A. Why is every spa cover custom made?

    Often when customers call us about buying a spa cover they ask if we have their size in stock. The truth is, we don't have any covers in stock. That is because every spa cover we sell is custom made. In fact I don't know of any company that has spa covers already made, unless it is for spas that they sell. The reason is this.

    There are literally dozens of spa manufacturers in the U.S. and each one builds several kinds of spas. Not only that, over the years they add and subtract to their line of spas as trends and tastes change. If you count all the companies that are in business now, plus all the ones that are no longer making spas, you'll discover that there are thousands of spas in existence. These spas vary in size and shape. If the cover is one inch off, it won't fit.

    Now consider the fact that every spa cover comes in one of 10 to 12 different colors. Given this, it makes sense that cover manufacturers wait for someone to order a cover for their unique spa and their distinct tastes. If they tried to anticipate what kind of covers to carry, they would have to stock 5,000 covers at any one time. And most of those would stay in the warehouse for years before the right customer came along.

    For the customer there are advantages and disadvantages to making covers one at a time. The advantage is that you get exactly what you want in a cover, and if measured correctly, it will fit exactly. Also you can select a color that will match the decor of your home. The only real disadvantage is that you must wait while your cover is being fabricated. The wait can be a few days, or a few weeks, depending on how many other orders are in front of you. Shipping time can also delay getting your cover, especially if you are on the East coast and the manufacturer is in California.

B. What is a spa cover made of?

    Most manufacturers use basically the same materials to make their covers. Styrofoam on the inside, covered with marine grade vinyl on the outside. But there's a lot more to it than that. The vinyl is treated to resist the damaging effects of ultra violet sunrays. The styrofoam inserts are reinforced with aluminum to make them stronger, they are typically tapered to be thicker in the center, and they are sealed in plastic to keep out moisture.

    Here's something many people don't know, even some retailers who sell spa covers. Foam inserts come in several densities. The density refers to how tightly the foam is packed, and thus how rigid it is. If you don't ask, then most manufacturers will make the cover with one pound density foam. This means that if you had a cubic foot of this foam, it would weigh one pound. 

    But foam also comes in one and a half pound density, and some manufacturers offer a two pound density. They will typically charge $15 to $25 more for denser foam, but it's worth it. As the foam gets more dense, it becomes more rigid and less likely to absorb water. As you may already know, once a foam insert breaks or becomes waterlogged, it is useless. 

    As mentioned above, the foam inserts are usually thicker in the middle than on the edge. This taper is important because it makes the cover slope like the roof of a house, so it's stronger and less likely to sag in the middle. Rain water will run off instead of accumulating in the center. Older covers don't have this feature. They were typically 2 inches thick all the way across. 

    Different manufacturers offer different tapers. The common ones are 4" to 2", 3.5" to 2", 3" to 2", and 3.5" to 2.5". The best tapers in my experience are the first and the last. A cover with a 4" to 2" taper will shed water the best, while a cover with a 3.5" to 2.5" is quite beefy and able to withstand more weight. Stay away from covers that have no taper.

    One more thing to know about foam inserts. Some manufacturers offer a walk-on cover. This is a cover that has a specially laminated foam insert. The foam is sandwiched between two pieces of rigid plastic (about 1/16" thick) making the cover able to withstand 300 pounds of weight. These stronger foam panels are inserted into the vinyl skin so they look just like a regular cover. 

    This is the ideal solution to protecting a cover from breaking when a child or animal walks on it. In fact if you have a spa that is level with the ground, you need a walk-on cover in case someone (even an adult) accidentally steps onto the cover. They do cost more than regular covers, but not as much as replacing a broken foam insert. Not all manufacturers offer a walk-on version, so you have to shop around.

C. Where is the best place to purchase a spa cover?

    There are four ways to buy a spa cover: 1) direct from the manufacturer, 2) through a pool or spa store, 3) from a broker such as myself, 4) and most recently on the internet. There are benefits and downsides to each method. 

    1) Buying directly from a spa cover manufacturer will probably save you a few dollars. The problem is, you don't get to see the folks you are dealing with, nor so you get to see their product before making the purchase. 

    2) When buying from a local pool or spa store, you get to see a sample cover and deal with people you are familiar with. But you must do all the work of measuring the spa, which is the most critical part of ordering a cover. If the cover doesn't fit correctly, it's solely your responsibility. 

    3) Buying a cover from a broker like me is the most convenient way because we come out to your house and measure the spa, show you sample covers, and help you decide which manufacturer offers the best solution to your situation. We place the order for you, deliver the cover to you home when it arrives, and take responsibility if something is not right. Of course, in order to buy from us, you must live in the Memphis area. But there is probably a person in your city who offers the same service we do.

    An additional benefit of buying a cover from a company like ours, is that we also repair spas. Many times we first meet a customer who just wants to buy a spa cover, and later develop a continuing relationship when spa repairs are needed. It's nice to deal with one person who can offer a complete range of services for your spa. 

   4) The internet is changing the way people do business. But I'm not convinced that buying a spa cover online offers any advantage to buying a cover one of the traditional ways. I've visited several online sites and have yet to find one that does any better than a real person over the phone. The online experience doesn't add anything to the shopping process, while leaving great holes that the ordinary spa owner must fill alone. I suppose if a person lived in a remote area and could not order a cover by conventional means, the internet might offer a solution.

    The price of online spa covers is OK, but not that good when you add in shipping. And the risk of getting the wrong size cover is great given that you don't know what you don't know, if you know what I mean. Radius corners are not explained very well, handrails aren't explained at all, skirt length is barely touched upon, and special situations such as flaps and cutouts are left out completely. Templates are not usually discussed. If you are ordering a simple square or circle you might do alright online. For anything else, proceed at your own risk.

D. What about those special situations you mentioned?

    1) Radius corners - Corners can be square or rounded. The amount of rounded-ness is expressed by it's radius. If you want a good fitting cover, you have to tell the manufacturer what the radius of the corners are.

    2) Handrails - Several spa manufacturers install handrails that rise above the lip of the spa. The cover can either go over them or around them. Knowing which is best depends on experience, though preference also may play a role. Other protrusions, such as fill spouts and waterfalls, pose the same question. 

    3) Skirt length - The skirt is the flap that hangs down around the edge of the cover. While some spas are flush against the floor or cabinet and may not require a skirt, most spas do require a skirt. The skirt may be 1" to 6" and can cover the edge of the spa or cover the edge of the cabinet. If a skirt is too short it will allow heat and moisture to escape. Too long and the cover will not lay flat.

    4) Flaps - Some hot tubs have odd designs that require a flap to make a good seal. Designing a flap is best left to the cover manufacturer, but they need to be told that one is needed.

    5) Cut outs - The same can be said for cut outs. Sometimes the cut outs are hard to draw a picture of, so a template must be made.

    6) Templates - Occasionally the spa is so difficult to describe or draw that the only option is to make a template. We take clear plastic sheeting and tape it to the spa. Then we use a felt tip marker to make an outline for the manufacturer to use as a template. The template must be exact or the resulting cover will not fit. Some manufacturers charge a template fee, others do not, so it's best to ask.

    7) Tie downs - All spa covers must be equipped with tie down straps if they are to qualify as safety covers. Placement of these straps are usually not an issue, but they can be in special circumstances. Most covers have a minimum of four, but more can be added.

E. Conclusion

    You may not have thought there was this much to say about spa covers. That's why it's best to consult with someone before spending hundreds of dollars. Manufacturers know about all these issues but they rarely convey them to the spa owner. Most pool or spa stores that sell covers also have ran into these issues before, but again may fail to bring them up if you don't ask. That's why we make it a point to visit each spa and measure it ourselves. We raise the questions to the spa owner and help them decide what to do. This way we are assured of getting an exact fit every time.

    If you would like to know more about buying a spa cover, contact us.

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