Maui Carolina Pools & Spas

Part 5:  Shell removed from the mold and sanded and buffed

Finally, our pool shell is nearing completion.  Once the shell is constructed and each layer of the surface has been added, the pool shell can be removed from the mold.  With machinery, the shell lifts straight up off of the mold and is stored on site, ready for delivery.  After each shell is removed from the mold, prior to delivery, workers at the manufacturing plant walk around the shell searching for any blemishes.  If any are found, they are sanded and buffed out, so by the time the pool shell arrives in your backyard, it is in pristine condition.  Pictures below are of the shell being removed from the mold and stored, workers removing any blemishes from the pool shell in the construction process, storage of completed pool shells at the Tallman property just south of Atlanta, and a pool shell loaded and ready for delivery.  Will the next pool shell to leave the lot be coming to your home?

Step 4 - Applying the black sealer coat

The pool shell is now nearing completion.  The gel coat has been applied and layers of the fiberglass woven cloth has been applied, layer on top layer on the high traffic areas of the pool, sealed in with the vinyl ester resin.  Last, added to the pool shell is a special sealer coat.  This black sealer adds a final layer of protection against any possible moisture penetration entering the structure of the pool shell from the outside.  Picture below is of a pool shell after having a fresh coat of the black sealer applied …

Step 3 - Strengthening the Stress Points

In addition to the standard layering of the fiberglass cloth that is added throughout the entire pool shell, additional layers of the special material are added on the stress points throughout the pool.  Extra cut pieces of the glass fabric are added to the step areas, as well as to coping areas and any benches, seats, or swim-outs along any of the pool shells.  These extra layers ensure added strength and sturdiness along points of the pool where one would walk or sit.  Pictures below are of the actual material being cut, as well as the fiberglass cloth being applied to the stress points, with the vinyl ester …

Step 2 - Adding the vinyl ester and woven fabric

Once the gel coat has been applied, multiple layers of vinyl ester and woven glass fabric are added to give the pool shell the waterproof barrier and extra stability and durability.  The vinyl ester resins used by Tallman Pools are extremely resistant to even the strongest chemicals.  Not one, but two layers of the 24 oz. glass cloth are added across the perimeter of the pool shell.  This extra layer of fabric, uncommon amongst most fiberglass pool shell manufacturers, gives this particular brand of fiberglass pool shell added reinforcement and the utmost structural integrity.  Pictures below are of the glass fabric being hand-laid across the pool shell and the vinyl ester resins being shot along the perimeter of the pool …

In another installment of our “How It’s Done” series, we will show you how a fiberglass pool shell is actually constructed.  We are the Charlotte area dealer for Custom Fiberglass Pools (aka Tallman Pools).  Their office and plant are located in Jonesboro, Georgia, just south of Atlanta.  On site, they build all of the fiberglass pool shells that have been delivered and installed, and could be installed in your backyard.  Over the next series of posts, we will show you step by step how a fiberglass pool shell is built, and the quality with which Tallman uses in their construction.  With their brand of pool shells, you can feel confident that you are getting one of the most well-built, sturdiest pool shells in the industry …

Step 1 - Applying the gel coat finish

Each pool shell that is offered has a mold.  The first step to constructing a new pool shell is to apply the gel coat finish - this can either be in the Pearl White finish or the Diamond Tech color finish.  As seen in the pictures below, with a spray gun, the gel coat finish is being applied to the mold to create the first layer.  36 mils of coating are applied in this step, giving an extremely sturdy base of gel coat …

Beat the Heat.  Contact us today and have your swimming pool in the ground, full of water, and ready to jump in by the time these temperatures arrive!!  It’s better to plan for your pool purchase in the winter and early Spring months so there will be no swimming delay or shortened swim season when the 90’s and 100’s come back.

The pictures in this post are of the 14x32 “Freeform” San Lucas model.  The San Lucas has the Freeform shape, with its many twists and turns as well as three separate bench seating areas at three corners of the pool shell, in addition to ample seating around the step entryway.  This particular pool, completed in the Summer of 2012 in the Mooresville/Lake Norman area is in the Pearl White finish, which is the standard finish, at no extra charge.  Once the water is in the pool, and the sun’s rays interact with the chemicals in the water, the water appears blue.  This particular install has a ring of tile around the top perimeter.  In addition, the homeowner chose a stamp concrete finish for the decking.  This pool deck has the cantilever edging and is nearly 1500 feet in size.  Also visible is a beautiful tiered-wall system and waterfall at the back of the pool. 

Happy 2013 from Maui Carolina Pools & Spas.  Let this be the year that you finally add that fiberglass swimming pool to your backyard.  A few tips as you plan on purchasing your pool …

- Plan ahead and do your research, but try not to wait until the middle of the summer to move forward.  We always encourage people to make their decisions in the winter and spring months to ensure a full year of swimming. 

- Stay tuned to this site for constant updates and how-to’s and pictures of our recent installations.  We should add a few posts per month throughout the year of various items such as “helpful tips,” different pictures of pool models, existing and new, and basic information on the installation process.

- Check www.custom-fiberglasspools.com for detailed information about Custom Fiberglass Pools, our fiberglass pool shell manufacturer

Thanks again for checking in.  Please do not hesitate to call if you have any questions or if you would like to schedule a free in-home consultation.  Let this be the year you add a swimming pool to your backyard!!

Danny 704-361-5144

Nick 704-231-5729

mauicarolina@yahoo.com

When we quote a pool for you, we include up to three LED pool lights, placed at different points across the pool.  15 ft. wide pools and under use two lights, while 16 ft wide pools and above use three lights.  Made by Fiberstars, the Treo LED light will light up your pool with various colors, giving it a very nice feature at a very affordable price.  Extensive information about the product can be found at the website below …

http://www.fiberstarspoolandspa.com/treo-led-underwater-light/

Pictures from a recent install with a couple of different colors, changing in sequence are below (pictured is the 15x29 Hampton, in the Pacific Blue) …

** Note, pictures are taken just after dusk, so the lights are not as bright as possible, and not all colors are pictured …

Multi-Color:

Pink/Magenta:

Green:

Blue:

This Christmas season, why not consider a swimming pool for your family?  Call and ask us about our off-season pricing, saving thousands off of spring/summer pricing!  Sign a contract this month and your pool can be complete and you can be swimming when warm weather returns in the Spring!