The Fabrication Process

BodyWorx Fitness Equipment begins its production process by choosing 11 gauge square American Made steel that has been hand selected by our engineers and delivered for use at our production site located in New Albany, MS (between Memphis and Tupelo off HWY 78). Using our exclusive plans  the steel is processed, cleaned and readied for production. All parts are then cut to size, bent on a steel bending machine, drilled, angled and cleaned again before being put on designated shelving by part number. The fabricator will then pull the appropriate parts from the shelves and start the assembly process on our specially designed fabrication tables with built in templates to assure repeatability and quality. All pieces when assembled will then be readied for  the next step the Powder Coating  process. Before going through this process the machine will go through its first full inspection to assure all quality codes have been met before Powder Coating.

The Powder Coating Process

The Powder Coating Process employed on BodyWorx Fitness Circuit Training Equipment is more extensive and thorough than any other Hydraulic Fitness Manufacturer. The process consists of many stages,  to assure the best coverage and quality available, at the proper thickness required, in order to achieve the durability needed to handled in the commercial fitness industry. The process begins by hanging our equipment on a Rapid I-Beam conveyor system which is set at slow travel speeds and will take each part on a 2 hour ride to complete its journey.

Phase one is the cleaning process a simple sounding stage which is very critical in the final look and durability of the finish of your equipment. Improperly cleaning can leave your product open to the possibility of chipping and cracking in the future.  The cleaning is a 5 stage process which removes all debris, chemicals and oils which may interfere wuth getting a proper coat on the steel. Starting with an alkaline cleaner which is heated up to 140 degrees it proceeds to a rinse and is treated with a multi-metal iron phosphate, followed by a second rinse and finally a sealer. The pieces at this time have achieved cleanliness and continue along the conveyor system to the first drying oven which has a temperature of 450 degrees to insure against any moisture remaining after cleaning.

Now that the cleaning and drying stages have been completed the circuits are ready to proceed to the environmentally controlled 7,500 CFM spray booth for coverage. The booth is equipped with two guns for applications from both sides of the booth to assure a smooth even finish. The application is manufactured by Wagner Powder Systems and has a CyMod collection system. Every surface of your product is thoroughly and evenly coated while releasing virtually no volatile organic compounds into the air. This Powder Coating process meets all F.D.A approval standards and disposal methods for powder coating is the same, in most states, as non-hazardous waste. No fumes, no harsh chemical sprays and no harmful chemical emissions, just a beautiful baked on finish.

The Curing and Cooling Process

Now that all the pieces have been fully coated with the fine powder used in the coating process, leaving it in a matte finish state, the equipment continues down the line and on to the next oven used for the curing process. The temperature in these ovens are also set at 450 degrees in order to promote the gelling of the powder into a strong, flawless coat covering the surface and enveloping your equipment with a safe scratch resistant, and environmentally friendly finish. The product has a long slow journey through the ovens and then continues down the line for cooling purposes and to be visually inspected for the 5th and last time before being removed from the line. The machines are now a shiny, (unless a matte finish was pre-selected)crisp, smooth and visually appealing coating upon leaving the ovens. The final stage after curing, cooling and being removed from the line is a check of each piece to assure the desired thickness has been achieved, and that each piece has been evenly coated. This is achieved through a special electronic tool which gives a read out of the coatings personality. Finally the equipment is ready for the final process the assembly and readying for shipping.

Final Assembly

Final stages include the assembly of all moving parts, upholstering of equipment and attachment of the hydraulic cylinder. Upholstery choices are sewn or stapled per customers choice, both have their own advantages. If custom embroidery is requested, depending upon your choice of upholstery  this is the stage for logo application. Every piece goes through a rigorous  final inspection and all hydraulics are tested for performance before being loaded for shipment. All equipment is blanket covered for shipment to insure the integrity of our coating. Upon delivery the equipment can be placed on your floor and with a simple adjustment of the cylinders you are ready to workout.  No gimmicks, just high quality equipment built to last.  Enjoy the comfort, ease of use and stability everyone deserves in a workout, and should demand. .