A new element of design
by Dave Flaherty | September 10, 2020 4:00 pm
By LaMont Drechsel
Since automatic covers were first invented, they have been installed on thousands of pools around the world. They minimize energy costs, lower maintenance requirements and enhance safety by limiting pool access to children and pets. Further, automatic covers can help pool owners save up to 70 per cent on water, energy, and chemical costs as they prevent approximately 681 L (180 gal) of water per week from evaporating. These covers conserve heat and keep pools clean by preventing dirt, debris, and pests from getting into the water.
So that begs the question, why are covers not included in every pool build?
The answer may lie in the technology. For decades, rope has been the mainstay material used in automatic covers, but the introduction of stainless steel cable technology offers pool professionals added durability, freedom, and flexibility for designing one-of-a-kind custom pools.
Traditional automatic pool-cover technology
First, it is important to understand how automatic pool covers have been designed for nearly half a century. Traditional systems are engineered with a rope pulley mechanism, with a separate rope pulling each side of the cover along tracks mounted on either side of the pool. A large motor and pulley system—including the reels around which the ropes and the pool cover’s roller tube wrap when the cover is not in use—must be installed at the base of the pool, and is typically concealed beneath a lid or large tiles that disturb the uniform lines of the coping surrounding a pool.
That said, the motor and mechanism offset in traditional pool cover systems are usually quite large and take up a significant amount of space, requiring pool designs to be altered to accommodate them. This limits designers from creating sleek, streamlined pools for customers.
Further, while rope is an inherently flexible material that lends itself to easily wrapping around the pulleys and reels of the system, making for a forgiving pool cover system that can accommodate imperfectly built pools, rope is prone to shrinking and stretching over time—particularly when exposed to water, weather, and mechanical damage.
Since traditional systems consist of two separate ropes that do not stretch and shrink at the same rate, this affects how the pool cover functions as one rope could eventually stretch or shrink more than the other rope, causing the two sides of the pulley system to become misaligned and the leading edge of the pool cover to run askew, requiring frequent adjustments and repairs. Further, the costs needed to maintain a traditional, rope-based automatic pool cover can be a concern for many pool owners.
Although traditional systems are effective, rope is the weakest component, which ultimately leads to costly repairs and maintenance over the lifetime of the cover. That alone can make many pool owners and builders hesitate when including an automatic pool cover in their designs. Combined with compromised esthetics due to the amount of physical space required to house the mechanism of a traditional system, it altogether deters them.
Overcoming the engineering challenges of stainless steel cable
While stainless steel has long been dismissed for being too costly and rigid of a material for automatic cover systems, many engineers have noticed its potential. The material is stronger, durable, and non-pliable—a superior option for outdoor pool environments. That said, the two major issues engineers had to face when designing an automated pool cover using stainless steel cable were:
1) How to keep the cable under constant tension; and
2) How to protect the entire system from getting damaged by the strong steel cable as the cover opens and closes.
These concerns are addressed when using pliable rope as it stretches like a rubber band. However, just a few inches of slack in a stainless steel cable line could tangle the cable, causing an entire pool cover system to fail.
To resolve these issues, a spring-loaded mechanism was built into the cable reels that maintains constant tension on the stainless steel cable regardless of unexpected movements within the pool cover system. This eliminates the risk of any slack in the cable line that could lead to system failure. Additionally, to prevent damage to the system from the rigid stainless steel cable itself, a mechanical slip clutch and electronic automatic shutoff sensors are integrated into the system. These mechanisms prevent the stainless steel cable from going past intended stopping points and causing damage as the pool cover is opened and closed.
As a result, the stainless steel cable accommodates a much smaller mechanism to operate, offering greater freedom and flexibility to designers to maintain the sleek, seamless lines of their pool designs.
Leveraging stainless steel cable for flexible pool designs
Pool design flexibility
A smaller mechanism creates a much smaller footprint. The reduced footprint for a stainless steel system requires only a 356-mm (14-in.) offset for most pools, compared to 813 mm (32 in.) commonly seen in standard, rope-based pool cover systems. With a smaller mechanism, designers can more easily incorporate a pool cover with no visible indication of an automated cover system positioned on one end.
Strong and durable
Stainless steel cable is water-resistant; therefore, it works better in a wet outdoor environment, as well as other weather conditions. The cable is even critter-proof and cannot be chewed or damaged by outdoor pests. Its strength alone means a small diameter cable can be used in automatic cover systems, increasing the ratio of the size of the cable to the size of the pulley. This increased size ratio leads to less mechanical wear and tear over time, meaning stainless steel systems have a long lifespan and require less maintenance.
Non-pliable
Unlike rope, stainless steel cable does not shrink or stretch; therefore, it does not change in length and the cover system does not need ongoing adjustments and repairs to function properly. This can be an incentive for those homeowners who do not wish to invest in the ongoing maintenance requirements of traditional pool cover systems.
Improved form and function
With advanced engineering in place, stainless steel cable is transforming automatic covers and pool designs. The smaller overall footprint of the cover system presents new design possibilities, while the strong, non-pliable material offers improved functionality and reduced maintenance over time. Due to its benefits, many pool builders have begun offering stainless steel cables to their clients as part of their ‘standard’ pool cover package instead of an upgrade. The technology has allowed many customers to view automatic pool covers as a necessity rather than an accessory, leading to greater opportunities for pool professionals and their ability to provide superior designs to clients.
LaMont Drechsel is an experienced operations executive with a strong background in product development and mechanical engineering for consumer goods and manufacturing. As the vice-president and general manager of specialty products at Fluidra North America, he oversees operations for various subsidiaries, including Cover-Pools Inc. Drechsel has overseen automated pool cover technology innovation and product development at Cover-Pools for more than 18 years. He holds an MBA in management and a bachelor of science degree in mechanical engineering from the University of Utah. For more information, visit coverpools.com/t4, or email cover-pools.sales@fluidra.com.
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