|Publication number||US3748810 A|
|Publication date||Jul 31, 1973|
|Filing date||Mar 24, 1971|
|Priority date||Mar 24, 1971|
|Publication number||US 3748810 A, US 3748810A, US-A-3748810, US3748810 A, US3748810A|
|Original Assignee||Mattingly Inc|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (6), Referenced by (27), Classifications (13)|
|External Links: USPTO, USPTO Assignment, Espacenet|
United States Patent 1 Mattingly  3,748,810 [451 July 31,1973
[75 1 Inventor: Charles D. Mattingly, Wichita, Kans.
 Assignee: Mattingly, Inc., Wichita, Kans.
 Filed: Mar. 24, 1971  Appl. No.: 127,709
Related US. Application Data  Division of Ser. No. 792,047, Jan. 17, 1969.
 US. Cl. 52/742, 52/169  Int. Cl E04h 3/16  Field of Search 264/31, 32, 35;
 References Cited UNITED STATES PATENTS 3,521,304 7/1970 Ghiz 4/172.16 2,873,505 2/1959 Sheldon 2,910,759 11/1959 Lifter 3,059,243 10/1962 Ross... 3,247,968 4/1966 Miller 3,355,897 12/1967 Mullen 264/32 METHOD OF SWIMMING POOL MANUFACTURE I Primary Examiner-John E. Murtagh Attorney-Phillip A. Rein ABSTRACT cifically, this invention is a method of constructing a swimming pool utilizing cooperating form structures whereupon a pool can be built in a minimum amount of time without skilled labor, in a variety of design variations, and using a plurality of pre-constructed engineered elements achieving a maximum of uniform and durability therefrom.
8 Claims, 19 Drawing Figures PATENTEDJULM I975 3 748,810
SHEET 1 [IF 4 IiET-Z IN VIiNfOR. CHAR; 55 [2 I144 TT/NGL Y METHOD OF SWIMMING POOL MANUFACTURE This application is a divisional application of the applicants parent application entitled Structure and Method of Swimming Pool Manufacture, filed Jan. 17, 1969, U.S. Pat. No. 3,610,546, with the identical inventor as to this application.
In the prior art method of constructing swimming pools, it is common to use conventional plywood or metal forms and these are fairly suitable for flat surfaces but not desirable for producing smooth, nongrainy finishes on exposed contoured concrete surfaces which is achieved through the form structures of this invention. The prior art form structures are generally bulky to handle and must be of a heavy grade steel if the same is to achieve and end product swimming pool wall or the like not having waving portions therein. The prior art methods of constructing a swimming pool are generally limited to the economically feasible rectangular contours and shapes to be achieved therefrom and require the use of extensive skilled labor in order to achieve an acceptable end product. In the prior art methods of swimming pool construction, the same is achieved through the use of conventional rectangular form structures whereupon a great portion of the forming work has to be done by hand and, likewise, the reinforcing, plumbing, electrical, filtering system, skimmer structures, and draining structures are conventionally hand formed requiring numerous types of skilled labor being tedious and time consuming. Also, the prior art structure and method of swimming pool construction is not operable to continually form the bottom, side wall, step portions, coping area, and the upper deck area in substantially one continuous pour to form a rigid, uniform structure therefrom.
In one preferred embodiment of the various elements needed to construct the swimming pool of this invention, the construction means includes inside form structures, outside form structures, cooperating step form structures, a skimmer structure, a drainage assembly, a plumbing assembly, an electrical assembly, and prefonned reinforcing assemblies. The outside, inside, and step form structures are constructed of laminated lightweight, extremely durable foam and fiberglass combination, each having latch or hook assemblies adjacent their upright edges for interconnecting to adjacent ones thereof. Additionally, the respective pairs of inside, outside, and step form structures are interconnected by ty-cone assemblies and support straps to provide the required vertical spacing and strength to receive freshly poured cement therebetween. The skimmer structure is constructed of an integral non-corrosive fiberglass and resin material having a main upright support body with an integral outwardly extended ventura throat section to receive fluid therethrough over a weir assembly. The drainage assembly includes a main drainage member mountable within the lowest portion of the swimming pool to receive fluid thereto for return to the pool pump and filtering system. The drainage member includes a generally cylindrical main housing having a drainage outlet at one side thereof and a hydrostatic relief tube mounted in a bottom wall to be opened and closed by a cap member. The plumbing assembly includes a pump member of the filtering system interconnected as by a plurality of pipe members to the drainage assembly, variable discharge outlets into the swimming pool area, a vacuum return line, and to the skimmer. structure to receive fluid therefrom as controlled through various valve members. The electrical assembly includes a motor member operably connected through a switch member to the pump member and to a light element mounted within the deep end of the swimming pool structure. The preformed reinforcing assembly includes main side wall reinforcing assemblies and bottom wall reinforcing assemblies to be interconnected to the lower portions of the side wall reinforcing assemblies. It is to be noted that the pre-formed reinforcing assemblies can be constructed of heavy guage reinforcing rods secured together as by welding so as to be easily movable and placed in position between the inside, outside, and step form structures during construction and the same can be pre-constructed during the off-season or winter months.
In a preferred method of constructing a swimming pool of this invention, the steps are generally as follows: (1) excavate a large area in which the swimming pool is to be constructed and hand contouring the bottom shape of the excavation; (2) add fill sand and rock to the bottom surface of the excavation to obtain the desired design depth; (3) set up a plurality of outside forms in adjacent relationship to each other and join together by latch and hook assemblies; (4) attach lift jacks to the outside forms so as to receive an accurate vertical adjustment thereof; (5) fill in area adjacent the lower outside edge of adjusted outside forms to assure that the concrete material to be poured therein will not flow outwardly therefrom; (6) lubricate the inner surface of the outside forms to be in contact with the concrete material; (7) install vacuum, return line, inlets, main suction line, and skimmer lines; (8) install drainage assembly in proper location having the hydrostatic relief tube therein opened; (9) position preconstructed reinforcing side wall assemblies connecting to the outside form structures in the proper spaced relationship; (10) install bottom wall reinforcing steel and tie all connections to the upright side wall reinforcing steel members having the same spaced approximately 3 inches above the bottom surface of the pool; (1 l) install electrical grounding and conduits to proper plumbing and power area and to swimming pool light areas; (12) install skimmer structure in proper corner location, support on reinforcing members, and attach to the fluid return line; (13) assemble inside form structures, interconnect through latch and hook assemblies, and attach to inside form structures through the use of ty-cone assemblies and support straps; (l4) pour selected test weight concrete with proper slump between inside and outside wall forms while continuously vibrating the same to cause concrete to move out the bottom of the inside form structures; (l5) pour the bottom completely covering pool bottom trowling hard and smooth to form the bottom wall; (16) after proper time interval, pour concrete filling the walls between the in- .side and outside form structures and vibrating the same, leaving approximately one inch of the deck and coping nose clear of concrete; (l7) pour top deck and coping through the use of sand and white portland cement and allow the same and wall concrete to cure before continuing; (18) remove inside form structures; (19) finish inside interior by acid washing surface with muratic acid solution and grout the ty-cone holes; (20) install pool light, fluid inlet fittings, wash down and clean the pool, apply interior paint; (2l secure plug in hydrostatic relief tube and start filling pool after the interior paint finish has set 24 hours; (22) remove outside form structures, remove ty-cone elements, and grout same; (23) install pool equipment being filter tank, pump, and/or heater, light conduits, utility connections, etc.; (24) using sand or a similar mixture, back fill area between swimming pool structure and that of the excavation; (25) install diving board, ladders, etc.; and (26) if required, pour extention of deck area about the outer periphery of swimming pool structure. It is to be noted that the various steps in the method of constructing the swimming pool of this invention are easily done through the use of the pre-engineered steps by those unskilled in the art requiring a minimum amount of supervision.
One object of this invention is to provide a structure and method of swimming pool manufacture overcoming the aforementioned disadvantages of the prior art structures and methods.
One other object of this invention is to provide a plurality of pre-constructed elements necessary to build a swimming pool structure which can be readily assembled and interconnected with a minimum amount of time and effort requiring only the necessary concrete to be poured between spaced, upright form members to achieve the end resultant swimming pool structure.
Still, one further object of this invention is to provide a method of constructing a swimming pool through the use of light-weight, durable, interconnectable form structures to produce a complete swimming pool having the needed electrical, plumbing, and reinforcing structures placed therein requiring a minimum amount of skilled labor.
Another object of this invention is to provide a method of constructing a swimming pool through the use of inside, outside and step form structures plus preconstructed drainage assembly, plumbing assembly, skimmer structure, electrical assembly, and reinforcing assembly readily available to be readily placed in the desired relationship so that the entire swimming pool structure can be achieved through one continuous concrete pour.
A further object of this invention is to provide a method of constructing a swimming pool structure which requires a minimum amount of time to efficiently and effectively construct a pool of the ultimate size and design and pre-engineered so as to be readily constructed through simple instructions.
Various other objects, advantages, and features of the invention will become apparent to those skilled in the art from the following discussion, taken in conmunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of a swimming pool structure of this invention;
FIG. 2 is a sectional view taken along line 2-2 in FIG. 1;
FIG. 3 is a sectional view taken along line 33 in FIG. 1;
FIG. 4 is a fragmentary elevational view illustrating the interconnected inside and outside forms used in the construction of the swimming pool structure of this invention;
FIG. 5 is a fragmentary front elevational view of the inside form structures of this invention;
FIG. 6 is an enlarged sectional view taken along line ,66 in FIG. 5;
FIG. 7 is a fragmentary elevational sectional view illustrating the cooperating step form structures of this invention;
FIG. 8 and FIG. 9 illustrate various steps in intercom necting and assembly of the inside and outside form structures of this invention;
FIGS. 10, 11, and 12 illustrate various steps in constructing the swimming pool structure of this invention through the use of the inside and outside form structures;
FIG. 13 is an upper fragmentary sectional view of the special connector sleeves used with the inside and outside form structures of this invention;
FIG. 14 is a fragmentary sectional view of the drainage area of the swimming pool structure of this invention;
FIG. 15 illustrates a sectional view of a corner skimmer structure area of this invention;
FIG. 16 illustrates the use of connector sleeves to add an additional deck area to the swimming pool structure of this invention;
FIG. 17 is a fragmentary upper sectional view illustrating the completed extended deck area to the swimming pool structure of this invention;
FIG. 18 is a schematic diagram of the hydraulic system of the swimming pool structure of this invention; and
FIG. 19 is an electrical schematic showing the operation of the motor and lighting system of the swimming pool structure of this invention.
The following is a discussion and description of preferred specific embodiments of the new structure and method of swimming pool manufacture of this invention, such being made with reference to the drawings, whereupon the same reference numerals are used to indicate the same or similar parts and/or structure. It is to be understood that such discussion and description is not to unduly limit the scope of the invention.
Referring to FIG. 1, a swimming pool structure, indicated generally at 12, is manufactured by the method and elements of this invention. The swimming pool structure 12 can be readily constructed in various sizes and shapes but the ultimate design is believed to be that as shown having an irregular contour and formed of varying depth with steps at the shallow end for ease of entrance thereto. More particularly, the swimming pool structure includes end walls 14 and side walls 16 and 18 integral with a common sloping bottom wall 20, the lowermost point leading to a drainage assembly 22. The side wall 16 is formed with an outwardly projected central section 23 so as to be appealing to the eye whereas the other side wall 18 is substantially perpendicular to one end wall 14 but having the other end formed with a contoured entrance section 25 having a plurality of step members 26 leading from the upper edge therein into the shallow end of the swimming pool structure 12. The upper edges of the end walls 14 and side walls 16 and 18 are formed with a laterally extended coping and deck area 28 of substantially uniform widthand integral rigid construction. There are a plurality of water outlets spaced about the inner walls of the swimming pool structure 12 to provide the utmost efficiency in water filtering. Additionally, the coping and deck area 28 is joined at its innermost portion by a plurality of tile members 30 to the end walls 14 and side walls 16 and 18 whereupon it is seen that the water level is normally kept at this height for return through a skimmer structure 32 and provides for ease of cleansing of the water or scum line formed on the tile members 30;
Generally, the swimming pool structure 12 is sufficiently well engineered in thickness, size, and shape so that all possible conditions that can occur such as water pressure, ground pressure, freezing pressures, varying temperatures, shifting ground, use and maintenance, or any other possible hazards cannot harm or cause problems to the pool structure. The swimming pool structure 12 is shaped and styled to make the same very enjoyable and practical to use and view and is designed for maximum efficiency in water fiow and water volume in order to insure the minimum need for maintenance. As will be explained, the method of constructing the swimming pool structure 12 of this invention is such that maintains total uniformity at all times regardless as to where the pool may be constructed, ground contour, soil consistency, and load requirements so that same may be constructed requiring little skill to preengineered design specifications.
In the manufacture of the swimming pool structure 12 of this invention, various devices are used so that the entire construction process is mainly an assembly of pre-engineered and pro-formed elements with the elements being substantially as follows:
1. outside form structure 33 to be placed within an excavation area in which the pool is to be constructed;
2. inside form structures 35 to be connected to the outside form structures 33 through the use of ty-cone assemblies 36 and support straps 38;
3. inside and outside step form structures 41 and 43 to construct the step members 26 of the swimming pool structure 12;
4. the skimmer structure 32 to be placed in one corner adjacent the upper edge of and between the inside and outside form structures 35 and 33;
5. pre-formed reinforcing assembly 45 tobe connected to the ty-cone assemblies 36 and placed in position in a proper relationship between the inside and outside form structures 36 and 35, respectively;
6. the drainage assembly 22 being the primary fluid return source;
7. a plumbing assembly 47 to interconnect various retum lines 49 and 51 to a pump and filtering system 53; and
8. an electrical assembly 55 including a light shell forming device 56 and other electrical elements to control operation of the pump and filtering system 53.
The inside and outside form structures 35 and 33 plus the respective step form structures 41 and 43 are constructed as set forth in the applicants co-pending patent application entitled FORM STRUCTURE filed Sept. 9, 1968, Ser. No. 758,255. The FORM STRUC- TURE as set forth in the co-pending application produces a sturdy, lightweight structure which can be readily carried and maneuvered by one and not more than two persons, the same being economical to manufacture and substantially maintenance free. More par ticularly, each of the form structures 33, 35, 41, and 43 are connected to adjacent ones thereof as by latch and hook assemblies 58 at spaced intervals to achieve rigid interconnected structures. Each form structure includes a main body 60 constructed of vinyl form core material indicated at 61; a contact form wall assembly 63; an outside form wall assembly 65; and upright joint members 66 secured to upright exposed edges of the main body 60. The details of the main body 60; the contact form wall assembly 63; the outside form wall assembly 65; and other such elements are set forth in the applicant's aformentioned co-pending patent application and further discussion thereof is not deemed necessary. The inside form structures 35 are formed with laterally extended block sections 69 to achieve recessed areas in the pool structure to receive the tile members 30. The step form structure 41 is provided with a plurality of holes 64 in the upper surface to permit escape of air during the concrete pouring operation on forming the step members 26.
The pre-formed reinforcing assembly 45 includes bottom wall reinforcing assemblies 67 and side wall reinforcing assemblies 68 which are constructed so as to be easily placed in the proper central location between the inside form structures 35 and the outside form structures 33. More particularly, the side wall reinforcing assemblies 68 are provided with a plurality of contoured reinforcing bars 70 interconnected as by a plurality of parallel lateral reinforcing rods 71 which are preferrably welded thereto. The upper and lower portions of the side wall reinforcing assemblies 68 are contoured so as to provided the required spacing of the inside form structures 35 and the outside form structures 33 to achieve the desired rigidity in the final structure.
The bottom wall reinforcing assemblies 67 are provided with a plurality of transversely interconnected support bars 72 to form the contour of the bottom wall 20 of the swimming pool structure 12. Additionally, each of the bottom wall reinforcing assemblies 67 are secured to the lower edges of the adjacent side wall reinforcing assemblies 68 as by welding, ty-members or the like. It is seen that the normal time consuming and tedious problem of properly placing reinforcing within a concrete wall structure is easily accomplished through the pro-formed reinforcing assemblies of this invention so that the same merely has to be placed and secured together during the assembly process in any easy, fast manner. It is noted that the construction of the reinforcing can be achieved during the winter months and other such slow periods and stored so that the most efficiency can be made of the swimming pool construction period.
The skimmer structure 32 includes a cylindrical, support body section 73 having an entrance lid 74 mounted thereon; a fluid inlet section 75 extended laterally from and integral with the support body section 73 having a weir device 77 mounted therein; and a discharge and basket support assembly 78 having a basket member 80 mounted therein and a discharge assembly 81 for return of fluid to the filtering and pump system 53. It is deemed that the detailed description and function of the skimmer structure 32 of this invention is not necessary as such information can be found in the applicants co-pending application, Ser. No. 759,619, filed Sept. I3, 1968, and entitled SKIMMER STRUC- TURE." It is noted that an outer ve'ntura throat section 83 of the skimmer structure 32 is placed so as to be horizontally aligned with the tile members 30 about the upper edge of the swimming pool structure 12. Also, the skimmer structure 32 is of a molded fiberglass material preferably provided with a gel polyester resin coat of a color to match the tile members 30.
As best shown in FIG. 14, the drainage assembly 22 includes a main cylindrical housing member 84 provided with an upper, laterally extended, flange section 85 to receive a lid member 87 thereon. The housing member 84 is formed with an upright side wall 88 and integral bottom wall 89 with an opening 91 in the side wall to be connected to the return line 49 to the pumping and filtering system 53. The bottom wall 89 is provided with an opening 93 having a hydrostatic relief tube 94 securely mounted therein. The hydrostatic relief tube 94 is a cylindrical structure having internal threads at an upper portion thereof to receive a sealing cap 96 therein and with the lower portion provided with a plurality of holes 97. The hydrostatic relief tube 94 is necessary whenever a swimming pool structure 12 is being constructed or left without water therein as the same will float if the water level of the ground rises sufficiently above the lowermost drainage area. The hydrostatic relief tube 94 has the lower end preferrably placed within loose gravel so that any water under the swimming pool structure 12 will enter through the hydrostatic relief tube 94 to fill the pool and keep the same from floatation. The lid member 87 is preferrably constructed of a non-corrosive material such as stainless steel and provided with a plurality of holes 99 therein. It is obvious that the lid member 87 is operable to keep undesirable debris such as leaves, toys, etc. from entering the return line 49 to the pump and filtering system 53.
The plumbing assembly 47 includes a plurality of pipe members to be supported by the reinforcing assembly 45 and having fluid inlets 97 spaced about the pool in predetermined locations to achieve the desired fluid circulation. The return fluid to the pump and filtering system 53 is derived from the drainage assembly 22 and/or the skimmer structure 32 and discharged from an output side of a pump member 98 through fluid discharge lines 101 to the swimming pool structure 12.
As seen in FIG. 18, the pump and filtering system 53 has the output pressure from the pump member 98 operable through lines 104 and 105 and control valves 106 and 107 to upper and lower sides of a filtering tank 109, respectively. The output from the'filtering tank 109 can be directed from lines 110 and 111 through control valves 112 and 114 and, thereupon, commonly connected to control valves 116 and 117. From here, the fluid is selectively directed to a fluid line 118 which is the waste or discharge side or through the fluid return lines 101. The pump and filtering system 53 of this invention operates in a substantially conventional manher with the plurality of the control valves operable to selectively send water through the upper or lower portions of the filtering tank 109 and alternately through the waste line 118 or back to the pool as such is common procedure during the filtering and the back washing cycles, respectively.
The electrical assembly 55 includes a motor member 120 connected in a conventional manner to the pump member 98 to drive the same. As shown in FIG. 19, the power source is provided through lines 121 and 123 and through a switch 124 and a line 126 to the motor member 120. The line 121 is additionally connected through a second switch member 127 and line 123 to a light member 128 mounted within the light shell device 56 of this invention. It is noted that the second switch member 127 is operable to close the circuit and energize the light member areas within the swimming pool structure 12 as desired. The light member 128 and the motor member 120 are grounded in a conventional manner to assure the utmost in safety in case of shorting or other such failures.
In the assembly of the aforementioned elements used to construct the swimming pool structure 12 of this invention, it is seen that the inside form structures 33 are secured to the outside form structures 35 through a plurality of the ty-cone assemblies 36. Similarly, the step form structures 41 and 43 are interconnected by ty-cone assemblies 36 and to the adjacent inside and outside form structures 35 and 33 through the hook and latch assemblies 58. Each ty-cone assembly 36 is provided with outer threaded ends to receive a bolt member 129 therein to positively space the formsto achieve the desired thickness of the end product. Additionally, the upper and middle rows of the ty-cone assemblies 36 of adjacent form structures 33 and 35 are interconnected by the support straps 38. This operates, after arriving at a proper height of the outside form structures 33, to automatically achieve the desired vertical position of the inside form structures 35 through the use of the support straps 38. It is seen that the reinforcing assemblies 67 and 68 are interconnected in the desired spaced relationship between the inside and outside form structures 35 and 33, and, additionally, above the lower surface of the excavation. The step form structures 41 and 43 are similarly interconnected and placed in proper location as shown in FIG. 7. The skimmer structure 32 is placed within one or more comers of the swimming pool structure 12 and secured in a proper relationship to the reinforcing assembly 45 as by wire straps so as to have its upper surface substantially flush with the deck area 28 to be formed. The drainage assembly 22 is positioned in the proper location within the bottom wall 20 of the swimming pool structure 12 and connected to the fluid return line 51. The plumbing assembly 47 with all the pipe members are connected to a common mid-point along, for example, the side wall 18 of the swimming pool structure 12. It is obvious that the required filtering tank 109, pump member 98, motor member 120, and the like can be positioned at a remote location as desired to control the filtering and cleansing of fluid within the swimming pool structure 12. It is seen that the various elements needed to construct the swimming pool structure 12 are in position whereupon one need only have the fresh concrete material poured between the form structures 33, 35, and 43 and, upon hardening of the same, touch up and finishing plus adding the tile members 30 provides the ultimate design in swimming pools as illustrated in FIG. 1.
The method of constructing the swimming pool of this invention provides a list of easy to follow steps along pre-engineered design specifications to achieve a low cost, easy to maintain, efficient and neat appearing swimming pool structure.
First, a given area indicated at 132 is excavated to the proper length and width dimensions to receive the completed swimming pool structure 12 and is actually over excavated in regards to length and width so as to have room for construction and attachment of the form structures 33, 35, 41 and 43 as will become obvious. A bottom surface 134 of the excavation 132 is additionally contoured so as to achieve the final desired shape of the pool strcuture 12. In fact, a fill of sand and/or rock is spread over the bottom surface 134 to obtain the desired depth and height relationship with an additional area of fill rock placed at the lowermost portion thereof to receive the drainage assembly 22 for reasons to become obvious.
Secondly, the outside form structures 33 and outside step form structures 43 are interconnected as through the adjacent latch and hook assemblies 58 whereupon the joint edges 66 are interlocked and, with the upper arcuate contour of the form structures 33 and 43, a rigidly interconnected structure is achieved. Lift jacks 135 are attached to the lower outside portion of the outside form structures 33 and operable to raise and lower the same to achieve a proper overall even height of the interconnected outside form structures 33 and step form structures 43.
The lift jacks 135 are provided with an angle iron support base 136 having a large load bearing surface and an attachment hook 140 secured to an elevating mechanism 141. The attachment hooks 140 having a large vertical bearing area 144 to assure vertical stability of the outside form structures 33 and 43. The support base 136 is provided with holes to anchor the same in a given position by reinforcing rods for lateral stability. It is seen that the outside form structures 33 provide the main starting or focal point in constructing the swimming pool structure 12 as the same must be held at a proper height which is most critical as can be understood when fluid is finally added to the pool.
Third, the ty-cone assemblies 36 are attached to the outside form structures 33 in theproper spaced holes and the aligning and support straps 38 are secured to the uppermost ones of the ty-cone assemblies 36. Additionally, as shown in FIG. 13, plastic sleeve members 137 are attached by lag bolts 138 to the upper portion of the outside form structures 33 if there is to be an additional deck extension added thereto which will be explained in detail.
Next, the area adjacent the lower edges of the outside form structure 33 are covered with dirt or sand in order to stop any outward flow of the concrete material during the pouring process to be explained. The adjusted position of the outside form structures 33 are leveled to within l/8 inch tolerance by the use of a transit so that the exact leveling and tolerance requirements of the bottom surface 134 of the excavation 132 can be achieved.
Then, a lubricant is placed on the inside surface of the outside form structures 33 and 43 to facilitate removing of the same on hardening of the concrete material thereagainst.
Next, the plumbing assembly 47 is attached to the tycone assemblies whereupon the vacuum and skimmer line 49 is connected to the skimmer structure 32 and the inlet lines 101 and drainage return line 51 are placed in the proper position relative to the outside form structures 33.
Next, the reinforcing steel assembly 45 is attached with the side wall reinforcing assemblies 68 positioned carefully so as to be in the proper space relationship whereupon portions of the reinforcing assemblies rest upon the ty-cone assemblies 36 to maintain the proper height relationship. Additionally, the undersurface of the upper portion of the side wall reinforcing assemblies 68 contact the upper surface of plastic sleeves 137 to provide additional support and the desired spacing. The bottom wall assemblies 67 are thereupon placed adjacent to the bottom surface 134 of the excavation 132 and tied together as by welding or the like. The interconnected bottom wall reinforcing assembly 67 is raised approximately 3 inches and placed upon concrete blocks to maintain this proper spacing. After achieving the proper overall height of the bottom wall reinforcing assemblies 67, the same is tied by the welding or the like onto the side wall reinforcing assemblies 68 to provide one, integral, overall conforming'pattem of reinforcing steel which is not only desirable but necessary to achieve the required strength and durability of the swimming pool structure 12.
Next, the electrical light forming shell 56 is placed in the proper position with a conduit 139 extended upwardly. The required electrical grounding wires are connected to the light forming shell 56 as required for safety code reasons and the same is ready for required local inspection.
In the next step, the inside form structures 35 and inside step form structures 41 are given an oil coating on the contacting inner surfaces to aid in removing after solidification of the concrete material thereagainst. The inside fonn structures 35 and 41 are interconnected by the latch and hook assemblies 58 and aligned and connected through bolt members 129 to the respective attachment means or ty-cone assemblies 36. It is seen that the support straps 38 are secured to the central ty-cone assemblies 36 to provide the required height of the inside form structures 35 relative to the previously accurately positioned outside form structures 33.
The skimmer structure 32 is now mounted within one or more corners in the deep end area connected to the return line 49 and secured as by ty-members to adjacent portions of the reinforcing steel assembly 45 so as to have its upper surface flush with the venturi throat section 83 of the skimmer structure 32 is placed firmly against the adjacent inside form structure 35 so as to be properly positioned in the final end product and horizont'ally aligned with the tile members 30 to be added.
It is obvious that certain life line anchor form structures and ladder anchor form structures can be placed about the upper surface of the inside form structures 35 so as to achieve the proper anchor holes and connecting means in the final product.
The drainage assembly 22 is now positioned in the lowermost portion of the excavation 132 so that its upper surface will be substantially level with the bottom wall 20 of the finished swimming pool structure 12. Also the hydrostatic relief tube 94 extends downwardly 1 a substantial distance within the fill rock having its sealing cap 96 removed to prevent flotation of the pool during construction.
In starting to pour the swimming pool structure 12 using concrete material preferrably of a 3,000 to 4,000 pound test rock with 4 inch slump, we first wet down the pool bottom and then pour the concrete material between the wall fonn structures 33, 43, 35, and 41 while continuously vibrating the same. to cause-the concrete material to extrude out the lower edges of the inside form structures 35 and 41. At this time, water is added cautiously to adjust the slump and when the slump is correct, the concrete will flow easily spreading outwardly over the bottom to a position three to four feet from the lowermost edge of the inside form structures 35 and 41. At this time, the first pour of the concrete material is vibrated enough to level the concrete material at about the top of the bottom row of the tycone assemblies 36 to assure that the complete area therebetween is filled with concrete without any air holes therein.
Next, the test rock concrete material is poured to completely cover the pool bottom with the same being troweled concurrently so as to be hard and smooth. Also, caution is to be taken on troweling the concrete material so as to insure trueness at mating area of the bottom wall and the lower edge of the inside form structures 35 and 41.
As soon as the first poured area in the lower portion of the inside and outside form structures 35, 41, 33 and 43 is set enough to support the wall concrete, the concrete material is then poured between the form structures in conjunction with vibration to completely fill the area above the lowermost ty-cone assembly 36 upwardly leaving approximately one inch clear of the upper deck and the coping area 28.
Next, we pour the upper top deck and coping area 28 with, preferrably, a 3,000 pound test concrete mix of sand and white portland cement so as to achieve a white finish. This upper, top deck and coping area 28 is troweled hard and smooth so as to eliminate any bubbles and then the upper surface is brushed to a fine textured finish. Joint marks are cut at the corner areas to achieve a neat appearing structure.
When hard, the top deck surface is sprayed with a curing compound and allowed at least 12 hours for the wall concrete to cure and harden before continuing.
After hardening of the concrete, the inside form structures 35 and 41 are detached by removing the bolts on respective ty-cone assemblies 36 and releasing the latch and hook assemblies 58. The concrete surface about the ty-cone assemblies 36 is ground to a smooth surface plus any uneven joints or high spots if formed, however, such defects will not be found in the method of this invention if followed accurately. This grinding operation is done immediately after removing the inside form structures 35 and 41 before the concrete material hardens in exposed atmosphere. Also, the exposed surfaces of the swimming pool structure 12 are kept sprayed with fluid such as water to remain damp for the proper curing thereof.
The inside surface of the swimming pool structure 12 is washed with an acid solution such as one part of muratic acid to four parts of water. This operates to etch and clean the surface to receive paint or the like thereon. Then, a proper grout mixture plugs the holes left by removing the ty-cone assemblies 36.
Next, the water line tile members 30 are grouted in place to achieve the neat appearing water line coloring which matches that of the skimmer structure 32. The inlet fittings to the water inlet lines 101 are installed and also the pool light 128 is mounted within the light forming shell 56 with its electrical connection extending upwardly through the conduit 139 to an external power source.
Finally, the'pool is washed down, cleaned, and an exterior finish, preferrably two coats of a white marble dust paint, is applied to the inner surfaces of the swimming pool structures 12. After the paint finish sets substantially 24 hours, the cap 96 is mounted over the hydrostatic relief tube 94 and the swimming pool structure 12 is filled from an external water source.
At this time, the outside form structures 35 and 41 can be detached on removing the other bolt member 129 from the ty-cone assemblies 36 whereupon the holes formed from such removal will be grouted to assure the utmost strength.
Finally, it is obvious that the filtering tank 109 with the pump member 98 and motor member can be interconnected to the proper fluid discharge and return lines and located in a separate filtering house, basement area, or the like. Additionally, a heater structure can be connected to the pump and filtering system 53 is desired for heating the water for extended pool usage. After having installed the plumbing and electrical conduit connections which may be placed in trenches if desired, it is obvious that a fill sand or similar material is used to level the area between the outside surface areas of the swimming pool structure 12 and that of the excavation 132 with caution being used on adding the sand and water with vibrations so as to prevent pool fiotation. In other words, if the pool is not filled, caution should be used to not present a floating situation.
Finally, it is obvious that a diving board, ladder, slide, dividing rope device, and the like can be secured to the swimming pool structure as desired.
As shown in FIGS. 13, 16, and 17, the deck and coping area 28 may be extended by the placement of deck reinforcing assemblies 143 having rod member 145 mounted with respective ones of the sleeves 137. This achieves a solid connection to the previously poured deck and coping area 28 to prevent separating and cracking due to normal settlement. This area is poured with a 3,500 pound test concrete mix of sand and white portland cement to achieve continuity with the deck and coping area 28. This reinforcing interconnection by the sleeves 137 and rod members 145 is extremely important to achieve a durable and long lasting pool structure 12 with the extended deck area.
It is seen that the various elements or special tooling needed to manufacture the swimming pool structure of this invention are constructed so as to be easily assembled in a most compact, accurate, and pre-engineered manner. The elements are operable to achieve a resultant swimming pool structure in the least amount of time with a minimum amount of skilled labor thereby reducing manufacturing and resultant customer cost. The method of constructing the swimming pool structure of this invention is such that the same is easily followed in a step to step process, preengineered so as to achieve the same with a minimum amount of labor and time while producing uniformity in the swimming pool structure which has been pre-engineered to provide the utmost in design utility, fluid flow and volume, shaped for efficient usage, and being of esthetic value..
The elements needed to construct the swimming pool structure of this invention has numerous items which can be pre-manufactured and engineered such as the skimmer structure; drainage assembly; the shapes, sizes and lengths of the various pipe members used for the fluid inlet and return lines; and the reinforcing assemblies whereby the same can be pre-constructed in the off season or winter months to minimize time required to construct the swimming pool structure .once the excavation has started. Also, the form structures of this invention provides lightweight but sturdy structures operable to provide the utmost in ultimate design plus being substantially maintenance free; relatively inexpensive; easy to use and handle; and achieving the desired contoured and smooth surface which is not possible through the use of conventional form structures. The method of this inventionoperates to set forth precise, simple, ,-easy to follow, I pre-engineered, predesigned, and tested steps of constructing a swimming pool, in the shortest, most economical manner.
Also, the swimming pool structure can be constructed in one continuous concrete pouring operation because, as each pouring step is completed, the previously poured concrete material has set sufficiently to permit continuation of the next concrete pouring step. The pool structure of this invention can be manufactured following this method within three days from start of the excavation which is very important in areas of limited pool construction season.
While the invention has been described in conjunction with preferred specific embodiments thereof it will be understood that this description is intended to illustrate and not to limit the scope of the invention which is defined by the following claims.
1. A method of constructing a swimming pool structure, the steps comprising:
a. preparing and contouring a surface to support the pool structure, said contoured surface to conform to the desired depth characteristic of the swimming pool structure, a
b. erecting and interconnecting a plurality of outside form structures on said surface to form the exterior shape of the pool structure, andupper sections of said outside form structures extended laterally to form the primary deck area of the pool structure,
c. securing attachment means to said outside form structures,
d. mounting a reinforcing assembly on said attachment means spaced a predetermined distance from said outside form structures, and elevating said reinforcing assembly above the support surface, to be positioned in the bottom wall of the final pool structure,
erecting and interconnecting a plurality inside form structures to each other and to said outside form structures by said attachment means whereby said reinforcing assembly is placed in a transverse vertical cross-section of the side wall in the pool structure to be formed,
. first pouring concrete material between said inside form structures and said outside form structures and having a proper slump so that a portion thereof extruded outwardly and inwardly of said inside form structures, and one g. before setting of said first concrete pour, continuing said first pour by secondly pouring the bottom of the pool structure between said inside form structures with the concrete material and finishing the same while filling the space between said inside and outside form structures with the concrete material to form an integral bond between the concrete of said first pour and said second pour whereby an integral rigid pool structure is created having the side walls, bottom wall, deck and coping area formed as one continuous unit.
2. The method of swimming pool construction as described in claim 1, wherein:
a. after erecting and interconnecting said outside form structures, assembling and securing a plumbing assembly to said attachment means and said reinforcing assembly to have return lines and drainage lines mounted between said outside form structures and said inside form structures and including a skimmer structure mounted in one comer thereof and a drainage assembly mounted in the lowermost portion of the pool structure being formed and having its upper surface level with the bottom wall to be formed.
3. The method of swimming pool construction as described in claim 1, wherein:
a. after erecting and interconnecting said outside form structures, leveling the upper surface of said outside form structures to a common plane utilizing jack means connected to said outside form structures, and
b. connecting support straps to said attachment means, said outside form structures, and said inside form structures, and said inside form structures are automatically positioned at the proper height location and lateral spacing from said outside form structures which have been properly leveled.
4. The method of swimming pool construction as described in claim 1, wherein:
a; after first pouring said concrete material, vibrating said concrete material continuously during the pouring process to assure escapement of air therefrom to achieve a smooth external finish of the swimming pool structure, and
said second pouring having a first portion of the bottom wall of the pool structure after said first pouring, and a second portion after sufficient setting of said first pouring to prevent further extrusion from said inside form structures to fill the area between said -inside form structures and said outside form structures.
5. The method of swimming pool construction, as described in claim 1, wherein:
a. said first and second pouring of said concrete material achieved by a first pour section of concrete material between said inside form structures and said outside form structures until the concrete material extrudes out the bottom edge of said inside form structures inwardly-from three to four feet, a second section pour wherein the concrete material covers the support surface and the same is troweled and smoothed carefully to a final surface, a third pour section whereupon the area between said inside form structures and said outside form structures is filled upwardly to an area spaced downwardly from the upper edges of said inside and outside form structures being the deck and coping area, and a fourth pour section wherein the additional area forming the deck and coping area is poured between said inside form structures and said outside form structures.
6. The method of swimming pool construction, as described in claim 5, including:
a. said fourth pour section of a concrete mixture of 55 v sand and white portland cement,
b. after all of said concrete material is hardened approximately 12 hours, removing said inside form structures,
60 c. grinding excess concrete material, any uneven joints, and areas where said attachment means was positioned,
d. cleansing the interior surface of the swimming pool structure with an acid solution,
e. applying an interior finish to the swimming pool structure,
f. filling the pool structure after the interior finish sets approximately 24 hours,
c. said interior finish being two coats of a white marble dust paint.
8. The method of swimming pool construction as dcscribed in claim 6, including:
a. after the grinding step, grouting all required areas,
and y b. setting and grouting tile members within recessed areas left by said inside form structures to form a water line.
i i i i
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|U.S. Classification||52/741.12, 52/169.7|
|International Classification||E04H4/12, E04H4/00, E04H4/14|
|Cooperative Classification||E04H4/0081, E04H4/148, E04H4/1272, E04H4/144|
|European Classification||E04H4/00D1, E04H4/14C, E04H4/12A6, E04H4/14M|