Pool Production Process
Step 1: Mould Ready For Production
Each of our pools has a 5 digit number for quality control purposes enabling us to track them once they have left site. This label is waxed and leaves an indent in the pool shell once released off the mould.
Step 2: Gelcoating
Our Royal Blue gel-coat in the 8.5 Monaco is applied at 0.8mm to 1.0mm thick. Our 7.2m Monaco that’s gel-coated in Sandstone is applied at 0.8mm to 1.0mm.
Step 3: Tie-Laying With Vinyl Ester
1.5mm to 2.0mm of vinyl ester is applied.
Step 4: Skin, Re-inforcement & Lifting Hook Application
After the skin has been applied, the Divinycell/Klegecell stiffeners are applied to the skin as the resin is curing to ensure maximum adhesion. At this stage of the process, the lifting hooks are glassed in. These will be later used to release the pool from the mould. These will be glassed over again for additional strength.
Step 5: Re-inforcement & Additional Skin
A reinforcement layer is applied over the Divinycell/Klegecell. The stiffeners and hooks are re-glassed to provide extra strength. To release the air trapped in the glass, this is then rolled.
Step 6: Curing & Release From Mould
Once the pool shell is completed and cured, it will be released off the mould, detailed and trimmed. Brick ties are placed in the coping in the construction phase of your pool. This is so the pool can be tied to the concrete bond beam during the installation process.
This is the Monaco pool in 8.5m getting released off the mould using hooks that were glassed in the pool during the manufacturing process.
Step 7: Trimming, Final Inspection & Detailing
This is the 7.2m Monaco being supported on drums. It will be trimmed, detailed and go through a final quality control inspection. At this time, the skimmer box is cut, as will be the main drain hole.
We retain the skimmer box cut out which is filed along with the pool number, shape, size as well as all detailed production records. We can then refer back to these at a later date if need be.
Step 8: Finished Pool Ready For Delivery
This Monaco 7.2m is now ready for loading and delivery. Before leaving site, the truck driver will verify all details, ensuring that the right pool is going to the right home.