Using a strong, durable alloy to create a custom hot water vessel

by jason_cramp | June 13, 2015 8:30 am

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By Greg Solmundson

When deciding on an aquatic vessel, potential customers are at times unaware of the vast potential a hot tub can present when it comes to enhancing a leisure space. Most clients have an appetite for a unique design—whether integrating a hot tub into a newly constructed home or an existing residence undergoing a renovation. That said, the most common request Ark Custom Pool & Spa International faces from customers is to have a personalized design that differs from traditional concepts.

Facilitating personalized design features can be easily managed with the ability to customize the hot tub first, then working on other areas of the project. For example, a hot tub engineered from stainless steel is not only available in any size or configuration, but also provides a bright, sophisticated-looking feature that is capable of withstanding harsh winters. Further, the ability to include ceramic and glass tile in a variety of colours and patterns allows the homeowner to easily integrate their hot tub with the surrounding environment (e.g. landscaping, decking, façade of the house, etc.) to match the vision they have for their outdoor space.

One recent project, which included a stainless steel hot tub as part of a complete backyard makeover, was completed in Calgary, Alta. On this particular job, VisionScapes, a local landscaping firm, commissioned a portion of the project to Ark Custom Pool & Spa International to design a custom hot tub for the property, which would be nestled amongst other outdoor amenities.

How did it all begin?

Upon receiving the invitation from the landscape company, a meeting was arranged with the customer to identify the specific features and designs they were interested in. To help this along, a preliminary conceptual design of the client’s property was rendered. The idea of presenting a stainless steel hot tub with integrated tile trim that was partially recessed into the ground next to a natural gas fireplace was very appealing to the customer.

Careful consideration was made by listening to the homeowner’s suggestions and ideas, which ultimately influenced the final design. The ability to provide the client with any shape or size hot tub helped to accelerate the decision-making process and enabled them to make the necessary design alterations.

Based on these discussions, it was clear the homeowner was looking to maintain sharp lines with the hot tub being a complementary feature to the preliminary design. Once the general design was established, the customer selected a tile combination to be applied on the hot tub’s interior trim, which also provided a basis for selecting the surrounding stonework, concrete colouring, and furniture combinations.

Controlled environment manufacturing

After finalizing the size and shape of the hot tub, and before the stainless steel vessel entered the production floor, the engineering team produced a detailed drawing for each manufacturing assembly team. Then, each sheet of stainless steel was passed through a state-of-the-art computer numerically controlled (CNC) laser machine, which cut the steel precisely based on the design. After being cut, the steel was formed using a press brake and then welded together. Once assembled, the tiles were installed using a proprietary epoxy adhesive. Plumbers and insulators then installed the hot tub’s hydraulic functions.

When the manufacturing process is complete, the hot tub undergoes quality control checks and operational tests before it is shipped to the project site in a protective crate.

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Acquiring jobsite permit approvals

Although the design stage, tile selection, and hot tub location were now finalized, the project could not commence without a permit. The permit approval stage can range between one and three weeks and applies to almost all hot tubs, depending on the size and nature of the project.

Prior to starting any site demolition and excavation work, clearance from all services running above and below grade was requested. Once the permit was approved and utility locates were performed, construction started in early October with the goal of laying the foundation prior to the frost penetrating the ground.

For this project, the demolition work comprised jack hammering aged concrete decking and removing outdated landscaping while at the same time protecting and preserving the structural columns for the upper balcony. Once this was finished, the property was laid out in accordance to the design drawings.

The next step was excavating the location where the hot tub was to be installed in addition to any outer areas that needed to be removed due to unstable ground conditions. This work was completed using a narrow excavator as space on either side of the house was restricted.

The original idea was to sink the hot tub into the ground; however, with the site being close to the house, several structural implications became apparent had the excavation been an extra 0.6 m (2 ft). That said, the homeowner preferred to have the hot tub partially recessed as per the conceptual drawings.

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Laying the ground rules

The base (foundation) material is one of the most pertinent aspects when installing a stainless steel hot tub. A solid foundation provides a safe and level platform for which the stainless steel base frame rests. There is no specified nominal thickness for the concrete base, nor does the platform need to be a cementitious material; however, a reinforced concrete foundation with a substantial amount of drainage relief—on the surface and underside of the platform—is preferred and was installed on this project.

Services

Prior to pouring concrete into the foundation forms, consideration for bonding, electrical conduits, drainage, and other provisions for accessory openings were made. Further, before the concrete foundation was poured, several inspections were performed by local authorities to ensure all services were installed correctly and the location of the hot tub was in accordance with the certified drawings.

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The vault

Having the luxury to install the stainless steel hot tub above-, mid-, or below-grade provides several options when nesting the hot tub. On this particular project, the foundation was primarily dictated by the elevation as well as the load factor of the walls and size of the hot tub (including the vessel’s weight when full of water).

The walls of the concrete vault were dimensionally assembled and formed on top of the foundation using 15 m (49.2 ft) of rebar installed 406 mm (16 in.) on centre. In doing this, the hot tub’s size and the condensed area for the mechanical equipment were also factored into the equation.

Due to the in situ of the property and house, the mechanical equipment could not be remotely installed; however, there was enough room to keep the equipment separate from the hot tub, but somewhat adjacent to the framework.

Exposing the vault and ensuring accuracy

The walls of the cast-in-place concrete vault were poured 203 mm (8 in.) thick. This method of installation provides the ability to double check for accuracy with respect to measurements and elevations to ensure they coincide with the approved drawings. Further, with the outlining vault structure in place, the customer had a better understanding of the project’s procedures, while also offering some foresight with respect to the overall design concept.

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Now the hard part

This project was not completed without some challenges. As mentioned earlier, one of the difficulties was accessibility—not just for excavation, but also when it came time to transport the hot tub from the front of the house to its final resting area. Again, there was not enough room on either side of the house
to safely move the hot tub into position; therefore, it needed to be lifted overtop of the house with a crane. Fortunately, the gross weight of the average size stainless steel hot tub is a lot less than most would expect (approximately 272 kg [600 lbs] without water).

The excitement and reaction from customers when the crane arrives never gets old. There is always a sense of nervousness that something could go wrong, but this is typically overshadowed by excitement and anticipation of the final look when the hot tub is set in place. Further, today’s craning equipment is quite advanced; for this project, the entire process—from positioning the crane to placing the hot tub and retracting the crane—took approximately two hours.

Level and in place

After some minor adjustments, the hot tub was level and square. To this end, having a level foundation is critical to the overall functionality of the hot tub. Once the placement of the hot tub was finalized, the base frame was fastened into the concrete foundation and a protective covering was placed over the interior of the hot tub to protect it from construction debris.

Overcoming project obstacles

With the hot tub in place, the surrounding work (e.g. landscaping, hardscaping, etc.) took full flight. During this stage, it is not uncommon for customers to have a change of heart when it comes to the final colouring and textures of the surrounding structures—especially with the hot tub temporarily exposed and gleaming against the house in this case.

For the most part, this client chose the right colours and textures with the exception of the stone materials they selected to surround the fireplace and structural deck pillars. Changing the stone on this project was not a matter of visiting the local big-box store and returning the same day with their alternate choice. Changes such as this become a process, especially when the stone is imported from another country. Further, trying to explain changes in price, extended deadlines, and scheduling conflicts is easier said than done. In delivering these messages to the client, a number of “what if” scenarios followed.

In this case, the contract that was signed during the initial negotiations came into play. It stipulated changes to the scope of work during construction, how it could present delays, as well as influence the final cost of the project. Therefore, as both parties originally agreed to these written terms, the contract was very influential when delivering the message regarding the impacts of changing the stone materials.

Regardless of the written terms in the contract, open communication with the client and detailed explanations pertaining to such changes is a necessity. It is also a good idea to compile daily reports (with supporting images) and submit them to the client in the form of an e-mail. Not only does this add clarity, but it also opens the door for constant communication from start to finish.

An amicable resolution was agreed to whereby the landscape company accommodated the client’s request to change the stone and complete the surrounding areas of the hot tub.

A large crew was designated to outline and form the area for the coloured concrete, which was poured and sealed for additional protection. Another crew strategically cut and installed the stonework using an adhesive epoxy, which was followed by the application of sparkling epoxy grout.

The concrete, stonework, and stainless steel hot tub and fireplace truly reflected the client’s wish for a contemporary looking backyard. Thanks to a little patience and the understanding of the homeowner’s needs, the finished project is an immaculate leisure space respectful of the look they sought after.

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The final touches

Finally, to ensure the family was completely satisfied with the work and overall performance, prior to commissioning the hot tub, several items needed to be cleared up. For instance, all hot tub components were tested to make sure the system was operating at full capacity and the job site was cleaned leaving no indication that it was a construction site just hours before completion. Then, the local authorities performed their final inspections and the construction permit was closed.

Finally, even though the client may be anxious to test the hot tub and enjoy the surrounding areas, consideration must be made when closing out a project. Prior to anyone entering the hot tub, someone with authority must sign off on the project. This procedure is standard and is the safest way to turn the completed project over to the client.

After the closeout procedures are completed, it is then time to go over operational practices. It is also imperative to provide the client with applicable warranties and operational manuals.

The follow up

After completing the installation, several visits have been paid to the client to ensure the hot tub continues to operate to its full potential. Contact with the client continues, but has become more infrequent now that they understand the functionality of the hot tub. Selling the job is one thing, but following up benefits both parties on all fronts.

[7]Greg Solmundson is the founder of Ark Custom Pool & Spa International, a design/build firm of swimming pools, supplier/installer of custom stainless steel hot tubs, and full landscape services in Vancouver, B.C. and Calgary, Alta. He graduated with honours from industrial welding school in 1990 and has more than 25 years’ experience in pool and hot tub assembly and construction. He can be reached via e-mail at greg@arkcustompool.com[8].

Source URL: https://www.poolspamarketing.com/trade/using-a-strong-durable-alloy-to-create-a-custom-hot-water-vessel/

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