Using reusable aluminum forms
Vinyl-liner pools built with poured concrete walls have a long history of success in the northeast and southeast areas of the U.S. and are now becoming more popular in Canada. Initially, the forms were built from steel, wood, or fibreglass, but these were costly, hard to maintain, and heavy. In contrast, today’s aluminum forming systems are not only lighter and easier to maintain, but also come in a variety of shapes and sizes, which allows builders to create geometric and freeform shapes, a number of different pool step styles (e.g. in-pool, corner, full end [often called stadium steps]), benches, tanning ledges, raised walls, attached spillover spas, vanishing edges, automatic cover boxes, and beach entries. Builders can place every feature at once during one pour.
In addition to using a forming system to build vinyl-lined pools, they can also be used to construct all-concrete pools. They can even be stacked to create raised walls for water features and raised deck areas around the pool. They are quite versatile as builders can even use them to pour retaining walls, as well as basement or other type of support wall.
Aluminum forming systems comprise an inside and outside panel form held together by wall ties that are inspected to yield a minimum pull strength of 3175 kg (7000 lbs). The ties are also notched for easy rebar placement. The forms fit together fast and easy using a pin-and-wedge system. These features keep labour costs to a minimum during the setting and stripping stages. Once the forms, plumbing, and structural steel are in place, a special design mix of 27,579 kPa (4000 psi) concrete with specified chemical add mixtures that produces stronger, faster setting and easier workable and flowable mix is used to create a 254-mm (10-in.) thick wall.
Typically, aluminum forming systems are 1219 mm (48 in.) in height and, when using the wall’s depth-pouring gauges, builders can pour either a 1067-mm (42-in.) or 1219-mm (48-in.) wall. The system does not require any footings and is set up directly on the ground. Before pouring concrete into the aluminum forms, a very light coat of release agent needs to be sprayed onto the surface. After allowing the concrete to cure for 12 hours, the forms are stripped, leaving builders with 254-mm (10-in.) thick reinforced pool walls. The walls are then finished just like any other pool wall system along with the vermiculite or concrete-grout floor.
After the forms are stripped, they can be cleaned and readied for the next project.
Once a builder buys a set of aluminum forms, they become the manufacturer of their pools and are no longer dependent on other material suppliers to determine when they can start building their projects. Additionally, builders can also eliminate any material shipment delays and paying expensive freight costs. In fact, the cost of a concrete aluminum forming system becomes less expensive after every pool installation. Further, with proper care, a forming system can last well over 3500 pours.
Comparing costs
When comparing the price of using an aluminum forming system versus a traditional vinyl-liner pool kit system, many builders see savings because of the efficiency of the construction process as every part of the pool is made of concrete.
“If the excavation goes well, the project will go well,” says Greg Butler, the owner of Bubba’s Pools & Tubs in Mount Pearl, Nfld., who has been using aluminum forms to construct pool projects for more than six years. “Concrete is reliable and readily available, and the savings is not only a result of the reliability, but also the simplicity.”
According to Butler, his company’s cost per pool installation are lower because he does not have to worry about lost income due to shipping delays, missing pieces, or damaged freight (e.g. dented steel panels).
“We no longer do crazy things like go to a local steel shop to get a panel repaired,” says Butler. “We are in a fairly isolated market and any delay on a pool project really used to disrupt our building schedule, which is extremely short in Newfoundland.”
Budd adds his company’s per-pool profit has increased since they started building concrete wall vinyl-lined pools.
“The reason is two-fold,” says Budd. “We are able to charge more for our unique designs and our freight and labour costs are also lower per pool.”
