Spa Shell | The Sparta Difference

Beauty that last forever

Many types of materials that can be used to construct a spa shell; gelcoat, OAS plastic, composite acrylic, and more. Sparta spas use the highest grade continuous cast acrylic available for good reason. CCA includes UV inhibitors that prevent color-fade when exposed to sunlight for prolonged periods. The surface is smooth and luxurious to the touch yet durable enough to resist stress cracking, a common problem associated with inferior acrylic and gelcoat surfaces. Unlike plastic, CCA is a non-porous material making it simple to clean and maintain. It easily withstands temperature changes from 50º–180º F. The result is a spa shell that will look beautiful for generations to come.

Choosing the right color

Many spa manufacturers offer standard spa color choices like Granite and Marble that are easier and less expensive to produce. More visually appealing colors always carry a premium charge. Sparta uses a luxurious three color mix of the xxxx colors to create that have proved highly popular with customers looking for a better looking spa. A special non-metallic mineral is added to the acrylic to refract light and add depth and sparkle to the finish.

Additional Color Options

We offer a wide variety of special and standard color options add no additional charge to satisfy every preference.

Built to be the best

The shell is the most important component when making a spa purchase decision. Pump, heater, filter, etc. can easily be replaced if they fail. A shell can not be replaced. In 2002 ThermoSpas formulated the ThermoBonding process that is used to manufacture every Sparta Spa. The result is an unprecedented 0% failure rate on tens of thousands of our spas built since that date.

Sparta shells are built for the consumer who wants a shell that is made to practically last forever. That’s why we offer a shell warranty that exceeds all others in the industry.

A checklist found on no other spa

Specialized Acrylic Forming: Custom designed screens for each model assure a controlled thickness that enhances shell construction and minimizes failure. State of the art machinery with unique infra red technology adapts to each color eliminates color variation.

Opaque Barrier Coat: A proprietary ThermoSpas mixture protects the shell from aggressive resin applications that prohibit color variation in the acrylic shell. This protects the understructure and enhances the outer surface.

Fiberglass Matting: Very high fiberglass content matting is placed along the coping and other hard to reach areas. This helps prevent air bubbles from forming that could lead to defects and provides added structural integrity in key areas.

Vinyl Ester Resin Coat: Costly high-styrene resin improves the bonding between the acrylic and laminate ten fold. This osmotic barrier coat is only used by a select number of spa manufactures and luxury yacht builders to help prevent blistering.

The Perfect Final Coat: Most manufactures utilize inexpensive fillers with less than 15% fiberglass content. Sparta shells are built with 33% fiberglass and a Green resin technology that has absolutely ZERO filler. The result is a product that offers high structural integrity and is good for the environment.

Consistent Quality and Dependability

Extensive testing has helped us determine the optimum weight of each shell. Underweight shells provide low structural integrity while overweight shells increase the risk of manufacturing flaws. A unique digital application program is used to monitor the weight, thickness and percentage content of the laminate on each shell. The result is that every Sparta shell is built with an unprecedented weight variance of less than 4% (compared to well over 20% by most competitors).


Specialized acrylic forming assures a consistent thickness	Multiple layers of unique laminate materials provide an impenetrable osmotic barrier	Each layer is hand rolled to eliminate trapped air pockets	Fiberglass matting and an opaque barrier coat add structural integrity	Computerized trimming guarantees a smooth, even finished edge on the completed Sparta spa.