HOW UNDERCOVER SYSTEMS ARE MANUFACTURED

Under deck ceilings are produced and manufactured to order at our state-of-the-art facility in Georgia.  Homeowners and contractors alike can have complete confidence in the quality and consistency of the material that goes into their under deck ceiling, as stringent quality controls are enforced at every stage of the fabrication process. We have invested heavily in a computerized and automated production process, ensuring the consistent beauty, cleanliness and finished look that USI’s under deck ceilings have come to stand for.

Step One:
Preparation – Pre-painted steel rolls are loaded into the machinery to start the manufacturing process.

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Step Two:
Leveling – The steel is precision leveled using a sophisticated machine that removes all factory imperfections from the material, rendering the sheets perfectly flat.

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Step Three:
Cutting – Next, the material is fed into a Cut-To-Length machine that measures the ceiling panel length needed and cuts the panel to the desired dimension. Every panel is specifically cut to the dimensions of your deck in an effort to minimize the material waste at USI.

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Step Four:
Forming – After the steel is cut, it is transferred to the forming station. Here, a precision roll former is used to shape the ceiling panels into our patented design, giving the panels enough engineered strength to support up to 12 inches of solid ice. The reliability of our precision roll former guarantees the dimensions of each panel is exact with the length being the only variable.

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Step Five:
Gutters – Our engineered gutters are the most critical component to the success of our entire ceiling system since they support the weight of the ceiling panels above, along with ice and debris that may rest on the panels for a period of time. USI spared no expense in purchasing a computerized forming machine that shapes the gutters to our exact specifications. Gutters, like the panels, are cut to job specific lengths so very little waste is incurred.

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Step Six:
Finishing – After production, the ceiling panels and gutters are wrapped in a protective coating and packaged for shipping to USI dealerships across the country to be installed under your second story deck or your waterproof pergola.

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