The spa cover business is rife with imposters these days, making low quality, junk spa covers. And it doesn’t matter which side of the border they are made on, Mexico or North America, you can find poorly manufactured spa covers.
Our business has always been to produce the best spa covers, all computer designed and made to exacting specifications, with quality materials and quality control. But there are cheaper ways to make a spa cover.
Here’s some things to watch out for if you’re shopping for a new spa cover.
First, let’s look at the anatomy of a spa cover. For strength, you have the foam core and the reinforcement channel. For weather and water resistance and to protect the core, it’s covered in marine grade vinyl and the foam core is wrapped and sealed in thick plastic.
Solid handles are useful in maneuvering the cover, and good locking straps keep it secure in high winds, and safe for kids and animals. A thick, well sewn skirt helps hold in heat and block any drafts into the spa.
Now, let’s look at some of these spa cover parts one by one, to show how the quality of materials can be manipulated. These are the distinct differences between a good spa cover and a junk spa cover.
TAPERED FOAM CORE
A tapered core will allow water to run off, very important for outdoor hot tubs, and also allows for use of a larger reinforcement channel, for greater strength.
The thickness of the foam core will affect it’s heat retention, strength and water resistance. The best spa covers are 6″ thick in the center, tapering to 4″ on the edges, but you can also find 5″ to 3″ or on the lower end, 4″ to 2″ thick spa covers.
But more than thickness, the weight of the foam or foam density, is important. Spa covers can be made with 1.0 lb foam, 1.5 lb. foam or 2.0 lb. foam. The greater the foam density or weight, the greater R-value your spa cover will have.
Galvanized steel channels will provide the best strength for a hot tub cover. These are available in many thicknesses, but almost all are superior to aluminum channels, which don’t have the strength of steel. I’ve seen some aluminum channels with the rigidity of thick aluminum foil.
As mentioned above, the thicker foam cores allow for using a taller reinforcement channel across the hinge of the spa cover, to add strength and rigidity. With one on each half of your spa cover, they form an I-beam support for your spa cover. Cheap spa covers will use smaller channels, with lower grade steel, or aluminum, to cut costs and maximize profit.
MARINE GRADE VINYL
This is a type of vinyl made for boats that resists moisture and water. It is available in many thicknesses, and with many options for backing the vinyl. Our 30 oz. marine grade vinyl is a heavy weight, and it’s treated with UV and antifungal inhibitors. Light weight 20 oz vinyl are common on a cheap spa cover, some used without any woven backing.
A thicker marine grade vinyl, treated against fading and mildew, and with a heavy gauge woven backing makes a longer lasting cover that can take years of heavy sun and snow, and even a little dragging around.
FOAM CORE WRAP
This is another profit center for cheap hot tub cover production. We wrap our foam cores with heavy duty 6 mil polyethylene sheeting, in a continuous sheet. Then we fold over and heat seal the edges, before vacuum sealing to remove air. Cheaper spa covers have thinner plastic that won’t stand up to spa chemicals, and use either tape or staple their seams, with no heat sealed edges and vacuum sealing.
As an option, we offer a double-wrapped foam core, with two sheets of 6 mil wrap, and a continuous heat seal that runs across the entire bottom of the spa cover, to stop mildew from forming and prevent heat loss through the fold.
Take a look at our advantages, and our low prices – and you’ll see how we manage to sell 100,000 spa covers every year. We have 6 grades of spa covers, from our Economy Spa Cover to The Works – to fit all budgets. But even our lowest price spa covers have quality materials, computer design and precise construction – unlike some junk spa covers out there!