Fabricating the stainless beauty
Once the client signed off on the drawings and options, fabricating the 2.4- x 5.4- x 1.4-m (7.8- x 17.8- x 4.5-ft) swim spa out of 316L stainless steel was the next step. This grade of steel offers great resistance to corrosion and pitting, has a high tensile strength, excellent formability qualities and exceptional welding characteristics.
DSI’s team, comprising machinists, welders and finishers, went to work on creating the spa, which involved cutting, forming, metal-bending, welding, buffing and testing.
A waterjet was used to cut all of the stainless steel in this project. Using a high-velocity stream of abrasive particles suspended in a jet of high-pressure water (50,000 pounds per square inch [psi]), a waterjet is capable of making intricate cuts in virtually any type of material. After the steel was cut, rollers, brakes and presses were used to enable the welders to manipulate the steel into the desired shape for the spa’s custom design.
To create precise clean-flowing seams, a tungsten inert gas (TIG) welding process was used, as it provides stronger, higher-quality welds. Once the spa was assembled, it was hydrostatically tested for 48 hours. This process involved filling the swim spa with water and operating the jets at full bore to make sure the welds were tight and no leaks were present.
Finally, hand-applied buffing tools were used on the swim spa’s surface, giving it an elegant etching and distinguished look. In mere days, sheets of stainless steel were formed to become the client’s envisioned work of art.
Delivering the dream spa
Six weeks after the initial meeting, the swim spa was on a truck headed to the client’s home. Upon arrival, DSI’s installation team was immediately presented with its first challenge—facilitating the large swim spa over the home, which was under construction, without causing damage to either. To perform this task, a crane was used to carefully place the swim spa in its desired location in the client’s day spa retreat.
“Installation is always the biggest challenge for us,” says Salazar. “We are getting close to perfecting the process; however, with installations in New York City and on large cliff sides in Hawaii under our belt, we have faced several challenging installs.”
Once the swim spa was in place, technicians went to work getting the plumbing and electrical pieces in place. Drainage systems were connected and plumbing was run into the central mechanical room. The water pumps were installed on vibration isolation pads to help with noise reduction. Finally, the LED lighting, swim current system and remote control panel was installed.
In completing the project, the swim spa was surrounded in white tile, with multi-coloured vertical bars on the floor and an abstract tiled pattern on the wall opposite the spa’s entrance. Teak was used to create a small seating area next to the spa in addition to floor grating at the foot of the swim spa, which provides access to the pump system and complements the clean minimalist look of the room.
Let the workouts begin
The client was extremely happy with the project. Finally, once construction of the home was completed, her very own day spa—complete with a custom-fabricated stainless steel swim spa, steam shower, dry sauna and solarium—was a reality.
Krista Payne is the marketing manager for Diamond Spas Inc., a custom fabricator of stainless steel and copper spas, pools, cold plunge pools and bath fixtures. She can be reached at kpayne@diamondspas.com.
