Swimming pool enclosure manufacturing is a systematic process that involves a number of stages. Normally, each stage determines the quality of the final product.
In this guide, I will take you through a step-by-step procedure that will make you understand every process involved. It is a simple and easy to understand.
Whether you are a swimming pool enclosure reseller/distributor or consumer; this is an important document that you must read.
Here we go:
Step #1: Choose right materials
Any manufacturing process begins by choosing the right raw materials. Without these raw materials, it will be useless to even plan for any swimming pool enclosure manufacturing process.
Remember, it is the raw materials that determine the cost of swimming pool enclosure. For a fact, companies that acquire raw materials at a cheaper price will sell their pool enclosures at a relatively affordable price.
Closely related to this, is the availability of labor. Labor, will determine the cost of production. Having said that, let’s focus on key materials we use to manufacture swimming pool enclosures.
Solid polycarbonate sheet
We use a solid polycarbonate sheet as the primary glazing material for all our pool enclosures. Since 2001, Excelite Plastics Ltd. has been the leading manufacturer and supplier of solid polycarbonate sheets in North America and Europe.
At Excelite, we believe solid polycarbonate sheet is the only materials that can withstand harsh weather conditions. Be it storm or wind.
It is for this reason that I will never recommend pool enclosures made from hollow polycarbonate sheets. The main advantages of solid polycarbonate sheets include:
- High impact resistance – virtually unbreakable
- Filter harmful UV radiations.
- Durable and reliable
- Dimensionally stable
- Easy to fabricate and customize
- Available in a wide range of options
In short, before you begin any manufacturing process, ensure you have enough polycarbonate sheets. For us, this is never a problem. We have more than enough polycarbonate sheets at our disposal.
Extruded aluminum rods
Swimming pool enclosure requires a strong structure. This makes extruded aluminum rods a perfect choice for this task.
Generally, aluminum rods combine all the desirable physical and chemical properties. That is,
- Lightweight – making it easy to install and transport.
- Corrosion resistance, thus, not affected by moisture
- Ductile – making it easy to fabricate
- Easy to decorate and customize
These are the main reasons why we insist on constructing the entire structure of pool enclosures using aluminum rods. In fact, the entire structure of pool enclosures is constructed from aluminum rods, including the track.
Excelite Plastics Ltd. gets enough aluminum rods from Dolle (Suzhou). One of leading supplier of aluminum and metal parts.
In short, swimming pool enclosure manufacturing raw materials is not a problem. Furthermore, we obtain both polycarbonate sheet and aluminum rods at an affordable price. This is the reason why our swimming pool enclosure is cheaper than other manufacturers in both America and Europe. They are also of high quality.
Basically, these are the key swimming pool enclosure materials you need. Next step, you need to design or have a drawing of the pool enclosure.
Step #2: Design and technical drawing
Designing is a critical stage in the pool enclosure manufacturing process. Ideally, it involves putting all ideas together with an aim of having a complete product – swimming pool enclosure.
As a matter of fact, we a have a wide range of swimming pool enclosure designs to choose from. The end user is at liberty to go for the standard designs or, customized options.
It is a requirement that the design process adheres to the building codes and standards. This is the only way pool enclosure will be considered safe for use.
At this point, you need to work closely with our technical team. It is the only way they will conceptualize all your ideas to come up with a technical drawing.
For a fact, this is one of the most challenging process in swimming pool enclosure construction. This because the technician must determine the following:
- Exact size (dimensions) of the pool enclosure – it is an important aspect in swimming pool enclosure product specification.
- Identify part by name with the right material specification.
In most cases, you will have three level designs of a swimming pool enclosure:
Schematic drawing – a sketch of pool enclosure design and its basic components.
Design development – this is a detailed plan of the pool enclosure.
Construction plan – this is a more detailed drawing than the above. It contains all the information about the swimming pool enclosure. Normally, it comes with the pool enclosure installation manual.
By the end of this process, you should have a complete swimming pool design. That is, a representation of what you will fabricate during the manufacturing process.
Step #3: Fabricate each component as per the above design
The good news is you can fabricate polycarbonate sheets and aluminum rods to any shape of choice. This will depend on the technical drawings you had in step #2 above.
Remember, the amount of materials you need for the entire process will depend on the design of the swimming pool enclosure. At this stage, you have to shape both the aluminum rod and polycarbonate sheet to conform to the desired shape. As I had indicated earlier, the good thing is, both polycarbonate sheet and aluminum rods are flexible.
There are 3 main operations you need to consider at this stage. These include:
Fabricating and shaping aluminum rod
As you begin the swimming pool enclosure manufacturing process, you have to shape aluminum rods. This may involve:
- Cutting aluminum rods into smaller pieces based on the design requirements.
- Drilling holes in the rods for fasteners.
- Grinding sections
NOTE: Always take accurate measurements at every stage. This is to avoid unnecessary wastage of aluminum metal. It is a better way of reducing unnecessary costs.
By the end of the process, you should be able to fabricate aluminum rods to form the desired shapes.
Fabricating polycarbonate sheets
Plastics fabrication involves a series of processes. Depending of your swimming pool enclosure designs, you may consider the following:
- CNC machining
In each of these processes, be sure to get the right tool and equipment for each task. Normally, a complex and customized shapes may require sophisticated equipment, thus, high cost.
In every process, you need to carry out all the necessary finishing operations. That is, remove all unwanted sections and give the final surface an appealing look.
For example, cutting surface may leave sharp edges. This can be dangerous as it may cut the technicians during the installation process. This is not what we want. All our products should be safe.
Conduct the necessary tests and quality validation
At this point, you should have all your swimming pool enclosure parts ready. However, before you begin sorting out every component, testing and quality validation is an important process in swimming pool enclosure manufacturing process.
Step #4: Sort every part as per specification
Sort out every component, of the swimming pool enclosure. You should give clear descriptions of every component where necessary.
You need to label every section of the swimming pool enclosure. That is, the labelling should be the same as that on the swimming pool installation manual. This is to avoid confusions that may arise due to wrong labelling.
As a general rule, cross check the label and the enclosure part at least twice to be sure there is no error. For Excelite swimming pool enclosures, this is never a problem.
Step #5: Pack the product for shipment
This is the last stage of swimming pool enclosure manufacturing process. You need to pack every component in the shipping box.
Don’t force anything in the box. By forcing components in a small box, it will be nearly impossible to remove them. As a result, some parts could get damaged in the process.
You should have all the necessary shock absorbers in place. This will protect the swimming pool enclosure parts from high impact during the shipping process.
Also, remember to label the products appropriately. More importantly, mark side that should face up plus all the necessary instructions.
Well, the process may seem simple, however, if you don’t have the right knowledge and expertise, it could be a nightmare.
End users don’t have to worry about this so much. You will get all the Excelite swimming pool enclosures delivered to your door step. Excelite has one of the most reliable and convenient shipping process.
Ideally, swimming pool enclosure manufacturing process involves these 5 basic steps. These include material selection, technical drawing, fabrication, sorting parts and packing. Of course, the process is not complete until the end user receives the final product. That is, a complete swimming pool enclosure.