01. Site Survey & Retrofit Requirements
The existing Endless Pools unit was installed on an elevated composite deck in the rear garden of a private villa. Before the enclosure project, the swim spa relied on a heavy folding vinyl thermal cover.
- Manual handling: The existing cover was cumbersome and required two adults to fold back.
- Weather limitations: The pool could not be used while covered during rain or cold weather.
- Thermal loss: The open swim spa lost heat during cold conditions, increasing heating demand.
- UV exposure: The existing vinyl cover was exposed to direct sunlight and outdoor weathering.
- Debris control: Leaves and wind-blown dust entered the water whenever the pool was uncovered.
- Low-profile requirement: The client wanted the new enclosure to remain below approximately 1.4 m to preserve garden sightlines.
02. Shop Drawings & Precision Dimensional Control
The project was manufactured from the approved layout for client Edward, signed July 15, 2025, using millimeter-level dimensions for the enclosure envelope, module spacing and extended track.
- Overall enclosure length: 6,227 mm
- Fixed segment length: 635 mm
- Sliding module pitch: 1,426 mm × 3
- Active travel baseline: 4,777 mm
- Track extension: 1,518 mm
- Maximum ridge height: 1,336 mm
- Internal clear arch height: 1,195 mm
- Overall width: 3,311 mm
- Internal clear span: 2,631 mm
- Base track width: 340 mm
03. Precision Manufacturing & Factory Quality Control
Production focused on consistent profile machining, protected surface finishing and accurate multi-track fabrication for the nested sliding system.
- 68 × 70 × 5.0 mm structural aluminum profiles were cut and machined for the curved portal frames.
- The white architectural finish was applied after profile preparation for outdoor exposure.
- The 340 mm multi-channel base track was fabricated with drainage features and embedded stainless-steel guide rails.
- Profile cut lengths and finished components were checked before assembly.
04. 1:1 Factory Trial Pre-Assembly & Kinematic Testing
Before export, SUNRAY completed a full-scale 1:1 factory assembly of the 6.2 m enclosure to verify fit-up and sliding behavior.
4.1Nesting clearance: The four modules were checked for consistent concentric gaps.
4.2Frame squareness: Cross-diagonal geometry was checked across the 3.3 m width.
4.3Sliding performance: The modules were push-pull tested on the factory tracks.
4.4Seal contact: EPDM sweep seals were inspected along overlapping module interfaces.
05. Export Packaging & Logistics
After factory testing, the enclosure was disassembled and packed for international transport to the United States.
- Curved portal frames, tracks and polycarbonate panels were separated and protected for shipment.
- Components were cushioned with foam and wrapped before placement in reinforced export plywood crates.
- The packed modules were secured for truck transport to the international shipping port.
06. On-Site Commissioning & All-Weather Operation
Following delivery to the American villa, the modular enclosure was assembled on the existing deck using the prepared track system and pre-machined structural components.
- One-person operation: The sliding system was developed to reduce the effort required compared with the previous folding vinyl cover.
- Open-air conversion: The three movable modules can travel beyond the swim spa on the extended track.
- Weather protection: The enclosure provides a sheltered microclimate around the swim spa during rain, wind and cooler weather.
- Debris control: The enclosed configuration helps reduce leaves and dust entering the water.
- Low visual profile: The 1,336 mm peak height keeps the enclosure relatively discreet within the villa courtyard.
07. Application Scenarios
The compact telescopic system is suitable for residential and hospitality projects where users need a low-profile, retractable enclosure rather than a permanent full-height building.
- Endless Pools and counter-current swim spas
- Private villa swim spas and courtyard pools
- Hotel and club hydrotherapy spas
- Low-profile pool applications with restricted sightlines or height limits