A spa is born
As you scroll down this page the following demonstration will show the production
time line of the creation of a work of art, a
Catalina™ the world most beautiful hand built spas.
Phase 1. Vacuum Forming
Acrylic sheet is loaded into the support frame and transferred into the oven. The spa shell mold is placed below the acrylic. The overhead heaters are switched on and the heat causes the acrylic to become pliable and able to stretch.
At the exact correct temperature the mold is raised in to the now flexible acrylic, a vacuum is applied to the area between the acrylic and the mold drawing the acrylic slowly down into the spa shell mold. Forming the perfect spa!
Phase 2 Shell Structure
To ensure a perfect bond between the spa shell and the next stage of production, strengthening, the reverse of the spa shell is given an Ultra Bond™ treatment and then several layers of Glass reinforced polyester resin are spray applied.
To ensure there is no trapped air between the layers a special tool is used by hand to roll out each layer of reinforcement. The whole spa is then inspected for thickness and uniformity.
Phase 3 Plumbing
When cured the spa is taken to the cutting shop where the holes for the jets and fittings are cut out. The shell then makes its way along the production line where the individual jets and all interconnecting pipe work installed.
As you will see the plumbing is not for the faint hearted! Blue glue is used so every joint can be visually checked. Some models have over 200 meters of pipe work! All of this is to ensure the client get the most effective bathing and hydrotherapy experience possible.
Phase 4 Hand Built Cabinets
We take great pride in the overall appearance of our spas and the cabinet is the part of the spa that will always be seen. This is why we only use the finest materials in our handcrafted cabinets allowing us to give them a 10-year warranty.
The spa structural timber is all pressure treated. All levels are checked and adjusted. After the cabinet is fitted all the exposed sections are protected before we begin the next stage of production, applying the insulation.
Phase 5 Insulation ECO Feature
We at Catalina are fully aware of the importance of saving energy that is why we build our spas with arguably the most efficient foam insulation available on any spa. The heat loss from the cabinet and plumbing can be substantial - so we insulate it all using our own thermal-pane insulation. We apply 2.5kg high-density closed cell foam that is sprayed onto the reverse of the spa shell and pipe work.
As you would have seen from the previous images there is a lot of pipe work around the spa and this has a large surface area that will radiate heat so unlike most manufacturers we foam all of the pipe work on the spa to keep the heat in and save on running costs. It also gives added protection and strength.
Phase 6 Testing
We test every spa and Swim Spa for a minimum of an hour. We test all of the pipe work, jet performance and the spa operating systems, only when it passes these tests is it sent to the finishing shop.
Before finishing and packaging we totally drain the spa. As you can see from the images we use special fork attachments to invert rotate the spa. How many spas can be picked up by the side of their cabinets? This is a clear indication of the strength of the Catalina Spa.
Phase 7 Finishing
After the spa is tested and fully drained the cabinet is fitted and stained to the clients chosen color. Then the spa is given a thorough cleaning and the acrylic is polished ready for final inspection.
Only after a 73 point check list is completed and signed off by the finishing supervisor will the spa be packaged and heat shrink wrapped so the client will receive it in perfect condition.
At Catalina Spas Ltd we take great pride in being a family company with three generations involved in the day-to-day business and a support team second to none. We centre our business on honesty, professionalism and service. Over the years we have sold thousands of spas to clients throughout the UK and now have offices in many European countries including France, Spain, Belgium, Denmark, Sweden, Norway, Italy and Portugal to name a few.
Whether choosing a spa or Swim Spa you are investing in not just a lifestyle but a product that you want to give years of trouble free fun and enjoyment. At Catalina we honestly believe in this desire too, that's why we manufacture our spas using only the finest components and equipment available. Our spas are second to none.
Thank you for viewing our Spa is Born demonstration and trust you will see from it that we take making the best spas very seriously because our customers are important to us.
The Catalina Team
Catalina Spas (951) 940-4556