Construction Process Guidelines
Overview
The installation of an in ground gunite pool or spa is a major construction process. It will be helpful if you know and understand the several steps that are necessary to complete the job. It is also helpful for you to know that there will be days when we will not be at the job site. In some instances we will be waiting for concrete to cure, or awaiting the delivery of material or the completion of an inspection. There may well be instances when weather will inhibit our ability to work, or we may have to address other projects that are concurrently in process. Please be assured that our desire is to complete your project as rapidly as possible and we will do all we can to facilitate that goal. While it usually takes over a month to complete a basic project, the time is well invested. The finished project will be unparalleled in quality and appearance.
In most instances the construction sequence is as follows:
· Contract and Deposit
· Permit
· Site inspection
· Layout
· Dig
· Steel & Plumbing
· Bonding inspection
· Gunite – Gunite Payment due
· Tile
· Coping
· Deck - Tile & Deck Payment due
· Electrical hook-up & Equipment - Pre Plaster Payment due
· Plaster and Fill
· Start-up - Final Payment due
The Process
The real process begins when your design consultant first meets with you to learn of your hopes and dreams regarding the pool you envisioned in your backyard. When you have signed a contract with us, that original design has been refined so that it currently includes permit drawings, a dig drawing, a CareTaker and plumbing schematic, and construction specifications. With that in hand, we are ready to go to work.
Permit: Design Pool & Spa, Ltd. will secure all permits and inspections required by your local building department so that your project can proceed in compliance with their codes and requirements. If there are any issues that might hinder this process, they will be brought to your attention immediately so that together we might navigate any problems and move on with construction.
Site Inspection: Before we can begin, it is necessary for us to contact Dig Safely New York who will visit your site to determine that no utility lines intersect the area to be excavated. Once this is complete, we can proceed.
Layout: When we are ready to begin the actual construction of your pool/spa we will outline the project in your yard using spray paint, and will establish the elevation of the pool/spa using a transit. To be sure we have honored your expectations and desires we will request that you inspect the layout and sign a form indicating that the location and elevations meet with your approval. We will also want to document any particular directions regarding the removal or relocation of the dirt. At this time we will need to acquire any signed releases from neighbors if access affects adjoining properties.
Dig: Once we have your signed approval, we will proceed with digging your project. Most projects can be dug in a day or so. Our excavator will arrive with the equipment appropriate for your job, and will make every effort to disturb as little of your property as possible. A reality we must live with, however, is that most excavation equipment is large, heavy, and always has some impact on your terrain. We must also move or remove a significant quantity of dirt. This often means that large trucks must traverse your property or driveway numerous times. While we will do all we can to minimize damage and can do some minor repair; we have not incorporated overall repair costs in your contract. In most instances, customers rely on their landscaper to bring things back to normal once the entire project is complete.
During the dig it will be helpful if you can keep children, visitors and pets away from the construction site. The presence of moving equipment, the possibility of wall collapse, and the frequent arrival and departure of large trucks make the area unsafe for non essential personnel. Your assistance in this regard will be greatly appreciated. After the dig, we will surround the entire dig area with orange construction fence that will serve as a safety barrier. Naturally this fence must not be removed.
Steel & Plumbing: Once the hole is dug, our “rough crew” will be working rapidly to move through the next several construction steps. It usually takes them a week or so to complete this phase and we are proud to convey that these guys really know their job, and perform it well. They must work rather rapidly at this point too, because an empty hole is vulnerable to collapse or erosion. This is often made more critical by any bad weather. It is therefore our aim to move to the gunite phase a quickly as we can, without compromising the vital work now required. During this phase gravel will be placed in the bottom of the excavation and rough plumbing will be installed. This plumbing includes the lines to support the CareTaker System, the Skimmer and main drains and feed and return lines that eventually will be connected to the pump and filter. For this process we use only rigid, schedule 40 PVC. Some companies use flex PVC because doing so may allow a more rapid installation. We feel strongly that doing so compromises quality however, and we just won’t risk that. It is our belief that you would prefer we take a bit more time and do it right. There is also electrical conduit to service the light niche, and any possible control systems to be installed. At this point we also install the steel skeleton that will support the gunite. As your contract specifies, the steel incorporates #3 steel rebar that is tied in place 12” on centers. The #3 means that each strand of rebar measures 3/8ths of an inch in diameter. As you can see, this is a substantial and vital process that requires a skilled and experienced crew. The steel will also be electrically bonded to assure safety. A bonding inspection is the last step in this stage of construction. Once complete the pool is ready to be gunited.
Gunite: This is when your project really starts to look like a pool/spa. It is good to note that your second payment is due upon completion of this step. Guniting can usually be completed in a day and you might want to arrange your schedule so that you can witness at least part of this impressive operation. We certainly invite you to do so. On the appropriate day, our regular rough crew will arrive, along with our compressor truck which is closely followed by concrete trucks that will be bringing the dry concrete mix to be used. You will notice two hoses that run from the compressor truck to the “gun” held by the man designated to do the shooting. The larger of these hoses carries the dry mix, and the smaller hose carries water. The gunman mixes these two elements as it leaves the gun giving him great control over the hydration. This also means that the chemical process that begins when water meets cement is uniformly controlled. Coupled with the intense pressure with which it is applied, the result is a density and consistency of concrete that is unsurpassed.
The morning after your pool/spa has been gunited, we ask that you begin spraying down the gunite two or three times daily. This process is known as curing and is extremely important. During very hot weather, more wetting may be helpful. Don’t be concerned about water gathering in the deep end of the pool as we’ll pump it out when necessary. When your gunite payment has been received, we can proceed to schedule your tile and deck work.
Once the pool has been formed in gunite, you will not have a very good idea of just what the finished project is going to look like. Consequently, this is the appropriate time to evaluate the functionality of the proposed pool deck and surrounding area. Additional decking or walkways can be installed for the per square foot price stipulated on your contract. Any additional cost so accrued can be added to your Tile and Deck payment which is the next payment and will be due when we arrive to pour the deck. Planning for any additional deck now will allow you to plan for an additional cost and will allow our crews to plan for additional construction. If the decking is to be of paving stones or some other treatment being installed by another contractor, they too will appreciate having some advance notice of changes.
Tile: We install your waterline and possible accent tile. The tile is set carefully using a transit to be sure it is precisely placed. You will notice that the tile sits above the gunite surface of the pool. This is as it should be because the final plaster finish is yet to be applied, and in fact, will be the final step of the entire project.
Coping: Coping is an optional treatment installed when cantilever deck is not being used. If your pool design calls for such a treatment, it will most likely be set in place at this point. There are a number of types of coping and the type selected will determine just who will be installing it. Some methods of coping a pool require a significant investment of time.
Deck: It is all beginning to look quite attractive by now, and we are entering the last stages of construction. If we are installing concrete deck for you, the forms will be set in place at this point. In some instances the decking will be of pavers or other substances to be installed by private contractors with whom you have made special arrangements. If this is the case their work should be done now so that the final stages of construction are not delayed.
Equipment & Electrical: The pump, filter, chlorinator, heater and any other equipment may now be placed at the previously prepared pad. An electrician will run the line from your panel box to the equipment location. Final connections for electrical service and connections to gas service can now take place. An electrical inspection must take place before the pool can be used and this will be scheduled and completed.
Plaster: The final step is the plastering. If your pool is to receive White Pearl Marcite, the process will most likely be completed in one day. If your pool is to be finished in a PebbleTec® surface, the process is much more involved and will probably require two days. The plaster must cure under water, so once applied we will begin to fill the pool immediately. In most instances this is done by simply flowing water into the pool through a hose. It is important that the flow of water never cease to prevent a dirt ring from forming. While you will hardly be able to see the level of water rising, this constantly changing depth is absolutely necessary. The plaster can only cure properly when under water. While it cures, however, it is very vulnerable to damage. Please be aware that it is vital that no one enter the pool or disturb the plaster in any way for at least 24 hours after the pool is completely filled. It is best if no major landscape work is done in proximity to the pool for at least a week after the plaster has been applied.
Start-up: We have finally arrived! We will be providing you with an owner’s manual that will aid you in maintaining your pool properly. We will also need to schedule a time so that we can directly instruct you in chemical applications and equipment usage. It will also be helpful for you to remember that your final payment is due upon start-up of your pool/spa. While there may be details that will require our further attention, once the pool is functional and being used, any delay in this final payment could void warranties as specified in the contract. We assure you that we are very proud of our work and won’t leave any job in less than proper form.
We hope that the construction of your pool/spa project proves to be as interesting and enjoyable an experience as possible. Perhaps knowing the procedure in advance will be helpful in that regard. When approaching such an endeavor it is always good to remember how complex and involved it all is. Throughout this formidable job, we are pleased to offer you our very best effort and our very highest level of expertise. Coupled with the finest in material and equipment, this allows us to assure you that the completed product will be a pool/spa that you can, and will, be very proud to own.