any standard PV triangle dimension, angles can be cut and assembled into bespoke triangular or trapezoidal support frames at any desired angle. The 4 mm variant provides the structural capacity for primary tilt frame legs.
• Ground-mount substructure fabrication — angles serve as cross-bracing, diagonal struts, and connection brackets between vertical posts and horizontal PV mounting rails in ground-mounted solar array foundations.
• Panel elevation brackets — on roofs with parapets, ventilation ducts, or other obstructions, angles are used to elevate the mounting rail above the obstacle, creating clearance for airflow and panel access. The L-profile shape naturally provides both a vertical leg (for height) and a horizontal leg (for attachment).
• Carport and canopy structures — integrated into aluminum carport frames as gusset plates, corner brackets, and connection reinforcements. The 40×40 mm dimension matches standard PV rail cross-sections, ensuring visual and structural consistency.
• Edge and perimeter framing — angles form the perimeter frame of ballast-mounted flat-roof arrays, holding ballast trays in position and providing a clean termination edge for the installation.
• Hybrid mounting solutions — combining angles with standard PV rails for installations that require both a profiled rail section (for clamp-based panel attachment) and a structural frame section (for tilt, elevation, or lateral bracing). The angle handles the structural frame while the rail handles the panel interface.

Why Choose This Product

The Aluminum Angle 40×40 is not a replacement for standard PV mounting rails — it is the component that fills the gap where rails cannot go. Every solar installation project encounters mounting challenges that fall outside the scope of standard profiles: a non-standard tilt angle, an obstruction that requires custom clearance, a ground-mount geometry that needs diagonal bracing, or a carport design that demands structural reinforcement at specific joints.

In these situations, the 40×40 angle provides the material to engineer a solution on site, without waiting for custom-fabricated components. The choice between 3 mm and 4 mm wall thickness gives engineers a clear selection criterion: 3 mm for secondary and auxiliary connections where weight and material cost should be minimized, 4 mm for primary structural elements where load-bearing capacity is the priority.

The 6 m supply length is deliberately matched to the standard PV rail lengths in the ULAMEX range, ensuring that waste is minimized when angles are fabricated to complement rail-based mounting systems. And because the angle is manufactured from the same EN AW-6060 T6 alloy as all ULAMEX PV profiles, material compatibility and consistent corrosion behavior across the entire installation are guaranteed.

Standards and Quality Assurance

The Aluminum Angle 40×40 is extruded from EN AW-6060 T6 per EN 755-2 (extruded profiles — mechanical properties) and EN 573-3 (chemical composition), with dimensional tolerances per EN 755-9 (tolerance on dimensions and form). The T6 temper guarantees minimum tensile strength of 190 MPa, minimum yield strength of 150 MPa, and Brinell hardness of approximately 75 HB across every production batch. The natural aluminium oxide layer provides corrosion protection in categories C1–C3 per EN ISO 9223, matching the outdoor durability of all other ULAMEX PV profiles and ensuring consistent long-term performance across mixed-component installations. ULAMEX operates under EN 1090 certification for structural aluminum, with full material traceability documentation on every delivery.

Frequently Asked Questions

What is the difference between the 3 mm and 4 mm wall thickness?

The 3 mm variant is suited for lightweight auxiliary structures: spacers, edge framing, non-load-bearing connections, and secondary bracing elements. The 4 mm variant is designed for primary load-bearing applications: tilt frame legs, ground-mount post brackets, carport gusset plates, and any connection that must resist significant wind, snow, or cantilever loads. When in doubt, specify the 4 mm version — the weight difference (~0.22 kg/m) is marginal, but the additional wall thickness provides a meaningful increase in section modulus and buckling resistance.

Can I weld the Aluminum Angle 40×40?

EN AW-6060 T6 is weldable using TIG (GTAW) or MIG (GMAW) processes with appropriate AlSi5 or AlMg5 filler wire. However, welding locally reduces the T6 temper properties in the heat-affected zone (HAZ) to approximately T4 levels. For structural welds, a post-weld heat treatment or oversized weld design may be required. In most PV installation contexts, bolted connections are preferred over welding because they are easier to execute on site, require no specialized equipment, and maintain the full T6 mechanical properties of the base material.

Is the Aluminum Angle compatible with ULAMEX PV clamps?

The Aluminum Angle 40×40 does not have an integrated T-slot channel, so ULAMEX clamps cannot slide into the profile as they do on standard PV rails. However, the angle can be through-bolted to PV rails, clamp assemblies, or panel frames using standard M8/M10 hardware. In custom substructures, the typical approach is to use angles for the structural frame and standard PV mounting rails for the panel interface where clamps are needed.

What fastener material should I use for aluminum-to-steel connections?

When connecting the Aluminum Angle to steel components (e.g., galvanized steel purlins, ground-mount posts), use stainless steel A2 (AISI 304) or A4 (AISI 316) fasteners to prevent galvanic corrosion at the aluminum-steel interface. Avoid using plain carbon steel or zinc-plated fasteners in direct contact with aluminum, as the dissimilar metal couple can cause accelerated corrosion in wet environments. Nylon or EPDM washers between the aluminum and steel surfaces provide additional galvanic isolation.