Aluminium Conduit Profile 200×80 mm Cable Duct Extrusion 2.5 mm Wall for Long Production Line Runs

OEM / ODM Available Free Sample Available ISO 9001:2015 EN 755-9 RoHS REACH

200 x 80 mm aluminium conduit profile duct in 6063-T5 with a 2.5 mm wall for long production line runs. Six Ø4 mm holes, three per wide face, and a 10.2 mm T-slot.

Wholesale Price $7.80 - $11.60 / m per m

Material	Aluminium
Alloy Grade	6063-T5
Temper	T5
Section Size	200 x 80 mm
Slot	T-slot 10.2 mm groove, 8 mm mouth, 40 series
Length	6 m stock, cut to drawing to +/-0.5 mm
Tolerance	EN 755-9 / GB/T 6892, wall +/-0.15 mm
Surface	Mill finish / clear anodised / black anodised
MOQ	300
Lead Time	20-30 days after deposit for mill finish
Loading Port	Shanghai / Ningbo
Supply Ability	400 t per month
Payment Terms	T/T 30% deposit + 70% before shipment \| L/C at sight
Trade Terms	FOB \| CIF \| EXW
Certifications	ISO 9001:2015 \| EN 755-9 \| RoHS \| REACH

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Cable management · Aluminium duct

A 200 x 80 mm aluminium conduit profile is a rectangular duct with a 2.5 mm wall, six Ø4 mm holes, three through each of the two wide faces, and a 10.2 mm T-slot along one narrow face. The internal free area is about 146 cm2, the largest in the aluminium duct range, and the section weighs about 3.4 kg/m. It is extruded in 6063-T5 and supplied cut to length, drilled or machined.

The wall is 2.5 mm rather than the 2 mm used on the smaller sections, and the reason is span. Local bending stiffness in a wall scales with the cube of its thickness, so going from 2 mm to 2.5 mm makes the side wall roughly twice as resistant to bowing under the weight of a cable bundle. That matters because a duct at this size is bought for a run measured in tens of metres, not for a short drop inside a machine, and on a run that long the side walls are the part that gives first.

200 x 80 section: 2.5 mm wall, three Ø4 mm holes through each wide face, and a 10.2 mm T-slot on the narrow face.

At this size you are buying a run, not a length

A duct inside a machine is a few lengths long and the section is the whole story. A duct along a production line is a different job. A typical run is 30 to 80 m, and because aluminium duct is supplied in 6 m lengths that is somewhere between five and fourteen joints in a single continuous run.

Every one of those joints is a place where the lid line can step, where the run can drift out of line, and where a fixing can be left loose. The engineering effort on a long run goes into those joints and into the order the work is done, not into choosing the section. The section is settled early; the joints are what the project lives or dies on.

Run length	6 m lengths needed	Joints in the run	Main risk
12 m	2	1	Joint alignment
30 m	5	4	Alignment drift along the run
48 m	8	7	Alignment plus thermal movement
60 m	10	9	Thermal movement becomes the governing case
80 m	14	13	Expansion joints are mandatory

Joining two lengths so the lid line stays straight

The lid runs in the tongue on the narrow face, and that tongue has to be continuous across a joint or the lid catches. Three things decide whether it will be: how the two lengths are butted, whether the splice stiffens the joint, and whether the joint is free to move.

Joint method	What it does	Effect on the lid line	Use it when
Butt joint, no splice	Lengths simply meet	Steps if the ends are not dead square	Short runs only
Internal splice plate	A plate bridges the joint inside the duct	Holds the line if the plate is a close fit	The usual production line joint
External coupler	A plate bridges the joint outside the duct	Keeps the line but leaves a step outside	Where the inside must stay clear
Overlapping cover strip	One length laps over the next	Continuous but the section changes locally	Where a sliding joint is needed
Welded butt	The two lengths are welded	The best line, no step at all	Shop-built runs that can be welded flat

Alignment: measure from one datum, never chain

On a 60 m run with nine joints, a joint set half a millimetre out of line is not noticeable on its own. Nine of them, each measured from the previous one, put the far end 4.5 mm out, and that is before any cutting error is added. That is the difference between a run that reads as straight and one that visibly wanders.

The fix is to mark every support and every joint position from a single datum at one end of the run, rather than measuring from the last support. Measuring from a datum means each position carries only its own error; chaining means every position carries the sum of all the errors before it.

Method	Error at the far end of a 60 m run	Comment
Chained from the previous support, 0.5 mm each	About 4.5 mm over 9 joints	Visible wander
Chained with 1 mm per joint	About 9 mm	Clearly out of line
Measured from a single datum	The error of that position only	The right method
Datum plus a laser or string line	Under 1 mm over the run	Best for long runs

Thermal movement, and why a 60 m run cannot be pinned at both ends

Aluminium expands by about 23 parts per million per degree Celsius. Over a 60 m run and a 30 degree swing between a cold workshop and a warm production day, that is about 41 mm of movement in the length of the run.

That movement is small enough to be absorbed if the duct is free to slide, and it is not small at all if it is restrained. The section has a cross-sectional area of about 12.6 cm2, and restraining a change of that size in a section of that area develops a force of roughly 60 kN, which is far more than any bracket, bolt or support will hold. The run will either buckle sideways or tear its fixings out.

Run length	Movement over a 30 degree swing	How to allow for it
12 m	About 8 mm	Absorbed by hole clearance in the fixings
30 m	About 21 mm	Slotted fixings at one end of each length
48 m	About 33 mm	One expansion joint about mid-run
60 m	About 41 mm	Expansion joints every 20 to 25 m
80 m	About 55 mm	Expansion joints, plus a check of the fixings

Fix one end, let the other slideEach section is anchored at one end and free to move at the other, with slotted fixings at the free end so the duct can travel without loading the support.

Put expansion joints at intervalsOn a run over about 25 m, break it into sections with a proper expansion joint so each section only has to absorb its own movement, which is a fraction of the total.

Do not rely on hole clearance aloneA Ø4 mm hole in a Ø4 mm screw gives almost no travel. Where the run has to move, use slotted fixings or a cover strip joint rather than a drilled hole.

Allow for the temperature it will seeSize the allowance on the temperature range on site, not on the workshop it was built in. A run installed cold and used hot moves more than the drawing suggests.

Installation sequence on site

Set the datum and mark everything from it Establish one datum line and mark every support and joint position from it before anything is fixed. Do not chain measurements along the run.
Fit the supports first and check them for line Supports go in before the duct. Fixing brackets to a duct that is already hanging means the duct becomes the straight edge, and it will not be straight.
Lay out the lengths and mark the joint positions Lay the cut lengths along the run in order and mark where each joint will fall. Move a joint rather than accept one that lands on a support or in a doorway.
Join the lengths on the ground before lifting Assemble as much of the run as can be handled flat, on the floor, where the joint line can be checked against a straight edge. Joints made at height are never as good.
Anchor one end and leave the other free Fix the datum end solidly and leave the far end of each section free to move in its slotted fixings. Then check the whole run for line before the lids go on.
Fit the lids last, working from the datum end Lids go on after the run is fixed and lined up. Working from the datum end means any accumulated step ends up at the far end where it can be trimmed.

This duct or the 160 x 80? Choose the 200 x 80 for runs measured in tens of metres, for large bundles, and where the 2.5 mm wall is needed to stop the side walls bowing between supports. For a shorter run inside a machine, the 160 x 80 carries almost as much and is lighter and cheaper.

Frequently asked questions

How long can a run be before I need expansion joints?

Above about 25 m. Aluminium expands about 23 parts per million per degree, so a 60 m run moves about 41 mm over a 30 degree swing, and restraining that develops roughly 60 kN in this section. Break long runs into sections with expansion joints.

How should two lengths be joined?

An internal splice plate is the usual production line joint: it bridges the joint inside the duct and holds the lid line straight. A welded butt gives the best line of all where the run can be welded flat on the floor before lifting.

How do I keep a long run straight?

Mark every support and joint position from a single datum at one end rather than chaining measurements. Nine joints each measured from the previous one put the far end about 4.5 mm out on a 60 m run, which is visible.

Why is the wall 2.5 mm instead of 2 mm?

Because a run at this length has long unsupported spans, and the side walls bow outward under the cable bundle. Local bending stiffness scales with the cube of the wall thickness, so 2.5 mm is roughly twice as stiff as 2 mm.

Can you supply the run assembled?

Yes. Send the run layout and we will cut to length, drill the Ø4 mm holes to pattern, machine the cable entries, fit the splice plates and supply the assembly in sections ready to lift into place.

Send the run layout and the temperature range on site

Tell us the run length, the temperature swing and what the bundle weighs. We will confirm the section, the support and joint spacing, the expansion allowance, and quote the duct, the splice plates, the lids and FOB pricing.

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