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Aside from appearance, you may not think there are many differences when comparing square tubing vs. round tubing (particularly when it comes to extruded aluminum tubing). Both are commonly used in construction and manufacturing, but the structural properties that each shape provides generally make them suited for different applications.
In this quick breakdown, we’ll outline the differences to help you choose the right shape for your next project.
With the right extrusion die, it’s possible to shape aluminum into nearly any profile. Still, square and round tubing remain two of the most common shapes for their broad utilities.
To that end, square and round tubing can be produced by appropriately bending a flat piece of aluminum into shape and welding it. Additionally, manufacturers can use a tool called a “mandrel” to maintain the hollow center as the aluminum is extruded around it.
Round tubing will generally offer greater structural benefits when comparing them without considering your use case. However, square tubing is often the ideal choice when:
When purchasing aluminum tubing, remember that the sizes are measurements of the outside diameter (OD) and wall thickness. Pipes, on the other hand, are measured by their inside diameter (ID).
Round tubing offers greater strength and durability because of how the cylindrical shape distributes both characteristics.
The 90° right angles of square tubing affect its strength and ability to withstand stress because they unevenly distribute them throughout the material, with torsional twisting being a greater concern. When under pressure, square tubing will lose some of its strength and durability.
With the cylindrical shape, all pressure is distributed evenly through round aluminum tubing. This makes it incredibly strong and durable—more so than square tubing when comparing the same weight, especially since round tubing is roughly 20% lighter when comparing equivalent lengths.
Square tubing is far easier to cut, while round tubing generally responds better to bending and other shaping.
However, their distinct malleabilities and ease of shaping partially depend on factors such as wall thickness and overall sizing.
For example, the greater the OD and the thinner the wall, the more likely tubing—round or square—is to distort under compressive and tensile forces during shaping.
Being hollow, tubing always risks ripping, rippling or buckling if too much force is applied during shaping. This phenomenon is exacerbated for square tubing.
Because of the flat surfaces, it’s significantly easier to cut square tubing with whatever tool necessary—from a powered cutter to a handheld hacksaw. The flat surfaces also generally make it easier to position the tubing in a vice—or tools adjacent—to hold it in place while you work.
But the flat surfaces and unevenly distributed pressure don’t help with shaping, as the material—particularly the two walls parallel to the bend—will be subjected to higher amounts of tension and compression.
With evenly distributed pressure and no corners, round tubing is superior when it comes to bending and shaping. The aluminum will bend and flow more consistently and smoothly throughout the shaping process, minimizing distortion and preserving strength afterward.
Again, the flat surfaces of square tubing provide a workability advantage, making welding easier along four straight lines. With round tubing, it’s more challenging to follow the circular path, and the continuous weld is inherently longer for similar sizes. Precision begets more complexity with round tubing, especially for difficult-to-reach or more complex welds.
Square tubing is often used for various projects because the use case demands outweigh the more robust structural properties that round tubing offers. Square tubing is also generally used for structural and aesthetic purposes.
While round tubing may have the same application, it’s sometimes used for carrying fluids and gasses in smaller quantities than would necessitate pipes.
Square tubing may be preferred if your application requires:
Round tubing may be preferred if your application requires:
The easiest way to remember the difference between square tubing vs. round tubing is that the former generally suits a wide range of applications. In contrast, the latter provides more robust structural properties and better shaping.
And whether you’re looking for square or round aluminum tubing—or other shapes—Orange Aluminum is your choice provider for extruded aluminum. With over 1000 SKUs in stock, we have nearly every shape and size of aluminum material readily available.
We also offer custom extrusion profiles to ensure your project needs are met, whatever they are, and will help you figure out your ideal profile if you need guidance.
Contact us today to talk about your next project.
Metal tubing comes in a wide variety of materials. Depending on your needs, you can find metal tubing in aluminum, steel, and an assortment of alloys. Most of this tubing, however, comes in two basic shapes: square and round.
Each shape has its own unique advantages, but which is best for your specific project? While the answer is complex and can involve a dizzying array of engineering specs, measurements, and strength ratings, most users can get a strong indication by looking at the basics of their project.
The answer goes far beyond the space, dimensions, and shape of the project. You need to consider the purpose of the metal tubing, how much material will be bent or cut, how much weight it needs to hold, and how it will hold this weight, among many other factors.
Ultimately, you’ll need to talk with an expert to determine the best materials for your need, but this article will help you understand the basic differences between square and round metal tubing…
Square tubing has many advantages, and some disadvantages, compared to round.
First of all, square tubing is generally easier to build with, as the cuts and edges fit together much easier. If you butt the end of a square tube against the side of another, you will have a flush fit that can be easily attached. To do the same with round tubing, you need to cut a rounded edge into the tube that will fit against the other. Because everything is essentially 90-degree angles, it’s much easier to cut and construct with square tubing.
Square tubing, because it has a flush face on four sides, is also easier to drill, bolt, and attach. Image drilling a bolt hole in a flat metal surface; now image doing the same on a rounded surface. You can drill into rounded surfaces, but it’s clearly easier to drill, screw, and bolt into the flat face of a square tube.
Square tubing is also easier to get closer together, which means there is less wasted space.
Structurally, it’s hard to say that one is stronger than the other, as so much depends on the specific application. However, square tubing tends to be stronger in a single, unbent piece.
While square tubing tends to be easier to work with, round tubing has two main advantages: cost and weight.
A 1-inch diameter round tube uses less metal than a 1-inch-wide square tube. Because it uses less metal, a 1-foot section of round tube (for example) will weigh less than a 1-foot section of square tube. (Again, assuming 1-inch diameter vs 1-inch square.) Less raw material also means a lower price tag, so round tubing is often the ideal choice when cost is a concern and you don’t need the advantages of square tubing.
But cost and weight are certainly not the only concerns. Tubing, regardless of shape, needs to be strong and sturdy. In the right application, round is often stronger, especially when it’s under pressure. There is less chance for unwanted bends, breaks, and crimping when using round metal tubes.
Round tubing tends to accept bending and shaping with greater ease. Because of the cylinder-like shape, metal moves more evenly as it is bent; when properly bent by an experienced professional, there is less chance for distortions or concaving.
It’s hard, quite frankly, so select the perfect one for your specific needs. Each project is different, and each buyer has unique goals and priorities. But there are still some basic principles that can guide you when selecting the metal tubes for your application.
Most of all, if your job will require a lot of cutting, welding pieces together, drilling, and bolting, square tubing is probably the best choice. Like 2×4 boards, square tubing is easier to build with and can be used to create the frame for a wide variety of structures and items.
However, if your project will include lots of bending and shaping, round tube is probably better. The strength and formability of round tubing make it better for an assortment of uses and other attributes, including its weight and price, make it more attractive as well. When properly oriented, square can be stronger (it’s stronger across the flats but weaker at the corners) but most will find that round is a stronger material.
If you need help deciding between square vs round metal tubing contact our friendly, knowledgeable team today.
We’ll help you make the right choice for your project, so contact Service Steel today!
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