The Aluminum End Cap for 80×80 Post is a flat, flush-mounted protective cover designed to seal the open top and bottom ends of 80×80 mm aluminum system fence posts. In any modern horizontal slat or privacy fence installation, the hollow square-section posts present open ends that — if left uncovered — become entry points for rainwater, condensation, debris, insects, and nesting material. Over seasons of exposure, trapped moisture inside a hollow aluminum post initiates internal corrosion, staining, and in severe cases structural weakening that is invisible from the outside until damage is advanced. The flat end cap eliminates this vulnerability entirely. Engineered from the same EN AW-6063 T6 aluminum alloy used throughout the ULAMEX modern fencing system, finished in matching powder-coated RAL 7016 anthracite, and installed in seconds through a precision friction-fit that requires no tools, adhesives, or fasteners, this cap is the simplest component in the system — and one of the most important for long-term fence performance. ULAMEX supplies end caps at B2B wholesale conditions for fence contractors, distributors, and project developers across Europe.
Technical Specifications
The end cap is manufactured from aluminum alloy EN AW-6063 T6 — the industry-standard extrusion alloy for architectural aluminum components. This alloy delivers the precise combination of formability, surface finish, and corrosion resistance required for an outdoor-exposed fence accessory with a service life measured in decades.
| Parameter | Value |
|---|---|
| Material | Aluminum EN AW-6063 T6 |
| Compatible post | 80×80 mm system post |
| Cap profile | Flat — flush with post edges |
| Standard finish | Powder-coated RAL 7016 (anthracite grey) |
| Alternative finishes | RAL 9005 (jet black), RAL 7035 (light grey), RAL 9006 (white aluminium) — on request |
| Raw aluminum | Available (mill finish) |
| Installation method | Friction-fit / press-fit |
| Tools required | None |
| Weight per piece | Approx. 35–45 g |
| Packaging | Wholesale cartons (25, 50, 100, 200 pcs) |
Tolerances conform to EN 755-9 for extruded aluminum profiles. The internal cavity dimensions are precision-matched to the ULAMEX 80×80 mm post with a controlled interference fit that ensures secure retention under wind uplift, thermal expansion, and repeated frost-thaw cycles. Each end cap undergoes quality inspection for dimensional accuracy, powder coating adhesion, and colour consistency before leaving the production facility.
Installation Guide
The flat end cap is designed as a tool-free, last-step installation component. The procedure takes under 10 seconds per post:
- Inspect the post end — confirm that the top (or bottom) of the 80×80 mm post presents a clean, square opening. Remove any sawing burrs, metal filings, or construction debris with a file or compressed air.
- Position the cap — place the end cap over the post opening with the finished (powder-coated) face outward. Align it squarely so the cap lip contacts all four post walls evenly.
- Press into place — push the cap down firmly with the heel of your hand until it seats fully. The friction-fit will hold the cap securely in position. You should feel a slight resistance as the cap engages the post walls, followed by a stop when it is fully seated.
- Verify the seat — run a finger around the cap perimeter to confirm it sits flush with the post edges on all four sides. If one side is slightly raised, apply targeted pressure to that corner until flush.
For bottom-of-post applications: end caps can also be fitted to the bottom end of posts before the post is set into a concrete foundation or bolted to a base plate. This prevents concrete slurry, groundwater, and soil from entering the hollow section during and after installation — a detail that is particularly important in regions with high water tables or clay soils.
Removal: if removal is necessary at any point (for cable routing, replacement, or maintenance), insert a flat-blade screwdriver or putty knife under one edge and lever gently. The cap will release without damage to the post or the cap itself, and can be re-fitted immediately.
Material & Finish
The EN AW-6063 T6 aluminum alloy used for the end cap is characterised by its excellent extrudability, good weldability, and superior anodising and powder coating response. The T6 temper — achieved through solution heat treatment at approximately 520°C followed by artificial ageing at 175°C — yields a minimum tensile strength of 205 MPa and a Brinell hardness of approximately 75 HB. These properties ensure that the press-fit retention force does not degrade through creep or stress relaxation over years of continuous outdoor service.
The standard polyester powder coating in RAL 7016 (anthracite grey) is applied electrostatically and cured at 180–200°C, producing a uniform 60–80 µm film thickness with excellent adhesion to the aluminium substrate. This coating provides:
- UV resistance — no visible chalking or colour shift after 10+ years under Central European conditions
- Chemical resistance — withstands exposure to common environmental pollutants, salt spray, and mild cleaning agents
- Scratch resistance — maintains appearance through handling, transport, and installation without protective wrapping
For projects with aesthetic requirements beyond the standard palette, RAL 9005 (jet black), RAL 7035 (light grey), and RAL 9006 (white aluminium) are available on request. Custom RAL colours are producible for wholesale orders exceeding 500 pieces, with a typical lead time of 3–4 weeks.
System Compatibility
The flat end cap is purpose-designed for the ULAMEX Aluminum System Post 80×80 and is dimensionally compatible with all 80×80 mm square-section aluminum hollow posts conforming to standard European extrusion tolerances. Within the ULAMEX modern fencing system, the end cap integrates with:
- Fence slat profiles — horizontal louvered, flat, and semi-open designs
- Mounting accessories — brackets, self-drilling screws, mounting angles, base plates
- Gate assemblies — pedestrian gates and driveway double gates using 80×80 mm frame sections
For posts with different cross-sections (60×60 mm or 100×100 mm), ULAMEX supplies matching flat end caps in the corresponding dimensions with identical RAL colour and finish options. Contact us for availability and pricing on non-standard sizes.
The end cap can also be paired with the Canopy for System 80×80 Post within the same fence installation — for example, using canopies on visible front-facing posts and flat caps on lower posts, interior posts, or posts trimmed to panel height.
Design & Aesthetic Benefits
The flat end cap embodies the principle of minimalist design: it does its job without drawing attention to itself. When fitted, the cap sits perfectly flush with the post edges, creating an unbroken plane across the post top that appears as an integral part of the post rather than an added accessory. This seamless integration is critical for modern fence designs where clean lines, concealed fasteners, and monolithic surfaces define the visual language.
In practical terms, the flat profile makes the end cap the preferred choice for:
- Posts trimmed to panel height — where the post top should be as inconspicuous as possible
- Interior fence runs — sections not facing the street or main viewing angle, where a simpler finish is appropriate
- Bottom-of-post sealing — where a flat profile is physically necessary to allow the post to sit flush against a base plate or concrete surface
- Contemporary architectural projects — where the design brief calls for maximum understatement and zero decorative embellishment on the fencing structure
The cap’s flat surface also offers a practical advantage: it does not collect standing water, pollen, or bird droppings the way textured or ridged caps can. A simple wipe restores the surface to its original condition — an important consideration for clients who prioritise low-maintenance boundary solutions.
Quantity Planning
Each fence post requires at minimum one end cap for the top. If posts are not set into concrete (i.e., they are mounted on base plates), a second end cap for the bottom is strongly recommended to prevent upward moisture ingress. The calculation per fence run:
| Fence length | Posts (at 2,000 mm spacing) | Top caps only | Top + bottom caps |
|---|---|---|---|
| 10 m | 6 | 6 | 12 |
| 20 m | 11 | 11 | 22 |
| 30 m | 16 | 16 | 32 |
| 50 m | 26 | 26 | 52 |
| 100 m | 51 | 51 | 102 |
Corner posts, gate posts, and any posts at fence junctions should be counted separately. For projects combining flat end caps with canopy caps (e.g., canopies on front-facing posts, flat caps on interior posts), specify quantities per type when requesting a quote.
We recommend ordering 5–10% extra to account for site damage, post additions during construction, and future spares. End caps are lightweight and compact, so the additional units add negligible cost and virtually no additional shipping volume.
Why Choose ULAMEX
With over 35 years in the European steel and aluminum trade since 1988, ULAMEX is a proven wholesale partner for fence contractors and distributors who need reliable supply, consistent quality, and competitive conditions. Ordering end caps from ULAMEX means:
- EN 1090 and ISO 3834 certified production — documented quality at every step
- Complete system supply — posts, slats, end caps, canopies, brackets, screws, and base plates from a single source
- Guaranteed colour consistency — all items in one order coated from the same RAL powder batch
- Flexible packaging — from cartons of 25 to palletised bulk for major projects
- European delivery network — Germany, Austria, Switzerland, UK, Scandinavia, Benelux, and beyond
Frequently Asked Questions
Can end caps be used on both the top and bottom of a fence post?
Yes. The flat profile is designed to work on both ends of the 80×80 mm post. Top-end caps protect against rain, debris, and UV exposure. Bottom-end caps are particularly valuable for posts mounted on bolt-down base plates, where the open bottom end is not embedded in concrete and would otherwise be exposed to rising damp, groundwater splashing, and insect entry from below.
Will the end cap stay in place in high-wind conditions?
The friction-fit is engineered for outdoor conditions, including wind, vibration, and thermal cycling. Under normal circumstances, the cap remains secure without any additional fixation. For exceptionally exposed sites (coastal locations, hilltop installations), applying a thin bead of silicone sealant to the inner rim before fitting provides extra retention. The flat profile of this cap generates less wind lift than raised alternatives, making it inherently more wind-stable.
How does the flat end cap compare to the raised canopy cap?
Both the flat end cap and the canopy cap protect the post interior from water and debris. The key differences are visual: the flat cap offers a minimalist, flush finish that blends with the post profile, while the canopy adds a raised, sloped element that sheds water more actively and creates a more prominent decorative accent. Many projects use both — canopies on visible, front-facing posts and flat caps on less prominent positions or at the bottom of posts.
What is the minimum order quantity for end caps?
ULAMEX supplies end caps in wholesale packaging starting from 25 pieces per carton. There is no fixed minimum order for standard RAL 7016 stock items — you can order from one carton upward. Custom RAL colours require a minimum of 500 pieces. Request a quote for precise pricing based on your quantity and delivery destination.