Undercover Systems® produces and manufactures the materials used for our deck ceiling systems. Our state-of-the-art facility services all Undercover Systems® dealerships nationwide. Homeowners and contractors can have complete confidence in the quality and consistency of the material they are getting as stringent quality controls are enforced at each stage of the fabrication process. Undercover Systems® has invested heavily in our computerized and automated fabrication process, ensuring you get a consistently beautiful, clean, and finished under deck ceiling every time.
How We Manufacture Our Patented Under Deck System
Our under deck ceiling system, which includes the under deck ceiling panels and the gutters for the under deck drainage, go through a 6-step manufacturing process. From loading the steel underdecking rolls to the finished product, here's a step-by-step process of how we manufacture our patented under deck system.
STEP 1:
Loading - Prepainted Steel rolls are loaded onto the machinery to start the manufacturing process
STEP 2:
Leveling – the material is precision-leveled using a sophisticated machine that removes all factory imperfections, leaving it perfectly flat.
STEP 3:
Cutting – 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. Very little material waste occurs at an UnderCover Systems® install because each panel is specifically cut to the dimensions of your deck.
STEP 4:
Forming – after the steel is cut, it is moved onto the forming area. 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″ of solid ice. The reliability of our Precision Roll Former guarantees the exact dimensions of each panel, leaving the length as the only variable.
STEP 5:
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, which includes anything like ice or debris that may sit on the panels for a period of time. Because of this, we spared no expense in purchasing a computerized forming machine that shapes the gutters to our exact specifications. Each gutter is custom-cut for each job-specific length, minimizing waste.
STEP 6:
Finished Product – After production, the ceiling panels and gutters are wrapped in protective coating and packaged for shipping to UnderCover Systems® dealerships across the United States.
Material Quality
Built from 22-Gauge Galvanized Steel
Every UnderCover System starts with 22-gauge hot-dipped galvanized steel, selected for strength, durability, and long-term performance beneath a deck. Unlike lightweight aluminum products, our steel system is designed for the moisture, runoff, and structural demands of an under deck ceiling application.
