Aluminium tubes

Aluminium Tubes for Truss, Stage and Event Construction

Whether you are building a stage backdrop, assembling an exhibition booth or repairing a truss chord — the right aluminium tube is the foundation of every reliable structure. At LTT, you will find a carefully selected range of aluminium round tubes (Alurohr) engineered for the demanding requirements of professional event technology, trade fair construction and stage rigging.

Our aluminium tubes are available in truss-grade alloys such as EN AW-6060 and EN AW-6082, in a wide range of diameters and wall thicknesses, and can be ordered cut to your exact length. From compact lighting bars to full load-bearing truss systems compatible with Naxpro-Truss, Global Truss and Prolyte — LTT has the tube you need, backed by over 25 years of expertise in professional event technology.

What Is an Aluminium Tube (Alurohr)? Properties and Benefits

An aluminium tube — commonly referred to as Alurohr in the German-speaking events industry — is a hollow, cylindrical profile made from aluminium alloy, produced either by extrusion (Strangpressverfahren) or by drawing. The result is a seamless, dimensionally accurate tube that combines low weight with high structural integrity.

Key material properties

• Lightweight: Aluminium weighs approximately one-third as much as steel, making it the material of choice wherever every kilogram counts — from portable truss systems to touring stage rigs.
• Corrosion resistance: Aluminium spontaneously forms a thin, self-renewing oxide layer on its surface, providing natural protection against moisture, UV exposure and most atmospheric conditions without any additional coating.
• High strength-to-weight ratio: Truss-grade alloys such as EN AW-6082 T6 deliver yield strengths above 250 MPa — significantly higher than the general-purpose EN AW-6060 used in DIY hardware stores.
• Non-magnetic: Aluminium tubes do not interfere with audio, video or DMX signal equipment — a practical advantage in densely cabled event environments.
• Recyclable: Aluminium can be recycled repeatedly without loss of quality, making it a sustainable choice for long-term infrastructure investments.
• Workability: Aluminium tubes can be sawn, drilled, welded (TIG/MIG) and bent with standard workshop equipment, enabling on-site modifications and custom fabrications.

Aluminium tube vs. steel tube in event applications

Steel tubes offer higher absolute load capacity per cross-section but at roughly three times the weight. For permanent installations where weight is not critical, steel may be appropriate. For touring rigs, portable exhibition stands and any structure that must be assembled and dismantled repeatedly, aluminium tubes are the professional standard — and the material used in virtually every major truss system on the market today.

Alloys, Manufacturing and Surface Finishes

Aluminium alloys — choosing the right grade

Not all aluminium tubes are equal. The alloy determines strength, weldability and suitability for structural applications:

• EN AW-6060 (AlMgSi 0.5, F22 temper): The most widely used alloy for extruded profiles. Compliant with EN 755-1/-2/-8/-9. Good corrosion resistance, excellent surface quality and easy to anodise. Suitable for exhibition stands, light-duty frames and decorative structures. This is the grade typically found at general hardware retailers.
• EN AW-6082 T6 (AlSi1MgMn): The preferred structural alloy for load-bearing truss applications. Higher yield strength (≥ 250 MPa) and better fatigue resistance make it the standard for professional stage and rigging tubes. If you are building or repairing chord or brace tubes for truss systems, EN AW-6082 T6 is the correct specification.
• EN AW-7075 (AlZn5.5MgCu): A high-performance aerospace-grade alloy with exceptional strength. Used in specialist rigging hardware and high-load applications where weight savings are critical.

Important for event professionals: Hardware-store aluminium is almost always EN AW-6060 in a soft temper. Using it as a structural replacement for truss chord tubes — which are typically EN AW-6082 T6 — can result in dangerous under-specification. Always verify the alloy and temper before using any tube in a load-bearing context.

Manufacturing process

Most aluminium tubes are produced by extrusion (Strangpressverfahren): a heated aluminium billet is forced through a die around a mandrel, producing a seamless tube with consistent wall thickness. For tighter dimensional tolerances and thinner walls, the extruded tube is subsequently drawn through a forming die with an internal mandrel rod, reducing wall thickness and improving surface finish.

Surface finishes

• Natural mill finish (pressblank): Raw extruded surface, suitable for structural applications where appearance is secondary.
• Anodised (eloxiert): An electrochemical process that thickens the natural oxide layer to 5–25 µm, significantly improving corrosion and abrasion resistance. Available in silver (E6/EV1), bronze and other tones.
• Powder coated: Thermally bonded polymer coating available in any RAL colour. Adds approximately 60–100 µm of surface protection and is ideal for exhibition furniture and visible structural elements.
• Polished / brushed: Decorative finishes for high-visibility applications such as truss furniture and display structures.

Dimensions, Wall Thicknesses and Cut-to-Length Options

Standard dimensions

Aluminium round tubes are available across a broad dimensional range:

• Outer diameter: from Ø 8 mm up to Ø 580 mm for industrial grades; event-relevant diameters typically range from Ø 30 mm to Ø 120 mm
• Wall thickness: from 1 mm (drawn, thin-wall) up to 5 mm and beyond for structural grades; truss chord tubes commonly use 2–4 mm walls
• Standard lengths: 1 m, 2 m, 3 m and 6 m stock lengths; oversized lengths exceeding 20 m are available on request from specialist suppliers

Choosing the right dimensions for your project

The correct combination of diameter and wall thickness depends on the intended load, span and connection method:

• Lighting bars and decorative frames: Ø 48–50 mm × 2 mm wall in EN AW-6060 is a common choice, compatible with standard half-couplers and clamps.
• Truss chord replacement tubes: Match the original manufacturer specification exactly — typically Ø 50 mm or Ø 76 mm × 3–4 mm wall in EN AW-6082 T6. Never substitute a lower-grade alloy or thinner wall without a new static calculation.
• Exhibition booth uprights: Ø 30–50 mm × 2 mm wall in EN AW-6060 anodised provides a clean appearance and adequate rigidity for modular display systems.

Cut-to-length service

For professional projects, ordering tubes pre-cut to your exact dimensions saves time and reduces waste on site. LTT offers a cut-to-length service so you receive tubes ready for immediate assembly. When specifying lengths, remember to account for the depth of any spigot, sleeve or coupler connection at each end — typically 50–100 mm per joint depending on the hardware used.

Applications in Event Technology: Truss Systems, Stages, Exhibition Booths and Rigging

Aluminium tubes are the fundamental raw material of professional event infrastructure. Understanding where and how they are used helps you select the right specification for every project.

Truss systems and stage rigging

Every aluminium truss — whether a Naxpro-Truss square truss, a Global Truss F34 or a Prolyte H30V — is built from aluminium tubes. The main chord tubes carry the primary bending loads, while the diagonal brace tubes transfer shear forces between chords. When a truss section is damaged in transit or during assembly, replacing the affected tube with an identical-specification component (same alloy, same diameter, same wall thickness) is the correct repair approach. Using an under-specified tube compromises the entire system's working load limit (WLL).

For complete truss system solutions, explore the full range of truss constructions and rigging and stage technology accessories available at LTT.

Stage backdrops and lighting bars

DJs, bands and theatre productions frequently build custom lighting bars from aluminium round tubes, mounting them horizontally between vertical uprights or truss towers. A Ø 48 mm tube in EN AW-6060 or EN AW-6082 accepts standard half-couplers and pipe clamps, making it directly compatible with most rigging hardware. For heavier fixture loads, increase wall thickness to 3 mm and verify the span-to-load ratio against a static calculation.

Exhibition booths and trade fair stands

Modular exhibition systems rely on aluminium tubes for uprights, cross-beams and canopy frames. Anodised or powder-coated tubes in Ø 30–50 mm provide a professional appearance while keeping the overall structure light enough for a two-person assembly team. Combined with exhibition stand systems, aluminium tubes allow rapid reconfiguration between events.

DIY truss repairs and custom fabrications

Event technicians and rental companies frequently need individual tubes for repairs, custom spacers or bespoke rigging solutions. Having the correct alloy and dimensions in stock — or being able to order cut-to-length within 24 hours — is critical for minimising downtime between shows.

Load Capacity, WLL and Compliance Standards for Event Use

For any aluminium tube used in a load-bearing event structure, understanding the applicable standards and load limits is not optional — it is a professional and legal requirement.

Relevant standards

• EN 1090: The European standard for the execution of steel and aluminium structures. Any load-bearing aluminium fabrication intended for public events must comply with EN 1090-3 (aluminium structures). This requires documented material traceability, qualified welding procedures and, for higher execution classes, third-party certification.
• DIN 4113: The German standard for aluminium structures under predominantly static loading. Widely referenced in truss statics calculations and TÜV SÜD assessments for event structures.
• BGV C1 / DGUV Regulation 17 & 18: The German accident prevention regulations for event and production venues. These regulations require that all load-bearing structures — including truss systems and rigging points — are designed, erected and inspected by qualified personnel, with documented load calculations for any structure above defined thresholds.

Working Load Limit (WLL) and tube selection

The WLL of an aluminium tube in a given application depends on multiple factors: alloy and temper, outer diameter, wall thickness, unsupported span length, connection type and the direction of applied loads. There is no single WLL figure that applies to a tube in isolation — the structural context determines the safe working load.

As a practical guideline for event professionals:

• A Ø 50 mm × 3 mm EN AW-6082 T6 tube spanning 1 m as a lighting bar can typically support several hundred kilograms of uniformly distributed load — but always verify with a qualified structural engineer or the truss manufacturer's load tables.
• Chord tubes in a truss system are pre-calculated by the manufacturer. Never replace them with tubes of a different specification without obtaining a new static certificate.

TÜV SÜD and third-party verification

For public events, structures above certain heights or load thresholds require a TÜV SÜD or equivalent third-party static assessment. LTT's own Naxpro-Truss systems are manufactured in Germany with full documentation to support these assessments. When purchasing individual tubes for structural use, always request the material certificate (EN 10204 Type 3.1) to confirm alloy, temper and mechanical properties.

Connection and Assembly: Couplers, Spigots, Clamps and Sleeves

An aluminium tube is only as useful as the hardware that connects it to the rest of your structure. Understanding the interface between tube and fitting is essential for safe, efficient assembly.

Conical spigots and sleeve connectors

Truss systems use precision-machined conical spigots to join tube ends. The spigot fits inside both tube ends at a joint, held in place by a through-bolt or quick-release pin. The taper ensures self-centring alignment and transfers axial loads efficiently. When ordering replacement tubes, confirm the internal diameter tolerance — a tube with an incorrect ID will not accept the manufacturer's spigot.

Half couplers and pipe clamps

For attaching lighting fixtures, motors or other equipment to horizontal bars, half couplers (also called pipe clamps or hook clamps) grip the outside of the tube. Standard half couplers are designed for Ø 48–50 mm tubes — the same diameter used in most scaffolding and truss systems. Using a tube with a non-standard outer diameter will prevent the coupler from closing correctly and creates a safety hazard.

Sleeve connectors and repair sleeves

When a tube section must be extended or a damaged section spliced, an internal sleeve connector of matching ID and sufficient length (typically 4–6× the tube diameter) can restore structural continuity. For critical load-bearing applications, sleeve repairs must be assessed by a structural engineer.

Clamps, hooks and accessories

For a comprehensive selection of compatible rigging hardware — including conical couplers, half couplers, safety hooks and spigot sets — explore the clamps and hooks and accessories for trusses categories at LTT. Matching your tube specification to the correct hardware from the outset avoids costly rework and ensures compliance with applicable safety standards.

LTT – Your Specialist for Professional Event Technology

LTT is more than a retailer — as a manufacturer with its own production facility in Germany and over 25 years of experience in professional event technology, LTT is a reliable partner for event technicians, trade fair builders, touring companies and B2B resellers worldwide.

When you order aluminium tubes from LTT, you benefit from a 3-year LTT warranty, free shipping on orders from €69, and the option of express dispatch for urgent project requirements. Orders are fulfilled from Bocholt, Germany, with worldwide shipping and an established international dealer network for resellers.

Whether you need a single cut-to-length tube for a repair, a full set of chord and brace tubes for a custom truss build, or expert advice on alloy selection and load compliance, the LTT team is ready to support you. Visit the consulting and planning page for personalised technical guidance, or browse the complete trusses category to find compatible systems, accessories and rigging hardware — everything you need to put your next production in the spotlight.

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