Unistrut Covers - Types, Benefits, Applications, Installation Tips

An Introduction to Unistrut Covers

Unistrut is a versatile metal framing system used in a variety of industrial, commercial and residential settings. It consists of channels, fittings and accessories that can be assembled into support structures. Unistrut is popular because it is strong, lightweight, corrosion resistant and easy to install. One of the key components of a Unistrut system are Unistrut covers.

Unistrut covers, also known as Unistrut caps or end caps, are important accessories that serve both functional and aesthetic purposes. They are used to cover the open ends of Unistrut channels. Unistrut covers provide a smooth finished look to pipe and cable trays, equipment racks, beam clamps and other support structures made out of the metal framing system.

Types of Unistrut Covers

There are several types of Unistrut covers available to suit different channel sizes:

• 1-5/8” Unistrut covers fit 1-5/8” x 1-5/8” channels
• 1-1/4” Unistrut covers are made for 1-1/4” x 1-1/4” channels
• 13/16” Unistrut covers are for use with 13/16” x 13/16” channels
• 3/4" Unistrut covers are designed for 3/4" channels

The most common sizes used are the 1-5/8” and 1-1/4” Unistrut covers. They are usually made of galvanized steel but can also be found in stainless steel or aluminum. The covers slide over the channel ends and clip into place. Spring steel tabs hold them firmly so they don’t slide back out.

Benefits of Using Unistrut Covers

There are several good reasons to use Unistrut covers on all exposed channel ends:

• They provide a more aesthetically pleasing finish. The smooth cover hides rough channel edges.
• Unistrut covers prevent debris, dirt and moisture from entering open channels. This helps reduce corrosion.
• They eliminate sharp corners and open ends that could otherwise catch on clothing or cut hands.
• Unistrut covers give a cleaner look for a neater, more professional installation.
• They improve safety by covering rough and sharp edges of metal framing.
• The covers protect wiring and cables running through channels from being damaged.

Unistrut Cover Applications

Unistrut covers have many uses across commercial, industrial and residential settings. Some of the most common applications include:

Cable Trays

Electrical cable trays are constructed by joining Unistrut channels together lengthwise. Unistrut covers neatly cap the ends of outdoor overhead or indoor tray runs. This protects the wiring from moisture, debris and physical damage.

Pipe Supports

Unistrut is often used to create rigid support systems for piping in plants, factories, commercial buildings and other facilities. The channels are assembled into racks, frames and hangers. Unistrut covers give the pipe supports a clean finished look.

Conveyors

Manufacturing facilities use Unistrut to construct conveyor bed framing. The open channels provide flexibility for securing conveyor side panels, stands and walkways. Unistrut covers enhance safety by eliminating sharp corners workers could brush against.

Mezzanines and Platforms

Industrial mezzanine floors and equipment platforms are built on Unistrut framing for strength and durability. Unistrut covers used throughout improve aesthetics and safety for workers using the structures.

Equipment Racks

Server equipment racks and industrial control panels are often mounted to Unistrut frames. The modular metal framing allows racks to be easily installed and reconfigured. Unistrut covers provide protection and give racks a streamlined look.

Choosing the Right Unistrut Covers

Selecting the proper Unistrut covers for your particular application involves considering a few key factors:

• Channel Size - Match the size of the covers to the nominal size of the framing channels used. Using properly fitting covers prevents unwanted movement or detachment.
• Material Type - Galvanized steel Unistrut covers provide corrosion resistance at a lower cost. Use stainless steel or aluminum covers for maximum durability in harsh environments.
• Installation Location - Indoor, sheltered installations can utilize standard galvanized covers. Outdoor or chemical-heavy indoor areas may require more durable stainless or aluminum covers.
• Exposure Risk - Covers protecting wiring in open trays or in high-traffic zones should be tightly fitting and impact resistant.
• Appearance - For aesthetics, match cover finishes to create a consistent look throughout the structural installation.

Consult manufacturers’ guidelines to ensure you get the right Unistrut covers for your specific needs.

Installing Unistrut Covers

Installing Unistrut covers properly ensures they stay securely in place. Here are some tips for correctly attaching covers:

• Only install covers on straight finished channel ends. Use a metal saw to cut channels squarely before covering.
• Clean channel ends to remove burrs, grease and debris prior to attaching covers.
• Place the cover squarely over the channel end and align the tabs with channel slots.
• Press the cover firmly and evenly until the tabs snap into place in the channel slots.
• Visually inspect that all tabs are fully engaged into channels with no gaps.
• Avoid hammering covers into place as this can damage the tabs and slots.
• Attach covers to both ends of channels for maximum protection and aesthetic appeal.

Taking the time to properly install Unistrut covers leads to a safer finished product that will hold up better over time. The covers guard against premature system wear and damage.

Unistrut Cover Safety Tips

While Unistrut covers improve safety, workers should still exercise caution when working around the metal framing system. Here are some safety tips:

• Wear PPE such as gloves, eye protection and sturdy shoes when working around Unistrut.
• Inspect regularly for loose, shifted or damaged covers that expose sharp edges.
• Use care when handling or cutting channels to avoid sharp burrs that could cause lacerations.
• Take steps to avoid tripping over Unistrut members that pose trip hazards.
• Exercise caution when working at height around overhead Unistrut assemblies.
• Follow appropriate safety protocols when welding Unistrut frames and working around live electrical wiring.

Staying alert and following common sense safety precautions reduces risk when erecting and using the versatile Unistrut system.

Conclusion

Unistrut covers are important accessories that serve both form and function. They cap channel ends to prevent debris entry, improve aesthetics and boost safety. Covers protect cables and piping while giving structural support systems a streamlined finish. Taking care to properly size, select and install Unistrut covers improves the performance and longevity of the metal framing. Following basic safety protocols helps reduce risk to workers installing or using the versatile support system in industrial and building projects.

FAQs

What are the main benefits of using Unistrut covers?

Unistrut covers provide an aesthetic finished look, prevent debris buildup, eliminate sharp edges that could injure workers, protect cables and wiring, and improve the safety of the Unistrut system.

What sizes of Unistrut covers are available?

Common Unistrut cover sizes include 1-5/8", 1-1/4", 13/16", and 3/4". The covers are designed to fit the nominal size of the Unistrut channels used.

Where are Unistrut covers commonly used?

Typical applications for Unistrut covers include cable trays, pipe supports, conveyors, mezzanines, equipment racks, and other structural framing systems.

What material are Unistrut covers made from?

Unistrut covers are usually constructed from galvanized steel but can also be found in stainless steel or aluminum depending on the application and corrosion resistance required.

How do you properly install Unistrut covers?

Cut channels squarely, align cover tabs with channel slots, press firmly and evenly until the cover snaps into place, visually inspect proper fit, and avoid hammering to prevent damage.