We use a true YKK#7 heavy-duty nylon zipper that is corrosion resistant. Our zippers are covered with a vinyl protective flap along the entire length of the zipper.

24 gauge “C” Channel provides strong support across the center of the hot tub cover. This non-corrosive steel channel strengthens the center of the Spa Top™ giving extra support in areas that experience extreme weather.

1.5 lb tapered 4” to 2.5” EPS foam facilitates water runoff and keeps heat in. These covers are strong yet light weight, making them easy to handle and providing more than-adequate insulation with an R Value of 14.3. Optional 2 lb. Dura Foam upgrades are available. Sunstar uses only virgin foam to provide you with a more durable, more insulated and more water-resistant hot tub and spa cover.

Our spa covers are made with 11 oz. double laminate vinyl with polyester weft reinforcing scrim-and are mildew resistant, with -40 degree cold crack. This material is so tough we use it throughout our cover for extra internal reinforcement.

These “low profile” grommets are another Sunstar exclusive, placed on the underside of the cover to prevent water from accumulating between the vinyl and the foam core. Made of industrial-grade nylon, these non-corrosive grommets are designed not to protrude; therefore they won’t scratch the lip of the spa as the cover is slid off.

Sturdier than the standard Sure-Loc hardware, center-release fasteners hold up better in extremely cold climates- but, the best thing about this feature is its ease of use. It opens with the simple push of a button, so it is especially good for anyone with strength or dexterity limitations. It also locks for safety.

Our triple-reinforced hot tub tie-down straps secures the spa cover to your spa or hot tub with our cradle-ready straps and Sure-Loc fasteners.

Our spa cover skirts are double stitched into the cover for strength and gusseted to provide the best protection, keeping heat in and dirt out.  While the sun beats down on your hot tub cover, extreme heat builds up between the skirt and the outer lip of the spa, and this heat can damage the outer lip of the spa. Our skirt enables this heat to escape, preventing heat damage from occurring while preventing any dirt from entering the hot tub.

Our five layers of internal reinforcement add strength where it’s needed most. Unlike the hot tub cover handles on most other covers our spa cover handles are engineered to be super strong and offer foam padding inside for a longer life and greater comfort when lifting. Our hot tub cover handles are made of extremely strong nylon webbing. They are fully integrated into the spa cover with additional stitching and internal reinforcing making them one of strongest available on the market.

Our Tough ‘n' Sturdy hinge offers four layers of vinyl, adding extra durability and strength to this high-stress area. Our hinge was put to the test when a Sunstar cover was hooked up to an automatic arm, which lifted the cover on and off more than 6000 times with no discernable wear to the hinge.

Every stress point is reinforced including the hinge, handles, straps, corners and skirts.

State-of-the-art equipment is used to heat seal the cores with Antaeus 2000™. Scientifically formulated plastic was developed exclusively for Sunstar to inhibit moisture absorption.

Our 4 mil plastic is more effective than the typically used 3 mil plastic. Our specially formulated material reduces vapor transmission and presents the same properties of strength, flexibility, transparency and seal ability our quality control standards require. Equally important is our perfect heat seal seam.

Sunstar uses an impulse sealer that makes a perfect seam using the right combination of temperature, pressure and timing. Unlike the less-expensive hand-held sealing machines, all human variables are eliminated, so your cover gets a perfect seal every time.

Our vinyl is treated with mildew and UV inhibitors for overall longevity year round beauty. We have not gone to the less expensive materials without the plasticizers.

Our material still has the flexibility to stretch with the core rather than failing at points of stress where the less expensive vinyl cannot compete. Our vinyl has a negative 20 degree cold crack rating and is tested to 1500 UV hours.

Highlights of Our Marine Grade Vinyl
• Cold cracking freeze resistant to -20 degrees Fahrenheit
• Ultra violet stabilized pigments 
• Oil stain resistant
• Mildew resistant
• Fungus resistant
• Sulfide stain resistant
• Resistant to salt water staining
• Easily cleaned with soap and water

We stand behind our product, regarding both materials and workmanship. Based on our historical data, we guarantee that we make an excellent and industry-leading product.

In 1993, our spa covers were first tested by an independent lab to gauge its compliance with the ASTM Safety Standard. All models passed and Sunstar was the first spa cover manufacturer to offer a safety-labeled cover. In 1994, Sunstar was the first to receive UL Classification and our covers are classified for ASTM Safety on all sizes, densities, and models, even swim spas. We are proud to offer the UL Classification mark on our covers,and you can be confident that Sunstar builds a spa cover that is favored by safety code officials nationwide.