How to Cut Bollard Covers

How to Cut Bollard Covers

We Cut Your Covers For Free

This article is for the rare cases where a customer wants to cut their own covers for whatever reason.

Higher the Better

Usually, visibility is a key function of a bollard cover, so keeping them high is a good thing. A cover can extend a few inches or even a foot or more above the bollard if desired.

Bollard Cover Height

The minimum height a bollard cover can be depends on the shape of the bollard cover and the height of the concrete dome on the bollard, if any.

With the Dome-Top Bollard Cover, the minimum height, measured on the straight part of the cover wall, is the same as the height of the bollard pipe steel, from the ground to the top edge. The dome of the concrete (if any) will fit inside the dome of the cover.

With Flat-Top Bollard Covers, you will want to measure the height of the concrete dome (if any) and cut the cover with some play, like maybe an inch extra.

With the varying shapes of Decorative Covers, you’ll have to determine how much play you need and cut accordingly.

For more, see our article on How to Measure for Bollard Covers.

Bollard Cover Height Explained

Planning Ahead

You probably want to look over all your bollard heights and dedice on a height for all in a group, assuming they are intended to be similar in height. Then, take the highest one and cut all of your covers to match. 

Measuring Bollard Pipe Group Height

Types of Saws to Cut Covers

The covers we sell are all Polyethylene: Low Density and High Density. Basically, plastic. So there are many ways to cut them. Use whatever you are most comfortable with.

Cutting with a Miter Saw

For straight sided covers, 6″ or smaller, we use a 12″ Miter Saw.

  • Beware: 1/4″ covers cut nicely because they are fairly rigid. Thinner wall covers like 1/8″ may be too flimsy for this method.
  • Be sure your fence is higher than the half-way point of the cover.
  • You want to hold the cover firmly as you drop the blade through the side.
  • With 5″ and bigger covers, it won’t cut all the way through.
  • Stop the saw after each cut and return saw to top resting position.
  • Rotate the cover and line up the blade with the cut.
  • Again, hold firmly and cut down again.
  • Another rotation and final cut should do.
Cutting Bollard Covers

Note in the picture that we are just showing you the setup. Your left hand palm should be firmly holding the cover steady.

Cutting with Other Saws

  • A bandsaw with enough clearance works well. Use a 90 degree fence to keep cut straight.
  • A jigsaw or reciprocating saw with a medium/fine toothed wood blade cuts well. Mark and measure around with 2″ tape. Make sure tape meets itself and cut will look straight.

Tips and Tricks

  • Clean up plastic burrs or wandering edge with a rasp, file, utility knife or sandpaper.
  • If bollard is on an incline:
    • First cut cover straight for tallest side.
    • Then slip cover on temporarily and mark cut line by scribing to match the incline.
    • Then cut with appropriate tool.

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How to Install Bollard Covers

How to Install Bollard Covers

What You Will Need

  • The covers and neoprene install tape sent to you.
  • Utility knife or scissors to cut tape.
  • If bollard pipe is wet from condensation, you’ll want rags to dry them off.

Bollard Cover Installation Instructions

Step #1

  • Remove the backing on a strip of the neoprene tape.
  • Wrap firmly around the top of post about 6″ from the top.
  • Make sure to leave about a 1″ gap between ends of the tape to allow airflow while installing the cover. You can cut the tape as needed.

Step #2

  • Remove the backing on a 2nd strip of the neoprene tape.
  • Wrap firmly around the bottom of post about 6″ from the bottom.
  • This time, don’t leave a gap in the tape. This will create the vacuum seal. You can cut the tape as needed.

Step #3

  • With the tape in place, slide the cover over the post.
  • If the tape is applied correctly, you will hear air being forced out while sliding it down the post, creating the vacuum seal.
  • The cover is now secure over the pipe.

Tips and Tricks

  • The tape may roll down as you force the cover on. That’s normal.
  • Make sure there is an adequated air gap on tape at the top by cutting the tape shorter. If you only offset the ends, the tape may roll enough to close that gap and then the cover can be very difficult to slide down because of the air pressure.
  • Do your best to make sure you are getting the cover’s bottom edge over the tape instead of plowing the tape down the post. Especially at the top tape, this can be achieved by swirling the cover.
  • Note that the covers often look slightly oval at the bottom edge. You can compress the long bias of the oval to round out the cover and get over the tape’s edge.
Installing Bollard Cover

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How to Measure for Bollard Covers

How to Measure for Bollard Covers

We’ll Do the Rest

When we know the height of your bollards, we can cut your covers to the correct height which depends on the style of bollard cover. If they are domed with concrete, don’t worry. We work that tolerance into all the covers we cut.


What You Might Need

  • Tape measure or ruler to measure height and diameter.
  • Sewing tape works well if you want to measure circumference.
  • Pen and Paper or Text App on phone to record measurements.
Sewing tape to measure circumference of pipe

Measuring Bollard Height

Measure bollard height from the ground to the top edge of steel. If it has a concrete dome, ignore that. 

Measuring Bollard Height

Use Highest Bollard

For consistent look with a set of bollards intended to be the same height, find the highest one and use that height for the heights of all the bollard covers in that set.

Measuring Bollard Pipe Group Height

Measure Bollard Pipe Diameter

Rarely, pipe bollards are out of the ordinary. In most cases, you will have 4″, 5″, or 6″ Pipe. These have outer diameters (OD) of 4 1/2″, 5 9/16″ and 6 5/8″ respectively. Your measurements will very likely be close to one of those common pipes.  See the chart below the next diagram for pipe and cover sizes.


Ways to Measure Diameter

  1. If the top of the pipe is flat or close to flat, just measure across the pipe.
  2. If you have concrete domed on top, you can use 2 straight edges to measure the diameter above the dome.
  3. Or you can measure the circumference around the pipe and divide by Pi (3.14) to get the diameter (or just use the chart below). Measure with a sewing tape, paper ruler or by carefully rocking a rigid ruler around the pipe. If you want to print a paper ruler, go to
Measuring Bollard Pipe Diameter

Common Pipe Diameters

Using your diameter (2nd column), or circumference (3rd column) you can determine your cover size in the 1st column.

Nominal Pipe Size & Cover Size

Outside Diameter (OD)

4″ 4 1/2″ (4.5″) 14.12″ (approx 14 1/8″)
5″ 5 9/16″ (5.563″) 17.48″ (approx 17 1/2″)
6″ 6 5/8″ (6.625″) 20.81″ (approx 20 13/16″)
8″ 8 5/8″ (8.625″) 27.10″ (approx 27 1/8″)
10″ 10 3/4″ (10.75″) 33.77″ (approx 33 3/4″)
12″ 12 3/4″ (12.75″) 40.06″ (approx 40 1/16″)

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