Sunstar Spa Covers

Sunstar has been the leader in spa cover innovation, quality, service & safety since 1977.
At Sunstar Spa Covers, we pride ourselves in offering products that are not only recognized for their fine quality and reliability, but in our people who custom craft each cover and who provide unparalleled customer service. We are the original innovator of the rigid vinyl spa cover, and have over 35 years of service and dedication to the spa industry.

  1. 3 year warranty

    We stand behind our product regarding both materials and workmanship. With less than a 1% failure rate on both encasement and cores, we can guarantee that we make an excellent product.

  2. 27-ounce marine Grade vinyl

    Ours still offers mildew and UV inhibitors; we have not settled for less-expensive materials without the plasticizers. Our material has the flexibility to stretch with the core rather than failing at points of stress and less expensive vinyl cannot compete.

  3. 2 lb density virgin foam cores

    While many competitors use regrind in their foam cores to save them money during production, Sunstar uses only virgin foam cores to save you money and provide you a stronger, more durable, and more energy-efficient cover.

  4. Full length heat seal gasket and end pillows

    Heat Seal
    Our revolutionary insulating gasket seal prevents heat loss where the two cover halves fold together. When the cover is shut, the two halves seal automatically which is critical to long-term energy savings. Payback on energy savings is typically seen in less than 12 months, according to independent testing. The Heat Seal Gasket design is another example of Sunstar innovation. (optional on all hinged covers).
    End Pillows
    Sunstar’s end pillow and full length heat seal are all specially designed to help save heat and prevent moisture loss for long-term energy savings.

  5. Antaeus 2000 vapor lock seal

    Our exclusive, proprietary plastic is more effective than what other manufacturers typically use. Our specially formulated material reduces vapor transmission and still has the strength, flexibility, transparency, and seal-ability we require. Equally important is the 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 makes a perfect seal every time.

  6. 20 gauge ‘C’ channels steel reinforced

    20 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.

  7. Double ply poly-laminated underside with nylon drain grommet

    The underside of our covers are made using this strong mildew resistant material. This product is so sturdy that we use it throughout the cover for extra internal reinforcement.

  8. 28 points of reinforcement

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

  9. Tough ‘n’ Sturdy hinge

    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 discernible wear to the hinge.

  10. Reinforced handles and skirt

    Handles
    Our five layers of internal reinforcement add strength where it’s needed most. Unlike the hot tub cover handles on 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. They are fully integrated into the spa cover with additional stitching and internal reinforcing making them one of strongest available on the market.
    Skirt
    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.

  11. Commercial grade nylon zipper and protection flap

    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. The zipper pull is neatly tucked away in its own pocket. This not only protects the zipper, but is also much more attractive than an exposed zipper and contributes to the finished appearance.

  12. Tapered

    All spa covers tapper to allow water to flow off. This stops sagging in the cover from the extra weight of the water.

  13. ASTM and UL classified

    Sunstar meet the ASTM Safety Standard along with other manufacturers and we have gone a step further to be independently UL Classified. 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.

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