Renovating commercial pools with reinforced PVC

by arslan_ahmed | March 30, 2023 6:00 am

By Matthew Sands

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As commercial aquatic facilities re-open after closures caused by the pandemic, managers and operators might have found themselves confronted with peeling, cracking, or leaking pools. A viable solution to these chronic problems is to line these commercial pools with reinforced polyvinyl chloride (PVC), as it is an ideal interior finish for pools and a complete waterproofing solution.

While price must always be taken into consideration, most facility managers and operators find reinforced PVC to be affordable over the long term. When considering this option, it is important for facility managers to consider the costs of refinishing or repairing their pools, compared to the cost of installing reinforced PVC. This finish does not require any maintenance year over year, and it can also solve underlying issues with a pool’s structure when the interior is encapsulated with reinforced PVC, as it can provide a complete watertight structure throughout the pool.

It is important for aquatic facility managers to understand that reinforced PVC is a pool interior that completely seals the structure of the pool and keeps it watertight, making it suitable for renovating existing pools and building new pools. Unlike concrete, reinforced PVC is not susceptible to deterioration from acidic water conditions. As many aquatic facility owners are aware, concrete pool interiors deteriorate over time due to the porous nature of the concrete. The acidity of pool water degrades concrete and requires painting and recoating of the surface to ensure the pool remains fully waterproof.

Commercial-grade reinforced PVC offers a long-term solution because it is not only thick and non-porous but also coated with a protective lacquer that resists chemical abuse, water absorption, and ultraviolet (UV) deterioration.

Once the reinforced PVC is installed, the surface underneath the pool can continue to shift and crack, but it will not affect the pool interior itself. Further, in many cases, this reinforced PVC pool interior often comes with a longer warranty than other pool interior options. In many cases, not only does the reinforced PVC interior pool finish help to solve a problem for an aquatic facility, but it can also make pool maintenance easier than a traditional concrete interior.

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Practical with less maintenance

Reinforced PVC is a practical solution for pool interiors because it can be applied over most existing pool shells to renovate deteriorated pools or to quickly provide an interior finish for new pools. In fact, the installation of reinforced PVC can even be done over cold joints in concrete and is not susceptible to freeze-thaw cycles. In addition, this pool interior finish stabilizes the pool structure by preventing future water infiltrations. The reinforced PVC is also easily combined with gutter-system and PVC decking to create a seamless, watertight solution for the entire pool area.

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Thanks to the product’s longevity, aquatic facilities can break the maintenance cycle of repainting and replastering pool interiors which is costly and time consuming, not to mention having to close the pool to drain, dry, replaster, repaint, and wait for the pool to dry before reopening. Many facilities do nothing to maintain the reinforced PVC interior and only some aquatic facility managers and/or operators choose to pressure wash the reinforced PVC to clean the surface after a busy season. There is basically no other maintenance required to preserve the longevity of this interior finish for pools and, since it is offered in both 60 and 80 mil thicknesses, reinforced PVC also provides a long-lasting waterproofing solution that is attractive and virtually maintenance-free.

This interior finish for pools can also offer another, more immediate benefit; rather than dealing with long lead times for pre-manufactured products, weld-in-place reinforced PVC materials are readily available. Installers can, therefore, overcome lead times by stocking material for upcoming services. Weld-in-place reinforced PVC can provide an exact fit for custom pools, even for the most challenging shapes, because they are installed on-site.

Understanding the installation process

The installation process is relatively straightforward. Before lining the pool with the reinforced PVC, crews must first prepare the surface, which can include repairs. Most pools require a day or less for preparation. However, if a pool is in particularly bad shape, a professional might need to spend three to four days patching the pool, fixing returns, etc.

Once the pool surface is prepared, a felt lining is installed along the floor and walls of the pool structure. This material, also referred to as geotextile, acts as an antibacterial agent to avoid bacteria proliferation behind the reinforced PVC and extends the life of the product.

After the geotextile is installed, the reinforced PVC pool interior is rolled out in either 1.5- or 1.8-m (5- or 6-ft) wide lengths which are then heat-welded together on-site to ensure a smooth fit. Steps, beach entries, safety ledges, and other elements are cut, fitted, and welded as well.

Reinforced PVC is also available with slip-resistant, embossed surfaces, which are generally used on steps, in shallow areas, and beach entries. Black material is also available to create racing lanes, transitions, and depth markers as needed.

Colour and texture options

Reinforced PVC also comes in new visually pleasing textures—giving pools a completely renovated look. These transformative textures can give bathers the experience of standing in a gunite pool, but are softer on the feet. The cushioned feeling makes them more comfortable to stand on. This is particularly beneficial for bathers using the pool for water conditioning, therapy, or aerobic purposes.

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Traditionally, the material colours of reinforced PVC were limited primarily to white and blue, with the use of black for racing lanes and transitions. However, there are now many new colours with subtle patterns and textures to imitate the look of gunite, slate, marble, and sand.

Additionally, this reinforced PVC pool interior also comes in slip-resistant finishes. There are now a wide range of colours available for aquatic facilities to choose from, many of which comply with the light reflectance value (LRV) safety requirement which is a standard for many public pools. LRV is a measurement of the amount of light reflected by a colour and may be used to determine the suitability of a pool basin colour. As a result, aquatic facilities now have more options when using reinforced PVC other than just plain white or light blue for the pool’s interior.

In terms of textures, there are different reinforced PVC options with extra texture to provide slip-resistance in aquatic facilities. The most common texture is known as a category “C” slip-resistance rating. A few manufacturers provide slip-resistant reinforced PVC that complies with several standards. Aquatic consultants and facility managers should check with the compliance ratings which should include:

(a) DCOF (dynamic co-efficient of friction) > 0.42 compliant with test method ANSI A137.1-2017.

(b) C-class rating compliant with test method DIN 51097:1992 // EN 1345-1; with a result of slip-resistance with barefoot test at > 24-degree angle.

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(c) 3-class rating compliant with UNE 41901:2017 EX; with a result of slip-resistance with pendulum test at a >45-degree angle.

Reinforced PVC now comes in various textures and prints, making it popular for use in pools at hotels, country clubs, homeowner’s associations, and community aquatic centres because it offers a more luxury appeal by going beyond the plain white or blue, while enhancing safety through the slip-resistance offered by its varying textures.

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Reinforced PVC for pool decks

The use of concrete, stamped concrete, wood, and flagstone have traditionally been the primary choices for surrounding pool and spa decks. However, like pool interiors, once these surfaces become worn and cracked, renovation is required.

Aquatic facilities can now look at reinforced PVC to renovate decks, as it provides a long-lasting waterproof solution that does not require recoating and comes with far less maintenance than traditional decking solutions. Reinforced PVC also offers safety benefits to aquatic facilities, as it is ideal for renovating decks experiencing cracking, flaking, delamination, and peeling.

In some cases, the decks around pools can be the most dangerous part of any pool. Older, cracked, or peeling decks can lead to injuries due to slippery surfaces. Some cracks can even cut bathers’ feet. Reinforced PVC encapsulates the deck, making the area slip-resistant and waterproof.

Welding techniques in installation

A major benefit of the weld-in-place liner is its ability to be fabricated on-site. This allows the greatest degree of customization, and can help with current supply chain issues, as it removes a step from the manufacturing process. To ensure proper fit, durability, and watertightness, installers use three different welding techniques in different parts of the installation process. The two basic techniques—spot welding and traditional overlap welding—are used by all contractors and achieve a watertight liner. Installers looking for a superior esthetic also use the “butt-welding” technique along the pool floor to make the welds virtually invisible. Spot welding This technique is used at the beginning of installation to help position and secure the reinforced PVC, ensuring it does not move through the rest of the process. Small, quick “pre-welds” are made between the overlapping reinforced PVC layers at intervals of around 117 to 203 mm (7 to 8 in.) down the seam. Even though this is what is known as a “tack weld,” the pieces must be aligned, and the reinforced PVC cannot move. Overlap welding The reinforced PVC layers overlap by approximately 50 mm (2 in.), and this overlap will ultimately turn into a 50 mm (2 in.) wide seam. Once the reinforced PVC is held in place with the spot welds, installers begin to apply the welding gun down the full length of the seam. They insert the welding nozzle under the overlap and heat both surfaces sufficiently to fuse the layers and form a lap. While the lap is still hot, they use a silicone roller to apply enough pressure to ensure the two reinforced PVC layers are pressed and fused together. For larger pools, robot welders are used to automate and speed up the process. Once the automatic welder is set up, it will continue welding for the entire length of the pool. Butt welding This technique is compatible only with 70 and 80 mil reinforced PVC pool interiors, and is generally used in more visible areas of the pool or deck where a seam would be easily detected, such as the horizontal pool floor. To do this, installers butt the reinforced PVC edges against one another, rather than overlapping them. When this technique is used, viewers cannot see the joints where the reinforced PVC meets on the floor. This particularly makes a difference at night when the water is illuminated by in-pool lighting. In the daytime, when the water is moving, the traditional overlap welding is not apparent. This technique is not required by any means, though it achieves absolute flatness with virtually invisible joints by day and night. Since it takes more time and will add to installation costs, it is only recommended for floor areas. Some installers stick with the overlap weld here as well.

 

For example, if the deck is not properly waterproofed, the water left by swimmers exiting the pool, by splashes, or due to cleaning processes, can penetrate the floor and infiltrate the substrate, causing future maintenance issues to the structure. This risk is frequently underestimated by construction companies. Often, after the first few months, the result is to have water in the deck that does not drain properly. Over time, in addition to making it less appealing, this water will infiltrate the structure and deteriorate the pool. Using reinforced PVC to waterproof the entire deck avoids all this because it guarantees complete waterproofing of the deck. When combined with a compatible gutter system, it ensures a seamless waterproofing from the pool to the deck. Further, the slip-resistant PVC ensures all safety requirements in all areas of the wet-zone are met.

Unlike concrete decks, the reinforced PVC finish for pool and spa decks can be installed in almost any temperature. In fact, reinforced PVC eliminates the common cracking problems in concrete that occur with freeze-thaw weather. In addition, the installation of the PVC pool deck takes far less time than traditional decking materials. If installed over existing concrete, the installation requires the following steps:

1. Filling any cracks or holes in the surface.
2. Levelling and cleaning the surface.
3. Applying glue.
4. Applying an antimicrobial felt.
5. Laying down and welding together the reinforced PVC.

Aquatic facilities also benefit from the shorter installation time required, as reinforced PVC does not require waiting on ideal weather or the necessary time required for drying paint and concrete. The only downtime is if the surface requires levelling, in which case a levelling material is poured prior to the installation of the reinforced PVC. The installation time is similar to welding for the pool. For instance, a 6.1- x 6.1-m (20- x 20-ft) area can be lined and welded in a few hours when using a robotic welder.

Similar to the installation of reinforced PVC on pool interiors, reinforced PVC for pool decks is also rolled out and welded together on-site to ensure an accurate, smooth fit to the shape of the deck. The process does require some skill, but many suppliers provide on-site training and initial installation assistance to pool professionals who are just getting started. Once trained, reinforced PVC can be installed year-round on indoor pools and even in cooler climates, such as late fall and early spring.

Reinforced PVC on the rise

The awareness of reinforced PVC for pool interiors and pool decks is definitely on the rise, especially among commercial aquatics facilities. In fact, many architects and aquatic consultants are now starting to require the use of reinforced PVC in high-rises or anywhere the waterproofing of the pool must be guaranteed. In general, it is becoming more common for facility managers to approach their trusted pool professional to provide a reinforced PVC solution after performing their own research. As a result, pool professionals are finding it even easier to suggest, sell, and install reinforced PVC as a pool interior or as a way to renovate a pool deck on commercial pools and other aquatic facilities.

Author

Matthew Sands is a sales engineer for Renolit, a manufacturer of plastics-based construction products, and weld-in-place, reinforced PVC systems for swimming pools and decks, with U.S. headquarters in LaPorte, Ind. He has more than a decade of experience in the construction renovation sector of the company.

Source URL: https://www.poolspamarketing.com/trade/features/renovating-commercial-pools-with-reinforced-pvc/

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