Aluminum Bus Pipe
Three D Metals supplies seamless and structural aluminum bus pipe engineered for high conductivity, durability, and long-term performance. Available in alloys 6101 and 6063 with Schedule 40 and Schedule 80 options, our bus pipe meets the performance demands of power distribution, substations, switchyards, and industrial electrical systems.
Seamless or Structural:
Which is Right for Your Project?
Both seamless and structural aluminum bus pipe options are used in power distribution and related applications, but their manufacturing processes and performance differ. Seamless bus pipe is ideal for critical electrical applications, while structural bus pipe is often used when cost and availability are bigger concerns.
| Seamless Aluminum Bus Pipe | Structural Aluminum Bus Pipe | |
| Manufacturing | Made from a solid billet of aluminum that’s extruded without any welded seams. | Made from rolled aluminum plate that’s formed and welded. |
| Strength & Conductivity | Higher structural integrity and slightly better electrical conductivity since there are no welds. | Adequate for many applications but slightly lower conductivity due to welds. |
| Appearance | Smooth and uniform surface. | Weld seam may be visible. |
| Common Uses | Preferred in high-performance electrical systems, substations, and environments requiring flawless conductivity. | Used where cost-efficiency matters more than absolute conductivity, like large-scale power distribution where minor losses are acceptable. |
Aluminum Bus Pipe Products
We stock seamless and structural bus pipe in a range of sizes:
- Sizes: ½” to 12” nominal pipe size
- Lengths: 30’ and 40’ standard, with special order lengths up to 50’
- Alloys: 6101-T6 (high conductivity) and 6063-T6 (excellent finish and corrosion resistance)
- Additional services: custom beveling, special packaging, and made-to-order dimensions available
Schedule 40 Aluminum Bus Pipe
6101-T6 and 6063-T6 | 0.5” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 0.5” | 0.840 | 0.622 | 0.109 | 0.294 |
6101-T6 and 6063-T6 | 0.75” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 0.75” | 1.050 | 0.824 | 0.113 | 0.391 |
6101-T6 and 6063-T6 | 1” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 1” | 1.315 | 1.049 | 0.133 | 0.581 |
6101-T6 and 6063-T6 | 1.25” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 1.25” | 1.660 | 1.380 | 0.140 | 0.786 |
6101-T6 and 6063-T6 | 1.5” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 1.5” | 1.900 | 1.610 | 0.145 | 0.940 |
6101-T6 and 6063-T6 | 2” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 2” | 2.375 | 2.067 | 0.154 | 1.264 |
6101-T6 and 6063-T6 | 2.5” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 2.5” | 2.875 | 2.469 | 0.203 | 2.004 |
6101-T6 and 6063-T6 | 3” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 3” | 3.500 | 3.068 | 0.216 | 2.621 |
6101-T6 and 6063-T6 | 3.5” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 3.5” | 4.000 | 3.548 | 0.226 | 3.151 |
6101-T6 and 6063-T6 | 4” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 4” | 4.500 | 4.026 | 0.237 | 3.733 |
6101-T6 and 6063-T6 | 5” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 5” | 5.562 | 5.047 | 0.258 | 5.057 |
6101-T6 and 6063-T6 | 6” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 6” | 6.625 | 6.065 | 0.280 | 6.564 |
6101-T6 and 6063-T6 | 8” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 8” | 8.625 | 7.981 | 0.322 | 9.878 |
6101-T6 and 6063-T6 | 10” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 40
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 10” | 10.750 | 10.020 | 0.365 | 14.004 |
6101-T6 and 6063-T6 | 12” | Schedule 40
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 12” | 12.750 | 12.000 | 0.375 | 18.516 |
Schedule 80 Aluminum Bus Pipe
6101-T6 and 6063-T6 | 0.5” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 0.5” | 0.840 | 0.546 | 0.147 | 0.376 |
6101-T6 and 6063-T6 | 0.75” | Schedule 8
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 0.75” | 1.050 | 0.742 | 0.154 | 0.510 |
6101-T6 and 6063-T6 | 1” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 1” | 1.315 | 0.957 | 0.179 | 0.751 |
6101-T6 and 6063-T6 | 1.25” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 1.25” | 1.660 | 1.278 | 0.191 | 1.037 |
6101-T6 and 6063-T6 | 1.5” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 1.5” | 1.900 | 1.500 | 0.200 | 1.256 |
6101-T6 and 6063-T6 | 2” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 2” | 2.375 | 1.939 | 0.218 | 1.737 |
6101-T6 and 6063-T6 | 2.5” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 2.5” | 2.875 | 2.323 | 0.276 | 2.650 |
6101-T6 and 6063-T6 | 3” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 3” | 3.500 | 2.900 | 0.300 | 3.547 |
6101-T6 and 6063-T6 | 3.5” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 3.5” | 4.000 | 3.364 | 0.318 | 4.326 |
6101-T6 and 6063-T6 | 4” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 4” | 4.5 | 3.826 | 0.337 | 5.183 |
6101-T6 and 6063-T6 | 5” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 5” | 5.562 | 4.813 | 0.375 | 7.188 |
6101-T6 and 6063-T6 | 6” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 6” | 6.625 | 5.761 | 0.432 | 9.884 |
6101-T6 and 6063-T6 | 8” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 8” | 8.625 | 7.625 | 0.500 | 15.010 |
6101-T6 and 6063-T6 | 10” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 10” | 10.750 | 9.5622 | 0.593 | 23.550 |
6101-T6 and 6063-T6 | 12” | Schedule 80
Type: Seamless or structural aluminum
Alloys: 6101 and 6063
Temper: T6
Schedule: 80
| Pipe Size | Actual OD | Actual ID | Wall | Lbs/Ft |
| 12” | 12.750 | 11.374 | 0.687 | 33.010 |
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