It is obvious that fibreglass pools are made from fibreglass… But how exactly are they made? Here at The Fibreglass Pool Company, we use only superior quality shells to build our pools. While there are many intricate steps involved in the production of a fibreglass pool, read on to give you a basic idea of how they are manufactured.
Firstly: Where are our fibreglass pool shells made?
There is an elaborate manufacturing plant in Beaudesert, Queensland where The Fibreglass Pool Company shells are constructed onsite. No expense has been spared in these state-of-the-art temperature-controlled plants. The plants can produce 26 shells a day. The site is massive, and not only houses the entire pool collection and equipment, it also has a warehouse dedicated to research and maintenance. This is where we ensure that our pool shells are unrivalled in quality. We are proud to be able to offer the highest quality fibreglass pool on the market to our customers.
Highlights of manufacturing a fibreglass pool shell:
Component 1: The pattern
There are 3 main components involved when constructing a fibreglass pool, and the very first thing is the pattern. The pattern is built from filler, primer, timber, and fibreglass, and will determine the size and design of the fibreglass pool. From the pattern, we then build the mould, and then we remove the mould and build the fibreglass shell on it. Pool builders will find it difficult to place the pool correctly if the shell that has not been built level, when it comes time to install your fibreglass pool. Time can be wasted if the shell has not been constructed evenly. This can result in as the pool having to be continuously lifted and replaced in attempt to get it correctly in place. However, if the pattern is made correctly, the shell will be to scale and the installation of the fibreglass pool is likely to be pretty simple. Reputable pool manufacturing companies use laser levels to avoid this from happening. Next after the pattern is finished, which is to create the mould.
Component 2: The mould
It is essential that your pool shell is built on a mould that is precisely level, otherwise your pool will not be level. A poor-quality mould will compromise the structure and quality of the pool shell drastically. The quality of a fibreglass shell is dependent on how well the mould has been created. If there are defects in the mould, there will also be defects in the fibreglass shell. All the pools and shells which we manufacture at The Fibreglass Pool Company have a 5-digit number which is unique to each shell. This will allow for them to be tracked once they have left the manufacturing plant. Each of our shells go through a very strict quality control process.
Component 3: The pool itself
Did you know that your fibreglass pool is made from the inside out, constructed from 7 layers, with each layer being hand laid or sprayed onto the mould.
The layers that make up the shell of the shell:
1st layer: Interior surface finish
This first layer is constructed onto the mould and is an Advanced Pool Colour Technology gelcoat. This makes up the interior surface of the pool it is applied on at 0.8mm to 1.0mm thick. This layer is UV and chemical resistant.
Wondering what colours your fibreglass pool can be? Click here to find out!
2nd Layer: Anti-Corrosion Barrier
This layer is the highest quality Vinyl Ester resin layer, providing excellent bonding to Advanced Pool Colour Technology as well as superior chemical and water resistance for the highest protection.
3rd layer: First structural and additional chemical resistant layer
Our third layer further increases the resistance to corrosion and strengthens the laminate. This Vinyl Ester resin It is an additional coating of high-quality resin that is combined with JUSHI E6-CR glass fibre, and is applied on at 1.5mm to 2.0 mm thick.
4th layer: Second structural layer and lifting hook application
Layer 4 has additional strengthening properties to add to the solidity of the structure of the pool. It consists of a layer of high-quality polyester resin combined with JUSHI E6-CR glass fibre. No filler is added, and the lifting hooks are put in place at this stage and are glassed in twice to ensure optimal strength. They are used to lift the shell out of the mould.
5th layer: Reinforcement layer
This is an additional layer of high-quality polyester resin with JUSHI E6-CR glass fibre with added strengthening properties. It is rolled to get rid of any air that may be trapped in the glass.
6th layer: Outer core laminate
This 6th layer product is a Klegecall/Divinycell sandwich core laminate and is commonly used on luxury yachts as well as F1 racing boats. Klegecell/Divinycell are world renowned and leaders in high performance sandwich core strengthening.
7th layer: Outer sealer coat
The last and final glossy layer used to construct the fibreglass shell is an outer sealer coat. The outer layer of the pool has a glossy finish coat that is made using high quality polyester resin to protect the interior layers of the pool.
Once all 7 layers of the pool are complete, the final steps involved before getting the pool installed include releasing it off the mould, once the pool has had adequate time to cure. The hooks that were glassed into the pool layers in the previous steps are used to remove it from the mould.
The pool shell is supported on drums as it is being detailed and trimmed. It is interesting to note that through the process, brick ties are placed to allow the pool to be tied into the concrete bond beam when it is being installed into the ground.
Then the skimmer box is cut into place and the main drain hole is put in. The detailed production records including the pool number, the size, and shape of the pool are all filed together for future reference if required. Then the shell will undergo its final quality control inspection.
The final step is when the fibreglass shell is loaded onto the truck for delivery, with all paperwork being checked prior to leaving the manufacturing plant, to make sure that the details are all correct.
Your pool will then arrive at your home, ready to be installed. We have a no-fuss installation process, and most pools can take as little as seven days to be completed, compared to concrete rendered or pebbled pools which can take three to six months to complete. We hope that this article has given you an overview of the construction process involved with building our fibreglass pools.
The Fibreglass Pool Company is a member of the Barrier Reef Pools Team, and our fibreglass pools boast a lifetime structural warranty. If you are considering a fibreglass pool for your place or if you have any questions, give our friendly team here at The Fibreglass Pool Company a call today.
