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Material Weight Calculator — Steel, Aluminum & Metal Stock Weight by Shape

9 Cross-Section Shapes, 16 Materials, Cut List with Cost Estimation in Imperial and Metric Units

Free material weight calculator for machinists, fabricators, and estimators. Select from 9 cross-section shapes (round bar, round tube, square bar, square tube, hex bar, flat/sheet, angle iron, channel, and I-beam) and 16 materials (carbon steel, stainless 304/316, aluminum 6061/7075, brass, copper, titanium, cast iron, tool steel, bronze, and more). Enter dimensions in inches or millimeters to calculate weight in pounds, kilograms, or ounces. Build a multi-item cut list and estimate material cost by entering price per pound or per foot.

Pro Tip: When estimating material for a job quote, always add 10-15% for kerf loss, facing, and end cleanup. A 12" piece of bar stock doesn't give you 12" of usable material — you lose a saw kerf on each end (0.125" per cut with a bandsaw), plus you need facing stock if the ends need to be square. For tube and pipe, add extra for weld prep if you're beveling ends. And always verify the material density in the mill cert against the nominal density, especially for aluminum alloys where density varies from 0.095 to 0.103 lb/in3 depending on temper.

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Material Weight Calculator
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How It Works

  1. Select Material

    Choose from 16 materials with accurate densities: carbon steel (0.2836 lb/in3), stainless 304 (0.289), stainless 316 (0.290), aluminum 6061 (0.0975), aluminum 7075 (0.1015), brass 360 (0.307), copper C110 (0.323), titanium Grade 5 (0.160), cast iron (0.260), tool steel (0.280), bronze (0.320), and more. Custom density entry is available for specialty alloys.

  2. Choose Cross-Section Shape

    Select the stock shape: round bar, round tube, square bar, square tube, hex bar, flat bar/sheet/plate, angle iron, channel, or I-beam. Each shape has a dedicated input form with the specific dimensions needed for that geometry.

  3. Enter Dimensions

    Input the cross-section dimensions (diameter, width, thickness, wall thickness) and length. All inputs accept inches or millimeters. For tubes and hollow sections, enter both the OD and wall thickness (or OD and ID) — the calculator computes the material volume minus the hollow core.

  4. Add to Cut List

    Add multiple items to build a cut list for a complete job. Each line shows the shape, material, dimensions, quantity, and weight. The cut list totals weight and estimated cost for the entire bill of materials.

  5. Review Weight and Cost

    See the weight per piece and total weight in pounds and kilograms. Enter a price per pound (or per linear foot) to estimate material cost. Export the cut list as a PDF or CSV for purchasing or quoting.

Built For

  • Machine shop estimators calculating material weight and cost for job quotes and purchase orders
  • Fabricators determining shipping weight for steel structures, frames, and weldments
  • Rigging and crane operators verifying load weights before lifts on fabricated assemblies
  • Structural engineers estimating dead loads from steel members for structural analysis
  • Purchasing agents converting between price-per-pound and price-per-foot for material cost comparison
  • CNC programmers estimating raw stock weight to verify the bar feeder or chuck can handle the blank

Features & Capabilities

9 Cross-Section Shapes

Calculate weight for round bar, round tube, square bar, square tube, hex bar, flat bar/sheet/plate, angle iron, channel, and I-beam. Each shape uses the precise geometric formula for cross-sectional area, not approximations.

16 Material Densities

Built-in densities for the most commonly stocked metals: carbon steel, 4140, stainless 304 and 316, aluminum 6061 and 7075, brass, copper, titanium, cast iron, tool steel D2 and A2, bronze, lead, and zinc. Custom density input for specialty materials.

Cut List Builder

Add multiple items to a running cut list. Each line tracks shape, material, dimensions, quantity, unit weight, and line total. The cut list provides a complete material summary for purchasing, quoting, and shipping weight estimation.

Cost Estimator

Enter material price per pound or per linear foot to estimate cost for each line item and the total bill of materials. Useful for quick job quotes when you know the current material price from your supplier.

Imperial and Metric

All dimensions accept inches or millimeters with automatic conversion. Weight output shows pounds, kilograms, and ounces simultaneously. Length accepts feet-and-inches, decimal inches, or millimeters.

Waste Factor

Apply a configurable waste percentage (default 10%) to account for saw kerf, end cuts, facing, and mill scale. The adjusted weight reflects actual material needed, not just the net finished dimension.

Frequently Asked Questions

The calculations use standard material densities published by ASTM and material suppliers. Accuracy is typically within 1-2% for clean, standard-grade materials. Variation comes from alloy composition differences between heats, mill scale on hot-rolled steel, and dimensional tolerances in the stock itself. For critical weight applications (crane lifts, freight shipping), always weigh the actual material with a scale rather than relying on calculated weight.
Nominal Pipe Size (NPS) does not refer to the actual OD. For example, 1" NPS pipe has an actual OD of 1.315". The wall thickness varies by schedule (SCH 40, SCH 80, etc.). This calculator uses actual dimensions, not nominal sizes, so enter the true OD and wall thickness for accurate results. Round structural tube (HSS) sizes are typically close to the stated OD, unlike NPS pipe.
Stainless steel (particularly 300-series austenitic grades like 304 and 316) has a higher density than carbon steel due to the nickel and chromium content. Carbon steel is approximately 0.2836 lb/in3 while 304 stainless is 0.289 lb/in3 — about 2% heavier. This small difference becomes significant on heavy fabrications: a 1,000 lb carbon steel weldment would weigh approximately 1,020 lb in 304 stainless.
This calculator works for standard stock shapes. For machined parts with pockets, bores, and contours, calculate the weight of the raw stock and subtract the removed material. CAD software (SolidWorks, Fusion 360) calculates finished part weight directly from the 3D model. For estimation purposes, calculate the bounding box weight and apply a 60-70% factor for typical machined parts with moderate material removal.
Yes, dramatically. A 2" OD round tube at 0.065" wall weighs about 1.35 lb/ft in steel, while the same OD at 0.250" wall weighs about 4.67 lb/ft — over 3x heavier. Always verify the wall thickness, not just the OD, when calculating tube weight. This is especially important for structural applications where schedule or gauge designations may vary between suppliers.
Disclaimer: Weight calculations are based on nominal material densities and ideal geometric shapes. Actual weights may vary due to alloy composition, manufacturing tolerances, surface condition (mill scale, coating), and dimensional variation in stock material. For critical weight applications such as crane lifts, shipping, and structural loading, always weigh actual material on a calibrated scale. ToolGrit is not responsible for weight estimation errors or resulting safety issues.

Learn More

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How to Calculate Metal Stock Weight: Round Bar, Tube, Hex, Sheet, and Angle Iron

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