Strut Channel Sizes, Finishes and Applications: What to Order for Your Project

What is a Strut Channel?

A strut channel is a C-shaped structural component used to mount, brace, support or connect lightweight structural loads. They are used to support pipes, electrical and data cables, ductwork and other mechanical components. The variety of strut channel sizes, standard dimensions and ability to be joined to a wide range of brackets and fasteners make them a go-to solution across countless sectors. From industrial warehouses to hospitals, they offer robust and flexible support that is easy to construct. Read more about what strut channel is in our blog post.

Strut Channel Sizes Explained

When it comes to strut channel sizes, there are various dimensions to consider: length, width, height and wall thickness gauges. Choosing the correct strut channel size depends on the application, installation environment and the required load-bearing capacity. The dimensions you need to consider include:

• Length: Although most come in standard lengths, generally 3m or 6m, they can also easily be cut to bespoke lengths for each unique situation, which helps to reduce waste and save time on-site and makes them easier to ship.
• Width: Deep channel is suited to medium to heavy loads and is generally used for vertical runs and heavier installations. A shallow channel is suited to lighter applications such as cable management and small pipe runs. Back-to-back channels offer greater strength and rigidity for demanding installations.
• Wall thickness gauge: This can vary depending on load requirements, and it’s essential to consider the spacing between supports, the weight of the mounted items and the environmental conditions and select the right strut channel size to suit.

Strut Channel Finishes Unpacked

The right strut channel finish also helps to ensure longevity and performance, especially in challenging environments. Some of the standard finishes include:

• Pre-Galvanised (PG): The best strut channel finish for indoor use as it offers the most basic level of corrosion protection.
• Hot-Dip Galvanised (HDG): With a thicker zinc coating, HDG is better suited to outdoor or damp environments as it has a higher level of corrosion resistance.
• Stainless Steel: The maximum corrosion resistance for chemically aggressive areas or those where greater hygiene levels are needed.
• Powder-Coated: An added level of corrosion resistance, but able to blend aesthetically or for colour-coding installation needs.

Strut Channel Applications

Strut channels are versatile structural supports used across virtually every sector for mounting, suspending and supporting a vast array of components of both structural and non-structural systems. With the selection of strut channel sizes, finishes and accessories for different configurations available, it’s necessary to select the right types of strut channel to ensure performance, durability and compliance with safety requirements.

Electrical Installations

For electrical installations, strut channels support cable trays, conduit runs and lighting systems. A shallow channel may be sufficient for lighter runs of cabling, whereas a deeper, more robust channel will be needed for larger trunking or control panels. Slotted channels allow for easier adjustment and cable alignment on-site.

Mechanical Systems

Strut channel applications for mechanical systems are likely to be more heavy-duty or back-to-back systems to be able to handle the heavier pipe loads, vibration and thermal expansion of HVAC (Heating Ventilation and Air Conditioning), plumbing and refrigeration pipework. The selection of strut channel sizes will depend on the weight and configuration needed.

Solar and Renewable Energy

Strut channel can be used to provide a reliable framework to mount solar panels. As they need to be in outdoor conditions, hot-dip galvanised or stainless steel strut channel finishes will be needed to withstand the outdoor environmental conditions.

Data Centres

A common strut channel application is for managing and organising the large bundles of power and data cables needed in data centres. In these high-performance environments, durable channels and easily adjusted fittings for flexible configurations are essential.

Customised Applications

Customised applications, such as racking systems, machine enclosures or modular shelving and gantries or catwalks, strut channel applications are easy to assemble and configure, and they create scalability for the future as well.

Accessories and Fixings to Consider

Strut channel applications aren’t simply created with the lengths of channel themselves, there are so many more accessories and fixings needed to complete the structure you’re looking to create. These accessories and fixings are essential to the integrity and adaptability of the installation, and some of the most common are:

• Brackets and Angle Plates: These are used to ensure all the connections of the structure are secured properly.
• Spring and Channel Nuts: Designed to lock into the channel’s groove for fast and secure installation, even in awkward or overhead locations.
• Cantilever Arms and Base Plates: These support wall or floor mounting of the channelling.
• Beam and Pipe Clamps and U-Bolts: Used for specialised applications such as pipe support or heavy industrial uses.

Making sure that the right accessories and fixings are used with the types of strut channel you’re using is vital to ensure optimal strength, compatibility and corrosion resistance. Our expert team are on hand to offer expert advice for the accessories and fixings you’ll need.

Common Mistakes to Avoid When Ordering

There are several common mistakes you need to avoid when ordering strut channels for your project, as these errors can delay your project and push up the costs. Some frequent mistakes we can help customers avoid are:

Undercalculating Load Capacity

Choosing a strut channel size that is too small or too thin for the intended load will mean needing to reorder, and this creates a waste of time, money and unwanted products.

Incorrect Strut Channel Finish

Choosing PG for a wet or outdoor setting where it will be subject to corrosion instead of HDG or stainless steel, also creates waste and time lost reordering the correct finish.

Overlooking Accessory Compatibility

Not all accessories are created equal, and not every fixing fits all channel profiles. Make sure when you’re ordering that you confirm your dimensions and finishes to ensure the accessories you’re getting with be compatible with your strut channelling. 

Not Future Proofing

Choosing a limited configuration can restrict any future expansion that might be needed further down the line.

Our expert team can support you by helping to decide exactly what strut channel to use and which accessories and fixings you’ll need to ensure your project is a success.

Why Order From Lenson Select?

With decades of expertise and satisfied clients across the UK, Lenson is your trusted supplier for all strut channel sizes, finishes, fittings and accessories. We offer expert advice, rapid delivery timeframes and custom solutions tailored to your project. Whether your project calls for standard lengths or bespoke kits, our team helps you choose what strut channel to use and how to avoid costly mistakes.

Whether you’re a contractor, engineer or procurement manager, we ensure fast, reliable and cost-effective customer service for every strut channel application. Let’s get your installation supported – the right way!

Get in touch with our online form, call us on 0121 553 6699 or email sales@lenson-select.co.uk to benefit from our expert advice and fast delivery times.

Strut Channel Sizes, Finishes and Applications FAQs

How do I Choose the Right Strut Channel Size?

Choosing the right strut channel sizes will depend on the load requirement, the installation environment and the mounting application. You’ll also need to consider the spacing between supports and the accessories needed. At Lenson, our expert team are on hand to help assess your requirements and guide you about what strut channel to use for the best performance and safety.

Which Strut Channel Finish is Best for Outdoor Use?

HDG is the most commonly used strut channel finish for outdoor use as the zinc coating creates a thick, corrosion-resistant product. For even more aggressive environments, such as coastal areas or chemical facilities, stainless steel provides an even greater level of corrosion resistance and durability.

What’s the Difference Between Slotted and Solid Strut Channels?

Slotted strut channels have pre-cut holes along the length, which makes them quicker to install and very flexible to adjust, which is ideal for mounting accessories. Solid strut channels have a continuous steel wall, which offers maximum strength and load-bearing capacity. Both types come in various sizes and finishes, and the choice should depend on the strut channel application and the installation requirements. Our expert team are always happy to advise you on the best option for your unique project.

Can I Cut Strut Channels to Size On Site?

Yes, you can cut strut channels to length on site with an appropriate saw. However, to save time and labour costs, many customers request pre-cut strut channel sizes directly from us, as we provide bespoke cutting services for small and bulk orders.