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How Are BERG Trampolines Made?

A Behind-the-Scenes Look at Quality, Safety & Innovation

For families across Ireland and around the world, BERG trampolines are a symbol of fun, safety, and premium quality. But few people realise just how much engineering, testing, and craftsmanship goes into each trampoline. If you've ever asked yourself, "How are BERG trampolines made?" — this article gives you a detailed, behind-the-scenes look at the materials, design philosophy, and manufacturing process that make BERG a standout in the industry.

🧠 The BERG Philosophy: Safe, Smart, and Sustainable

Before diving into the nuts and bolts, it's important to understand BERG’s core values. Based in the Netherlands, BERG Toys has been a leading manufacturer of outdoor play equipment for over 30 years. Their approach to design and manufacturing is based on three principles:

  1. Safety First: Products must exceed international safety standards.

  2. Built to Last: Materials are chosen for durability, weather resistance, and ease of maintenance.

  3. Environmentally Responsible: Wherever possible, components are recyclable, and production waste is minimised.

These principles guide everything from initial design sketches to final quality control checks.

✍️ 1. Design & Engineering: Where It All Begins

Every BERG trampoline starts life on a designer’s sketchpad. The product development team uses 3D CAD software to model prototypes, simulate bounce behaviour, and optimise the shape and spring placement for maximum safety and performance.

Key Decisions at the Design Stage:

  • Shape: Round (safest for central bounce), oval (efficient space use), or rectangular (optimal for gymnastics).

  • Size: Ranging from small garden trampolines to large professional models.

  • Bounce Performance: Spring configuration is fine-tuned to balance softness, height, and control.

  • Installation Type: Options include above-ground, InGround, and FlatGround variants.

BERG’s R&D process includes prototype testing in their on-site lab, where engineers analyse bounce height, impact absorption, and frame stability under thousands of simulated jumps.

🧱 2. Materials: Built for Strength and Weather Resistance

BERG trampolines are renowned for their long lifespan — some lasting 10+ years with minimal maintenance. That durability starts with their choice of materials.

a. Frame and Legs

  • Material: Heavy-duty galvanised steel

  • Treatment: Double galvanisation inside and out, followed by powder coating (on Champion and Elite models)

  • Benefit: Maximum rust resistance, strong load-bearing capacity, and structural integrity

b. Jumping Mat

  • Material: Polypropylene (PP) mesh, UV-resistant

  • Features: Open weave for air flow, reinforced stitching at spring loops

  • Benefit: High bounce responsiveness, safe landing, and resistance to sun and moisture damage

c. Springs

  • Standard: BERG GoldSpring Solo or TwinSpring (on Champion & Elite models)

  • Material: Zinc-coated steel

  • Shape: Long and tapered for smoother bounce curve

  • Benefit: Longer life span, reduced noise, and improved comfort when jumping

d. Safety Padding

  • Material: Closed-cell foam with PVC outer layer

  • Thickness: Up to 30mm on Elite models

  • Benefit: Shock absorption, UV resistance, weather durability

e. Safety Net

  • Mesh: Tear-resistant synthetic fibre

  • Poles: Galvanised steel with foam covers

  • Design: Self-closing entry with overlap or zipper

  • Benefit: Safe, durable enclosure with minimal visual obstruction

🔩 3. Manufacturing: Precision Production at Every Step

BERG's trampolines are assembled across several highly automated and quality-controlled production lines.

a. Frame Cutting & Welding

  • Tubes are cut to exact length using automated laser cutters.

  • Steel is bent and welded for connection points (e.g. leg braces, T-joints).

  • Welds are pressure-tested for strength and alignment.

b. Galvanisation & Coating

  • All steel parts undergo hot-dip galvanisation, then are treated with a powder coat (Champion and Elite ranges).

  • Galvanisation adds corrosion resistance and improves outdoor durability.

c. Mat Sewing & Spring Looping

  • High-speed sewing machines add 8-rows of stitching to attach spring loops.

  • Loop points are reinforced with additional webbing to prevent tearing under tension.

d. Padding Assembly

  • Foam inserts are precisely cut and inserted into UV-resistant PVC sleeves.

  • Padding is heat-sealed to avoid water ingress and mold formation.

e. Spring Manufacturing

  • Springs are coiled from zinc-coated wire and stretched to ensure proper tension.

  • Random sampling checks measure tensile strength and elasticity.

🧪 4. Safety Testing: BERG’s No-Compromise Policy

Every trampoline undergoes rigorous testing before it leaves the factory. BERG exceeds standard requirements set by European norms (EN71) and does additional in-house testing.

Tests Include:

  • Load Testing: Frames are subjected to over 500kg to ensure structural integrity.

  • Spring Fatigue: Simulates 500,000+ jumps to confirm long-term bounce performance.

  • UV and Rain Exposure: Materials are exposed to accelerated UV and moisture conditions.

  • Wind Simulation: Wind tunnel tests assess trampoline stability and anchoring effectiveness.

Trampolines that don’t meet these standards are reworked or scrapped — no compromises.

📦 5. Packaging & Shipping

Once passed through quality control, each trampoline is disassembled and packed for shipping:

  • Boxed in weather-resistant, double-layer cartons

  • Each component clearly labeled for easier installation

  • Minimal plastic usage in line with BERG’s eco policy

Orders destined for Ireland are shipped via regional logistics hubs, ensuring timely delivery through trusted retailers like Trampolines Ireland.

🔧 6. At-Home Assembly: Designed for DIY

BERG trampolines are engineered for easy home installation. With clearly labeled parts, step-by-step manuals, and online video guides, most families can assemble a trampoline in under 3–4 hours.

Assembly Tips:

  • Two adults are recommended for safe setup

  • Tools are included or common (spanners, rubber mallet)

  • Trampolines come with optional anchor kits to secure in Irish weather

🌿 7. Sustainability and the BERG Promise

Sustainability is a core BERG value. The company continues to invest in:

  • Recyclable materials in matting, foam, and frames

  • Eco-friendly paints and coatings

  • Energy-efficient factories and reduced carbon logistics

Additionally, BERG offers spare parts for most trampoline models, extending the lifespan of your product and reducing landfill waste.

🏆 Why BERG’s Manufacturing Process Matters

When you invest in a BERG trampoline, you’re not just buying garden play equipment — you're getting:

  • Decades of design experience

  • Dutch engineering excellence

  • Products built to last through Irish weather and childhood roughhousing

BERG’s manufacturing process prioritises not just bounce performance, but long-term value, safety, and visual appeal.

🔚 Final Thoughts: From Concept to Your Garden

From the first CAD model to the final box on your doorstep, every BERG trampoline represents a meticulous, thoughtful process. It’s this dedication to safety, quality, and durability that makes BERG a favourite among families, schools, and sports clubs across Ireland.

So next time your child is bouncing high into the sky with a huge smile on their face, you’ll know: it’s the result of world-class craftsmanship, tested thousands of times, and built to bring joy for years to come.

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