Square Bar Weight Calculator

Basic Formula

Material Densities

Example Calculation

What is the difference between square bar and round bar?

Square bar has a square cross-section with flat sides, while round bar has a circular cross-section. Square bar provides flat mounting surfaces and resists rotation better, making it ideal for brackets, frames, and structural supports. Round bar is better for shafts, axles, and applications requiring smooth rotation. For the same cross-sectional area, square bar is typically stronger in bending than round bar.

How is square bar measured?

Square bar is measured by the dimension of one side of the square cross-section. For example, a "1 inch square bar" has sides that are each 1 inch, giving it a cross-sectional area of 1 square inch. The length is typically specified separately in feet or inches. Standard sizes range from 1/4" to 6" and larger.

Can square bar be bent or formed?

Yes, square bar can be bent, but it requires more force than round bar of similar size due to its larger cross-sectional moment. Hot bending is recommended for larger sizes to prevent cracking. Cold bending is possible for smaller sizes and softer materials like aluminum. When bending, the square bar will distort at the bend, with the outer corner stretching and the inner corner compressing.

What material is best for square bar applications?

The best material depends on your application. Steel offers good strength at low cost and is widely used for general fabrication. Stainless steel 304/316 provides excellent corrosion resistance for outdoor or wet environments. Aluminum is ideal when weight reduction is important and offers good corrosion resistance. Brass is used for decorative applications and provides good machinability and corrosion resistance.

How do you weld square bar?

Square bar can be welded using standard welding methods including MIG, TIG, and stick welding. The flat surfaces provide good access for welding. For structural applications, ensure proper joint preparation and full penetration welds. Stainless steel square bar requires special stainless filler rod to maintain corrosion resistance. Aluminum requires TIG or MIG welding with aluminum-specific equipment and filler.

What tolerances are typical for square bar?

Standard commercial square bar typically has dimensional tolerances of ±0.005" to ±0.015" depending on size, with larger sizes having looser tolerances. Cold-finished square bar has tighter tolerances (±0.002" to ±0.005") and better surface finish. Hot-rolled square bar has looser tolerances and rougher surfaces. Precision ground square bar is available with tolerances as tight as ±0.0005" for critical applications.

How do I prevent square bar from rusting?

For steel square bar, apply protective coatings such as paint, powder coating, galvanizing, or oil. Store in dry conditions and avoid moisture exposure. Alternatively, use corrosion- resistant materials like stainless steel or aluminum. For outdoor applications, hot-dip galvanized steel square bar provides excellent long-term protection. Regular maintenance and touch-up of protective coatings extends service life.

What is the difference between hot-rolled and cold-finished square bar?

Hot-rolled square bar has a rough, scaled surface and looser dimensional tolerances, but is more economical. Cold-finished square bar is drawn through a die at room temperature, resulting in tighter tolerances, better surface finish, and slightly increased strength. Cold-finished is preferred for precision applications and when good surface finish is important. Hot-rolled is suitable for general fabrication where appearance and precise dimensions are less critical.