A 090 aluminum sheet hits a sweet spot. It is thick enough for structural jobs. But it is still light enough to handle without a crane.
What 090 Aluminum Sheet Actually Means
The number 090 refers to thickness. It means 0.090 inches. That equals 2.286 millimeters. In the trade, people round it to 2.3 mm.
This thickness sits in the middle of the sheet metal range. It is heavier than 063. It is lighter than 125. That makes it useful for panels, covers, and parts that need some rigidity.
| Unit | Thickness |
|---|---|
| Inches | 0.090″ |
| Millimeters | 2.286 mm |
| Gauge (approx.) | 13 gauge |
| Weight per sq ft | 1.26 lbs |
A 4 ft by 8 ft sheet of 090 aluminum weighs about 40.3 pounds. Two workers can move it. A single worker can manage smaller cuts.
Why Buyers Pick 090 Thickness
This gauge is popular for practical reasons.
- Strong enough. It does not wobble like thin sheet. It holds its shape under load.
- Light enough. You save on shipping. Installation is easier than steel.
- Easy to fabricate. It cuts with standard tools. It bends in a brake press.
- Wide stock. Most suppliers keep 090 in multiple alloys and widths.
- Cost balance. You get real strength without paying plate-level prices.
Alloy Options for 090 Aluminum Sheet
Not every alloy works the same at 0.090 inches. Some bend easier. Some resist salt water. Here is the breakdown.
1xxx Series: Pure Aluminum Grades
These alloys are almost pure aluminum. For they are soft. They form easily. They cost less.
1100 is the most common. It has 99% aluminum content. There resists corrosion in normal air. It is a top pick for decorative panels and chemical equipment.
1050 is slightly purer. It conducts heat and electricity well. You see it in heat exchanger parts and reflective panels.
| Alloy | Purity | Tensile Strength | Typical Temper | Best Use |
|---|---|---|---|---|
| 1100 | 99.0% | 90–145 MPa | H14 | General fabrication, panels |
| 1050 | 99.5% | 70–130 MPa | H14 | Reflectors, heat transfer parts |
3xxx Series: Manganese Alloys
3003 is the workhorse. Manganese adds strength. The sheet stays workable. It resists corrosion better than pure grades in some environments.
This is the alloy you will find in truck bodies, tool boxes, and roofing. At 090 thickness, it makes sturdy panels that do not dent easily.
3004 is a step up in strength. It is less common but appears in applications needing extra hardness.
| Alloy | Key Element | Strength Range | Temper | Typical Application |
|---|---|---|---|---|
| 3003 | Mn (1.0–1.5%) | 110–200 MPa | H14 | Truck panels, tanks |
| 3004 | Mn (1.0–1.5%) | 140–240 MPa | H34 | Structural panels |
5xxx Series: Magnesium Alloys
These are the marine grades. Magnesium gives excellent corrosion resistance. Especially against salt spray.
5052 is the star. At 090 thickness, it makes strong boat hull sections and dock panels. It welds well. It also works for fuel tanks and pressure vessels.
5083 and 5086 are even tougher. They are common in shipbuilding. At 0.090 inches, they are usually reserved for smaller hull patches and framing.
| Alloy | Mg Content | Strength | Temper | Best Environment |
|---|---|---|---|---|
| 5052 | 2.2–2.8% | 170–305 MPa | H32 | Marine, general outdoor |
| 5083 | 4.0–4.9% | 275–350 MPa | H116 | Heavy marine, structural |
| 5086 | 3.5–4.5% | 240–320 MPa | H116 | Welded marine structures |
6xxx Series: Heat-Treatable Grades
6061 is the big name here. Magnesium and silicon make it strong. It responds to heat treatment. At 090 thickness, it is used where parts need to carry load.
6063 is softer than 6061. It extrudes well. In sheet form at 0.090 inches, it shows up in architectural trim and frames.
| Alloy | Main Alloys | Strength | Temper | Use Case |
|---|---|---|---|---|
| 6061 | Mg, Si | 124–290 MPa | T6 | Brackets, machine parts |
| 6063 | Mg, Si | 150–240 MPa | T5 | Trim, window frames |
Temper Guide for 090 Gauge Aluminum
Temper tells you how hard the metal is. It matters for bending, cutting, and welding.
| Temper | Description | Hardness | Forming | Best For |
|---|---|---|---|---|
| O | Annealed, soft | Very low | Excellent | Deep drawing, complex shapes |
| H12 | Quarter hard | Low | Very good | Light bends, panels |
| H14 | Half hard | Medium | Good | Most common. Balanced. |
| H16 | Three-quarter hard | Medium-high | Fair | Flat panels, little bending |
| H18 | Full hard | High | Poor | Rigid parts, no bending |
| H32 | Quarter hard, stabilized | Low-medium | Good | 5xxx series forming |
| T4 | Solution treated, natural age | Medium | Good | 6xxx series parts |
| T6 | Solution treated, artificial age | High | Fair | Structural brackets |
For general work, H14 is the default. For it bends. It holds shape. It machines without gumming up.
090 Aluminum Sheet vs. Other Common Thicknesses
Buyers often compare gauges. Here is how 090 stacks up.
090 vs. 063 Aluminum Sheet
| Feature | 090 (0.090″) | 063 (0.063″) |
|---|---|---|
| Thickness | 2.3 mm | 1.6 mm |
| Weight per sq ft | 1.26 lbs | 0.88 lbs |
| Rigidity | Good | Fair |
| Dent resistance | Better | Lower |
| Typical use | Trailer sides, panels | Sign blanks, trim |
| Cost per lb | Same | Same |
| Cost per sq ft | Higher | Lower |
For 090 vs. 125 Aluminum Sheet
| Feature | 090 (0.090″) | 125 (0.125″) |
|---|---|---|
| Thickness | 2.3 mm | 3.2 mm |
| Weight per sq ft | 1.26 lbs | 1.75 lbs |
| Rigidity | Good | Very good |
| Brake press bending | Easy | Harder |
| Typical use | Covers, enclosures | Heavy-duty panels |
| Cost per sq ft | Lower | Higher |
090 vs. 250 Aluminum Plate
| Feature | 090 Sheet | 250 Plate |
|---|---|---|
| Thickness | 0.090″ | 0.250″ |
| Class | Sheet | Plate |
| Weight per sq ft | 1.26 lbs | 3.5 lbs |
| Cutting | Shear or saw | Saw only |
| Welding prep | Minimal | Bevel edges |
| Typical use | Body panels | Machine bases |
Standard Sizes You Can Actually Buy
Suppliers stock 090 aluminum in standard widths and lengths. Custom cuts are available. But standard sizes cost less.
| Width | Length | Alloy | Common Temper |
|---|---|---|---|
| 36″ | 96″ | 3003-H14 | H14 |
| 48″ | 96″ | 5052-H32 | H32 |
| 48″ | 120″ | 6061-T6 | T6 |
| 48″ | 144″ | 3003-H14 | H14 |
| 60″ | 120″ | 5052-H32 | H32 |
Coils are also common. A 090 aluminum coil might be 48 inches wide and several thousand feet long. Fabricators run coils through roll formers or cut them into blanks.
| Coil Width | Inner Diameter | Typical Weight |
|---|---|---|
| 36″ | 16″ | 3,000–5,000 lbs |
| 48″ | 20″ | 5,000–8,000 lbs |
| 60″ | 20″ | 7,000–10,000 lbs |
Surface Types and Finishes
The surface of a 090 aluminum sheet can vary. The finish affects looks, welding, and coating adhesion.
| Finish Type | Appearance | Use Case |
|---|---|---|
| Mill finish | Smooth, slightly shiny | Industrial, hidden parts |
| Brushed | Matte, fine lines | Decorative panels, appliances |
| Tread plate (diamond) | Raised diamond pattern | Trailer floors, steps, ramps |
| Tread plate (5-bar) | Raised bars | Walkways, platforms |
| Anodized clear | Slight tint, protective | Outdoor architectural |
| Anodized color | Bronze, black, gold | Signage, design elements |
| Painted (PVDF or polyester) | Solid color coating | Roofing, cladding |
| Perforated | Holes in pattern | Screens, guards, vents |
At 0.090 inches, tread plate is a strong seller. The thickness gives the raised pattern enough backing. It does not bend under foot traffic.
This thickness shows up in many industries. Here are the main ones.
Real-World Applications for 090 Aluminum Sheet
- Trailer and truck bodies. Side panels, roof sheets, and door skins. The weight savings over steel add up.
- Boat building. Hull plating, deck covers, and transoms. 5052-H32 in 090 is a favorite.
- Tool boxes. Chests for trucks and workshops. The metal is thick enough to resist dents.
- Walkways and platforms. Tread plate in 090 supports foot traffic without flexing.
- Enclosures and cabinets. Electrical boxes, generator housings, and HVAC casings.
- Automotive patch panels. Floor pans and inner fenders. Easy to cut and shape.
- Agricultural equipment. Grain trailer sides, combine panels, and sprayer tanks.
- Architectural panels. Decorative wall systems and soffits. Often anodized or painted.
- Food equipment. Work tables, splash guards, and cabinet bodies. 3003 is common here.
- Signage and displays. Rigid blanks that do not warp in the sun.
- Aerospace ground support. Tool carts, steps, and non-critical covers.
- Military transport. Skid plates and storage boxes where weight matters.
Fabrication Notes for 090″ Aluminum
Working with 090 aluminum is straightforward. But there are tricks.
Cutting
You have options. A circular saw with a carbide blade works. A shear handles straight cuts on thinner 090 sheets. A band saw is good for curves. Water jet and laser also work if you need precision.
Cut speed matters. Too fast and the edge melts. Too slow and the blade gums up. Use cutting fluid for 6xxx grades.
Bending
A standard brake press bends 090 aluminum without trouble. The minimum bend radius depends on temper:
| Temper | Min Bend Radius (× thickness) |
|---|---|
| O | 0× |
| H14 | 1× to 2× |
| H32 | 1× to 2× |
| T6 | 3× to 5× |
For a 090 sheet, that means a 0.090″ to 0.180″ inside radius for H14. For T6, you need at least 0.270″ to avoid cracking.
Welding
MIG and TIG both work. Use 4043 filler for 1xxx, 3xxx, and 6xxx. Use 5356 filler for 5xxx. Clean the joint with a stainless brush first. Aluminum oxide melts at a higher temp than the base metal.
Punching and Drilling
Standard drill bits work. Use a lubricant. Punch presses handle holes up to a few inches in diameter. The 090 thickness is thick enough that the hole edges do not deform easily.
Packaging and Delivery
090 aluminum sheet needs protection. Scratches show. Moisture stains the surface.
| Packaging Item | Purpose |
|---|---|
| Paper interleaving | Prevents sheets from rubbing |
| PE film | Moisture barrier |
| Edge protectors | Stops dings on corners |
| Wooden pallet | Safe forklift handling |
| Steel banding | Keeps stack tight |
| VCI paper | Corrosion prevention for sea freight |
Standard bundles weigh 1,000 to 3,000 pounds. A full truckload carries 40,000 to 45,000 pounds. Lead time for stock items is 3 to 7 days. Custom sizes or alloys take 2 to 4 weeks.
Quality Standards to Check
Do not buy without standards. Reputable mills follow these.
| Standard | What It Covers |
|---|---|
| ASTM B209 | Sheet and plate specifications |
| ASTM B209M | Metric version |
| EN 485-2 | Delivery conditions for European orders |
| EN 573-3 | Chemical composition |
| AMS-QQ-A-250/1 | Aerospace-grade 1100 sheet |
| AMS-QQ-A-250/12 | Aerospace-grade 5052 sheet |
| GB/T 3880 | Chinese standard for general sheet |
If your project needs certification, ask for a mill test report. It shows the exact chemistry and mechanical properties of the sheet you are buying.
Frequently Asked Questions
What is 090 aluminum sheet in millimeters?
It is 2.286 mm. Most people round it to 2.3 mm. It is a common imperial size that converts neatly to metric projects.
Is 090 aluminum sheet considered plate or sheet?
It is sheet. In the aluminum industry, plate starts at 0.250 inches. Anything below that is sheet. So 090 sits comfortably in the sheet category.
What alloy is best for general fabrication?
3003-H14 is the safest choice. It forms well. It welds without trouble. For it resists corrosion. And it is stocked everywhere. If you need more strength, move to 5052-H32. If you need structural rigidity, pick 6061-T6.
Can 090 aluminum sheet be bent easily?
Yes, in the right temper. H14 and H32 bend well in a standard brake. T6 is harder. It requires a larger bend radius. If you need tight bends, order 090 in O or H14 temper. Avoid T6 for complex shapes.
How much does a 4×8 sheet of 090 aluminum weigh?
A 4 foot by 8 foot sheet weighs about 40.3 pounds. That is based on 1.26 pounds per square foot. A 4×10 sheet weighs about 50.4 pounds.
Is 090 thickness good for trailer floors?
It works for light-duty trailers. Many builders use 090 tread plate for trailer decks under 3,000 pounds capacity. For heavy equipment trailers, 125 or 188 is better. The extra thickness prevents denting from rocks and dropped tools.
Can you weld 090 aluminum sheet?
Yes. It is thick enough that burn-through is rare. TIG gives the cleanest weld. MIG is faster. Use the right filler wire. Clean the surface with a dedicated stainless steel brush. Do not use that brush on steel.
What is the difference between 090 and 063?
090 is 0.090 inches. 063 is 0.063 inches. The 090 sheet is about 43% thicker. For it is stiffer. It weighs more. It costs more per square foot. For panels that face wind or foot traffic, 090 is the better choice. 063 is fine for trim and signs.
Is 090 aluminum sheet available in diamond plate?
Yes. Diamond plate in 090 is a common stock item. The raised pattern adds grip. The 0.090 base gives enough support that the diamonds do not flatten under normal loads. It is popular for trailer ramps, truck bed liners, and step treads.
How do I cut 090 aluminum sheet at home?
Use a circular saw with a carbide-tipped blade. A jigsaw with a metal-cutting blade also works for curves. Wear safety glasses. The chips fly. A shear is best for straight cuts if you have access to one. Do not use a wood blade. It will dull instantly.
Product Quick Reference
| Alloy | Temper | Thickness | Width | Length | Typical Use |
|---|---|---|---|---|---|
| 1100 | H14 | 0.090″ | 48″ | 96″ | Chemical tanks, reflectors |
| 3003 | H14 | 0.090″ | 48″ | 120″ | Truck panels, tool boxes |
| 3003 | H16 | 0.090″ | 36″ | 96″ | Rigid panels, signage |
| 5052 | H32 | 0.090″ | 48″ | 144″ | Marine hulls, decks |
| 5052 | H34 | 0.090″ | 60″ | 120″ | Structural marine parts |
| 6061 | T6 | 0.090″ | 48″ | 96″ | Brackets, machine covers |
| 6063 | T5 | 0.090″ | 36″ | 96″ | Architectural trim |
Final Thoughts
A 090 aluminum sheet gives you real strength without plate-level weight. For it cuts clean. It bends in a brake. It welds with standard equipment. And it comes in alloys for every environment. From 3003 for truck bodies to 5052 for boats, you have options.
Pick the right alloy and temper for your job. Use the tables above. Check your bend radius. Order standard sizes when possible. And always ask for a mill test report if the project demands it.