Custom spa fabrication

by Sally Bouorm | January 1, 2011 8:11 am

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By Krista Payne

In 2009, Diamond Spas Inc. (DSI), a custom fabricator of stainless steel and copper aquatic vessels in Frederick, Col., was approached by a client and her interior decorator with a vision of incorporating a custom metal swim spa into a luxury ‘getaway’ retreat she was building in central Wyoming.

The client wanted to use stainless steel not only for its anti-erosion qualities and distinguishable look, but also because it would blend harmoniously with the other features inside her home. She was interested in a swim spa that could be used for relaxation and play, with jets that would turn on with the push of a button to transform the spa into an aquatic workout pool.

Vision quest

After taking a tour of DSI’s facility and learning about the company’s fabrication capabilities, the client’s architect sat down with the engineering team to discuss the geometry of the swim spa and its intended use.

“We really encourage our clients to list all of their desires for the spa,” says Caleb Salazar, DSI’s sales director. “How will they utilize it? Is this purely for relaxation or for health and sport? This way they get a spa that is designed to fit their specific needs.”

With a napkin drawing in hand, the client, architect and DSI team worked through several sketches until the custom design was finalized. The next step for the client was selecting the options that would round out the swim spa she envisioned.

DSI presented several options, which included jets, pumps, lighting, waterfalls and covers. The client’s love for exercise and swimming made her yearn for a true swimming experience, so DSI suggested an axial flow system.

“An axial flow swim current system is capable of providing a strong flow that dog paddlers would find themselves moving backwards,” Salazar says. “The flow has a natural feel and provides a true swimming experience.”

This system generates a smooth, powerful river-like current, with no jets, bubbles, or high-pressured turbulence, to challenge swimmers of all levels. Using a remote control, the client can easily select the appropriate level of resistance, as well as program features to create any workout event, allowing her to partake in several different exercises.

The swim spa would also have a dual effect because it would enable both exercise and pain management. The currents in these pools are used to aid arthritis, osteoporosis, multiple sclerosis, asthma and chronic joint or back pain symptoms.

Maintenance was made easier for the client via a two-part sanitation system comprising an ultraviolet (UV) sterilizer and hydrogen peroxide (H₂O₂) (oxidation), which is a mix of hydrogen and oxygen (active water) that reverts back to hydrogen and oxygen once it is spent. The bulb used in UV sterilization is replaced annually and can help outweigh the negative effects of chlorine on the environment. DSI also added an automatic retractable cover for added ease of maintenance.

Finally, the client added changing light emitting diode (LED) lights for ambience and connected the swim spa to her home automation system, allowing her to control the spa and lighting features from anywhere in the house.

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

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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[3].

Source URL: https://www.poolspamarketing.com/trade/custom-spa-fabrication/

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