Question 1

How long should the rails be between the legs of an aluminium profile frame?

Accepted Answer

For rails fitted between the legs, subtract two profile widths from the outside size: a 1600 mm bench with 40×40 legs needs 1520 mm long rails. With middle legs, also subtract their width and divide by the number of bays.

Question 2

40×40 or 40×80 profiles for a workbench?

Accepted Answer

A 40×80 rail standing upright is about five times stiffer than a 40×40 for less than twice the weight. For spans over about 1.2 m or heavy loads, use 40×80 rails or add middle legs; the calculator checks both.

Question 3

Angle brackets or hidden connectors?

Accepted Answer

Angle brackets need no machining and stay adjustable, but they show and take up slot space. Hidden connectors give a clean, stiff joint but need a drilled access hole and often a tapped thread, so they are harder to move later.

Question 4

How much weight can an aluminium profile workbench hold?

Accepted Answer

It depends more on the span than on the profile: sag grows with the fourth power of the span. Short spans in 40×40 carry a few hundred kilos spread over the top; long spans need double rails or middle legs. Check your own size with the calculator, and remember that joints limit point loads.

Question 5

Should I buy profiles cut to size or full bars?

Accepted Answer

Cut to size gives square, precise parts with no saw needed, for a small fee per cut. Full bars are cheaper per metre when there are many parts, but you need a mitre saw with a suitable blade, and long bars cost more to ship.

Question 6

What protective equipment do I need to cut aluminium profiles?

Accepted Answer

Safety glasses (EN 166) and hearing protection (EN 352) when sawing, and gloves (EN 388) for handling, but not near the blade. Clamp the profile, use a blade for non-ferrous metal, and sweep up the chips rather than grinding: fine aluminium dust is a fire risk.

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