Insulating Spa Cover FAQ

Below is a table listing some general sizes and approximate weights.

People frequently ask how much weight a cover will hold. While all of our covers meet or exceed ASTM Standard  F1346-91¹, there is not specific weight rating for each specific thickness and density of foam. There are many reasons for covers not having a "weight rating" or "load rating", but the most prevalent would be general liability issues.

That being said, the chart below compares the overall strength of different foam densities and thicknesses. This comparison is based upon an 8' square cover, of  the longest industry standard, of 4" to 2" tapered foam with a density of #1 (with a rating of 1). A rating of 2 would be twice as strong as a rating of 1, a rating of 3 is 50% stronger than a rating of 2 etc.

¹ - 7.1.1 In the case of a pool with a width or diameter not greater than 8 ft (2.4 m) the cover shall withstand the weight of 275 lb (125 kg) (weight of a child and an adult).

² - This is the weight of the foam only (rounded off to the closest full pound), and does not include the vinyl. For estimation purposes ad 20 pounds for the vinyl

³ - Listed R-value is based only on the foam and does not include the additional insulation value provided by the vinyl covering,  polyethylene vapor barrier (R-0.85) or other materials involved in the construction of the cover.

One piece continuous skirts, which are easier to manufacture, have many inherent problems as compared to skirts that are gusseted (also called "slits"). Gusseted skirts not only hang much straighter, but also have less of a tendency to bunch-up under the cover when putting it on your spa. If the skirt folds under the cover it prevents a proper seal between the cover and spa, greatly reducing the covers insulating ability.

More importantly though, as the sun beats down on a cover, extreme heat can build up between the skirt and the outer lip of the spa. This intense heat can actually damage the outer lip of the spa. A gusseted skirt allows this excessive heat to escape, preventing heat damage from occurring.

The most common cause of spa cover failure is due to the foam cores absorbing moisture. Besides the moisture causing the cover to gain excessive weight, the saturation also greatly reduces the insulating ability of the cover. One of the most important features of an insulating is the vapor barrier surrounding the foam. Not only is the type of material and it's thickness important, but how it's sealed is also important.

The simplest way to seal the foam is to simply wrap it in plastic sheeting and tape it closed. Unfortunately the tape will fail rather quickly thereby allowing moisture to penetrate into the foam. The preferred method for sealing the plastic sheeting is to properly heat seal it. Special care must be taken when heat sealing, otherwise failure can occur prematurely. Just the right temperature must be applied to the plastic sheeting to achieve a proper seal. Too hot and it will become brittle and crack open, too cool and it wont remain sealed. The ideal temperature will literally "weld" the polyethylene together.

Single-extruded, polyethylene sheeting has proven to be the best type of plastic to use for sealing the foam. Our machinery used for heat sealing is thermostatically controlled to maintain exact temperature tolerances. We also use a very heavy, 6 mil polyethylene and seal it extra wide, to assure years of performance. One of the options we offer is to double wrap the foam core with the polyethylene sheeting, which further extends to covers lifespan.

All spa covers must have a drain hole on the underside. This is too allow moisture and condensed water vapor to drain out of the cover. Due to the properties of the two materials we use for the underside, scrim and Reflex Energy Shield, they do not require anything to strengthen this hole or prevent the fabric from fraying. All a grommet would do is cause scratches in the spa as the cover is slid off and on.

ASTM developed standards which include a category intended to protect children five years of age and under. ASTM Standard F1346-91 for spa covers includes specific performance tests and labeling requirements. Covers must be able to pass certain tests. The first is Static Load. "In the case of spas with a width or diameter greater than 8' from the periphery, the cover shall be able to hold a weight of 485 pounds to permit a rescue operation. In the case of a spa with a width or diameter not greater than 8' the cover shall withstand the weight of 275 pounds".  Second is Perimeter Deflection. "The covers shall be designed in such a way that when tested, deflection of the cover does not allow the test object to pass between the cover and the side of the spa, or to gain access to the water". Additionally, testing for surface drainage is conducted to see if a dangerous amount of rain could collect on the cover's surface. There are also requirements to include labeling in consumer information and on the cover itself. Labeling must contain proper warnings (as described by the Standard) and identify the product as a safety cover.

The life-span of a spa cover is dependent upon many different things. How much direct sunlight it gets, how well it's cared for or abused, how extreme weather conditions are and how the chemicals in the spa are dealt with all have an effect on life-span. Generally though, if reasonably cared for a spa cover should last five to eight years.

Although very durable, a small amount of general care and maintenance can help extend the life of any spa cover.

- Do not over sanitize the water, and remove the cover when shocking. This is the most important thing. As excessive sanitizers evaporate, they can actually deteriorate many of the plastic materials a spa cover is constructed from.

- Periodically cleaning, treating and protecting the outer vinyl from the elements is the most important thing. 303 Protectant is the best thing for treating and protecting the cover from sun damage. Stay away from any petroleum based products that claim to condition vinyl. They actually do much more harm than good.

- Remove excessive snow to prevent the cover from sagging and possibly breaking.

- Never sit of stand on a spa cover.

As with any product, a comprehensive warranty is important. It's important however, to look closely at, and understand the warranty. Warranties are frequently used as a marketing tool and can be  very deceptive. While the warranty may state an extremely long time frame, the exclusions can make it virtually worthless. Some retailers are adding an extremely long extended warranty, to the actual manufacturers warranty, as a marketing ploy. It should be interesting to see if they're still in business (or have any happy customers) towards the end of this time frame.

Most warranties exclude damages caused by animals, fire, vandalism, excessive chemicals, improper installation, excessive weight load, acts of God and possibly more. Almost certainly, they also have an exclusion for "normal wear and tear". What exactly is "normal wear and tear", and who makes the determination on this?

The most important exclusion in all spa cover warranties is "shipping and handling". The customer is ALWAYS responsible for this, and the cover has to be shipped back to the manufacturer and then again back to you. Unless you can personally deliver the cover to the manufacturer, almost certainly the cost of shipping will be MORE than the cost of a brand new cover.

Prorated warranties are some of the most deceptive! It  makes it look like the warranty has an even longer time frame, but now you're paying not only for the shipping costs (in both directions, which can be more than the cost of a new cover), but also a percentage of the retail cost.

We have been in the manufacturing business since 1976, and though it's rare, what few warranty problems we've seen, have never occurred after the first year! In fact, almost all have occurred within the first month. Since we started double stitching every aspect of our spa covers, we have never had a warranty problem. While it is stated in our warranty that the cover must be returned to us for repair, we have never required the actual return of an entire cover at the customers expense for repair.

This is an interesting question, that even we have had to wonder about sometimes. We've seen different retailers offering the same exact spa cover, yet the R-value "claimed" can vary by as much as 30%.

The insulating core of almost all spa covers is EPS (Expanded Polystyrene). The insulating value of this product is very specific, and is listed in the table below. Please note, the R-value shown is for 1 inch of thickness.

The average spa cover cores, tapered 4" to 2", made of 1 pound density foam, have a total R-value of R-10.74 (calculated by averaging the thickness). Going to a 2 pound foam increases the R-value to R-13.05. Additionally, some R-value can be added for the vinyl and poly wrap that seals the foam cores. But only about R-2. The R-value of a 1 pound density spa cover only calculates to, at most, R-13 (2 pound = R-15).

Preferably not. Unlike cars, spa manufacturers are constantly modifying the spas. Sometimes twice a year!!!!......Although we have thousands of measurements for templates, your measured dimensions are the most accurate and ensure a proper fit.

There are a number of reasons we prefer your actual measurements over our measurements on file;

1. Your spa may have warped slightly out of shape over time.
2. Manufacturers may have supplied us with fictitious measurements.
3. You may want a cover different from the original.
4. Your year or model may actually differ from what you believe it is.
5. We have a typo, or are simply wrong.

There are some exceptions to this. For spas in which the sides are bowed out and not straight, we most likely have a template. We also are working at acquiring templates for spas that have raised speakers in the corners that require "pockets" in the cover to properly cover them. For these types of spa cover, please call us to check if we have the template and to place an order. We'll need you to tell us the exact brand and model of your spa, and the year of production.

Depending upon your location, typical delivery time is two weeks after time of order. Frequently delivery time is much sooner, however during busy times it may be slightly longer. Usually most covers will be manufactured and shipped within a week.

There are literally thousands of different shapes and sizes of spas and hot tubs in existence today, and with all of the manufacturing options we offer, cost and storage space make stocking covers impossible.

Besides excessive force, most tie downs tear out due to poorly designed or poorly made spa covers. While the tie downs shouldn't be use as handles for lifting a cover, they should hold up to quite strong winds. We have virtually eliminated "tie down tear out" by using nylon webbing and sewing it into the cover at 4 different points.

In general, the answer is "no". The foam for the cover's core, is initially manufactured in large blocks. It is then cut or sliced to order (we're one of the few manufacturers that starts with whole blocks and slices them ourselves). Most all cover manufacturers use foam cores that are cut specifically for them, to their specifications. Each individual manufacturer specifies the thickness and taper of foam that they desire. Because the foam is almost 1/3 the cost of the materials in a cover, many manufacturers try to "skimp" in this area. We've seen covers advertised as being 4" thick, as thin as 3-1/4" (our foam cores are TRULY as thick as we claim).

Secondly, over time the sun shrinks the outer vinyl covering slightly compressing the foam. A cover can actually shrink up to 1/2" over it's life.

As said, in GENERAL the answer is no, but it can be done. The real problem is expense! First off we would need to have your cover shipped back to us. If the cover is symmetrical, we can copy the good piece of foam. If it's not symmetrical (or both piece of foam are broken), we can through a little trial and error cut a new piece of foam (start a hair large, try it for fit, and trim if necessary). It's rather imperative that the foam core be exactly the correct size. Too large and it wont fit, too small and the outer vinyl will wrinkle and sag.

The problem though is shipping expense. The covers are too large for UPS and have to ship via common carrier. Common carriers have a MINIMUM shipping charge of around $75.00 to $100.00........ Each way. Though a new foam core may seem reasonably priced, when you add in shipping both ways, it can cost almost as much as a whole NEW cover for just a single foam core.

Just like trying to replace the foam cores, replacing just the vinyl outer covering usually isn't cost effective. Our entire process for making spa covers, including patterns, cutting the vinyl and other fabrics, and cutting the foam cores, is completely computerized. The additional work involved to make a proper fitting vinyl covering could cost as much or more than a complete new spa cover.

Besides the obvious reason of a loosely fitted vinyl covering, the frequent cause of sagging is excessive air inside the polyethylene that seals the foam cores. Manufactured at cool temperatures, once on your spa the additional heat of the water will cause any trapped air in a cover to expand. It's important (though difficult) to vacuum out any air that might be trapped during the process of sealing the foam cores in the polyethylene.

The foam a cover's cores are made of is called Expanded Polystyrene and is made of small beads that are expanded with steam. Once expanded they are dried and then "attached together" simply by compressing them. The more pressure they are compressed under, the high the density of the foam. The individual "beads" are waterproof! HOWEVER, water can saturate between the beads.

To prevent (actually reduce) water absorption, the foam cores are "sealed" in polyethylene. The method used to seal the polyethylene is an important factor. Many cheep covers simply have the polyethylene taped closed. Not good, as the tape will eventually fail. Better covers have the polyethylene heat sealed. While this is usually better than tape, if not done carefully and properly it can actually be worse. When the polyethylene is heat sealed, if it's over heated the seam will be excessively brittle and can crack, allowing water to enter the foam.

The most obvious cause of water absorption would be a small hole punctured through the cover. Even the smallest hole will allow a large amount of water to enter the foam over time.

The most common cause of water absorption is the "natural degradation of the polyethylene". Over time, chlorine, bromine, non-chlorine shock and ozone will break down the polyethylene causing it to become porous. The thicker the polyethylene (we use a 6 mil thick polyethylene), the longer it will resist this chemical degradation. At some point however, it will become porous enough to allow evaporation and steam to penetrate through it. It WILL NOT be porous enough to allow the steam that has condensed back into water to drip back out.

Since eliminating all the chemicals isn't possible (and still have a safe spa) the best preventative measure is a floating blanket. The blanket will greatly reduce both chemical off gassing, and more importantly evaporation. It's also important to completely remove the cover for a minimum of 20 minutes when shocking the water. This will allow the off-gassing chemicals to freely escape without penetrating into the cover itself.

Welt cording is a feature that is typically used to "straighten" out crookedly sewn seams. The down side is that it gives dirt and mold a place to attach, and gives an extra 'ridge' to get hung or torn when handling the cover. We prefer to simply work a little harder and sew straight seams.

There have been quite a few fine compliments about our spa covers. Following are just a few;

I just wanted to thank you so much for the excellent service regarding the purchase of my hot tub cover. The order process was very easy and the prompt delivery was great! Even the delivery man was very friendly.

We love the cover which far exceeded our expectations.

Thanks again!
Jane Fitzgerald

Just a quick note to let you know that the hot tub cover arrived in great shape. I also wanted to let you know that I appreciate the customer service, as well as the quality of the cover. It fits like a glove!

I will be recommending you to other friends that I have for their hot tub needs.

Thank you...
-Mike Ricci-

Thank you so much for the great workmanship on our new Hot Tub cover. It turned out much better than we anticipated, and was well built to boot! What a difference in protection, water run-off, color, and construction. I know that most of the time, we only hear about the "Bad" things... but I just wanted to let you know how "Good" your product is.

Count me in as a VERY satisfied customer, and will happily turn more customers your way!

Thanks again...
-Gary Thurman-

I have to write and tell you what a pleasant experience we had doing business with your company.

We stumbled across your webpage while trying to put our lives back together after Hurricane Charley came swirling through Charlotte County, Florida.

Your information was clear and your prices seemed fair, so we measured our spa, decided on the colors and options we wanted, and e-mailed off our order.

Your followup was excellent, and your packing, shipping and delivery were perfect.

Our spa now looks brand new, and we're getting at least that portion of our life back to normal. Thanks for making one home in Punta Gorda look better than it did before this terrible hurricane season!

Bob & Mary Ann Bengtson

I just received our new hot tub cover from you and it is fantastic! The workmanship is outstanding and is exactly to spec.

Thank you for you easy-to-follow instructions and great product. It has been a pleasure doing business with you and I will pass the word about your fine offerings!

Brian Walker

Hello, we ordered a hot tub cover and lifter and just wanted to thank you. This is our third cover in ten years and want you to know that this is by far THE BEST one yet!!! I will be sending you some customers, our friends all have hot tubs and will be needing covers and lifters. You have great prices, great quality, and free shipping.

Thanks again, Paula Clingerman

Some weeks back I ordered a new cover for our hot tub and a cover lift. Both arrived in excellent condition and both are installed. I just want to thank you for excellent products and how well the cover fits and how the lift operates.

I am truly a satisfied customer and if and when I need any additional parts, supplies or optional accessories, I'll be back.

Tom Wagner

Hi Dear;
I got my spa Cover today ;-)Please send me some Business Cards so I can spread the news about your excellent service!

Take care, Michael

Just wanted to let you know how nice it is to have a new cover. It's so light weight, but works so well at keeping the heat in, that I've had to turn down my thermostat! The EZ-lifter is well worth the extra money, too! I bought my hot tub because of my bad back, but with my old lid, I had to find someone to lift it so I could get in when I wanted. No more!!! I can now lift the lid up and out of the way with the lifter and enjoy a healing soak anytime I please! Thank you for this and the best part is, for what I paid for both, it would have cost me much more for just a cover alone, at any outside retail store!

You guys are great!!!
Sincerely,
Michelle Thomas

Recently, I spoke to one of your representatives on the phone and ordered a cover. My order was delivered within the time specified and arrived in great condition. Your organization as a whole handled my order with nothing but professionalism. I will definitely be doing business with you in the future. Your customer service was awesome, something you do not see that much of now a days. Great Job!!!

Mark Boulet

Hello,
Just wanted to say Thank-you for such great service. Our new cover came and fits perfectly,, including the 2 inch corners that you called and asked us about. It looks nice!! We liked that you sent a confirmation letter about our order, called and asked us a question about our measurements when they sounded different to you AND the order arrived much earlier than the estimate (great to be earlier than later!!).

Thank you,
LeeAnn and Bill Cooper

I just wanted to say thank you. I received my custom made hot tub cover a few weeks ago and it fits perfect. I was a little leary ordering from a company over the internet that I had never used before. Your directions for measuring the cover were so helpful and you delivered everything you promised. Great Job!

Donna Schlosser

Have received the spa cover I ordered.

WOW!!!

It fits perfect and is a better quality than the original one which came with the spa.

Thanks!!!
Everett Sullivan

We've seen some rather interesting "claims and statements" throughout the years regarding spa covers. Here's a list of some of the most "interesting", and the "other side" of the story.

• "100% Certified "Spa Hyde" 5x stronger than marine grade vinyl."
  
  "Spa Hyde" is actually a brand name of a mid-quality marine grade vinyl that is imported from Southeast Asia. There are 3 different "Spa Hydes". Spa Hyde IV, Spa Hyde VI and Spa Hyde IX. #6 & #9 are 27 oz. vinyl, while #4 is 24 oz vinyl. All three of them only have a UV rating of 1000 hours. Our marine grade vinyl is 30 oz. and has a UV rating of 1500 hours.

• "Hand heat sealed vapor barrier to prevent water absorption"
  
  A spa cover's foam cores are sealed in polyethylene sheeting. There are 3 ways to seal this sheeting to make it as water proof as possible. The first is to tape it closed. Although this is the easiest, generally the tape fails rather quickly allowing moisture to penetrate into the foam. The second is to heat seal (melt) the sheeting together by hand. This involves using a hand held "clamp" type mechanism, clamping in onto the plastic and counting the seconds to a predetermined time, then removing the clamp and moving on to the next area to seal. As you may be able to tell from the description, this is not a very exacting method. The third method involves using an automated machine to heat seal the sheeting. This is what we use. To get the perfect seal, the temperature must be within 10 degrees and the time of the sealing process within 2 tenths of a second of the predetermined settings. Any further off and the seal will fail prematurely (rather difficult to do by "hand sealing).

• "Selling factory direct"
  
  This phrase can be a bit misleading. Usually it's interpreted as meaning the website you're buying from is the manufacturer of the product. Unfortunately in most cases it really means that the web site is drop shipping the product from the actual manufacturer to you. Frequently there's little if any contact information other than a phone number (no address listed). At the time of this writing we are one of only four actual manufacturers selling directly to consumers via the internet, yet more than 18 separate web sites claim to be.

• "We offer the longest warranty in the business"
  
  If you can't find a better warranty today, look again next week. Warranties are becoming one of the biggest marketing ploys around. Read the warranty CAREFULLY and you'll likely find that all it covers is MANUFACTURERS DEFECTS. With almost 30 years of manufacturing behind us, it has been our experience that almost all "defects" will show up within the first few months, possible as long as a year after purchase, but NEVER have we, nor any other manufacturer we know, seen a defect after more than about 18 months.

  Another thing to consider is WHO is "issuing" the warranty. Many internet retailers are now adding on their own warranty on top of the actual manufacturers warranty to give the appearance of a longer warranty time. ANY warranty is only as good as the company issuing it. Chances are a company that's been around for 25 or 30 years is going to continue to be around to stand by it's warranty...... A three year old internet company may be another story.