Easy Kit Basic - how to build a DIY pool with a filter backpack
1 - Layout
The first step in building a pool is choosing the right location. An area without plants or obstacles, no manholes or foundations, should be chosen.
It is necessary to find the reference square, which can be the house or the garden fence. Based on that, draw the excavation dimensions on the ground.
For example, in the case of a pool with a water mirror of 4.00 x 8.00 m, we will have an overall dimension of 4.50 x 8.50 m (the depth of the formwork is 25 cm), so we will make an excavation of 5.00 x 9.00 m (leaving another 25 cm to facilitate work and the necessary space for any recirculation pipes).
In the case of a pool with a water mirror of 5.00 x 9.00, we will make an excavation of 6.00 x 10.00 and so on…
Precise calculation will save money on excavation and slab, and we will also have less backfill and less settlement.
So, once the area and precise dimensions have been chosen, you can start tracing the pool itself on the ground.
What you need:
- pointed wooden stakes or iron rods;
- a rope;
- white powder (lime, plaster or cement);
- measuring tape;
- chalk line.
Once the four outermost stakes are fixed, we stretch the rope and effectively mark the pool excavation, distributing the white powder along the rope.
Then remove the rope and move the stakes outside the excavation to quickly bring back the pool measurements once the excavation is complete.
At this point, all that remains is to re-measure all sides and diagonals, which must be equal, to check the correctness of the dimensions and the squareness of the traced shape.
N.B.: if present, at this stage, it is also good to choose where to position the technical room.
A distance of 3 to 5 meters is recommended; the excavation must be about 10 cm deeper than the room itself. Therefore, also trace the overall dimensions for the excavation of the technical room.
2 - Excavation
Once the layout is complete, we proceed with the excavation using an excavator.
ATTENTION: the excavation must be at least 20/25 cm deeper than the planned depth for the pool, in anticipation of the creation of a 20/25 cm thick foundation slab (depending on the soil characteristics) reinforced with double mesh D.8/20”x20” placed on spacers of appropriate height.
Therefore, if our pool is to be 1.50m high, we will excavate to a total height of about 1.70 / 1.75m. A few more cm should also be considered for the support feet of the formwork (about 2 cm), for the lining profile (about 1.5 cm) and for the paving (1 or 2 cm thick), but we deliberately advise that the pool be a few cm higher than the ground level, so that rainwater drains towards the surrounding ground and not into the pool itself.
As a zero point, always consider the highest point near the pool.
NB: At this stage, if present, install the main drain at the correct height.
3 – Area preparation and slab pouring
Once the excavation is complete, we will re-trace the pool inside it. This is a very quick process, thanks to the previously positioned pegs. At this point, the laying of the double-layer electro-welded mesh can proceed. This operation must be done by lifting the mesh plane from the ground with spacers, so that the mesh is raised at least 5 cm from the ground.
Then proceed with laying the second layer of mesh, on top of the first, maintaining the spacing between the two layers. The spacers must be numerous to ensure excellent stability during pouring. The meshes of the same layer must overlap by at least 40 cm to create stability. It is also advisable to have reference points between the meshes to which the concrete plane will be aligned. Then insert metal pegs on which the reference levels will be struck, in order to have a perfect plane. Once the bottom reinforcement operations are completed, use the concrete pump for pouring.
ATTENTION: make sure that the metal pegs on the bottom are perfectly level, so as to have the levels under control at all times.
Then proceed with pouring the slab. The use of concrete of good consistency class (S3-S4) is recommended, so as to facilitate operations and its distribution.
During pouring operations, prioritize the outer part of the slab, where we will lay the pool walls, then proceed with the innermost part.
The use of a screed for leveling the slab and subsequently a power trowel for quartz finishing is recommended.
It is very important that the bottom is perfectly level and smooth. Every small imperfection will be highlighted by the PVC lining and the water will make every defect stand out like a magnifying glass.
4 – Laying Easyblok formwork and concrete pouring
Wait for the slab to dry completely.
Using a tape measure, locate the 4 internal vertices of the tank perimeter and mark them with nails, to which a chalk line will then be anchored to redefine the tank's shape. It is advisable to check the actual squareness of the defined shape by measuring the diagonals and sides. The diagonals must be identical to each other, as must the long sides and the short sides.
Now begin laying the EASYBLOK formwork clockwise or counter-clockwise, with the feet facing downwards, interlocking.
Once the first round is finished and the structure is squared, we can prepare the vertical reinforcement by drilling ∅16 holes, 10/11 cm deep, at a distance of 25 cm, in a zigzag pattern, into the base.
The vertical irons will then be positioned before laying the last row of formwork.
The D.12 vertical bars will then be inserted into ∅16 holes, 100-110 mm deep, cleaned and filled with fine-grained cement mortar, Basf Masterflow 960 one-component or two-component chemical adhesive. Alternatively, insert the reinforcement bars into ∅12 holes, 100-110 mm deep, with simple mechanical compression.
In the formwork placed in the corner, cut a small side window in the upper part with a hacksaw, so as to obtain a continuous space for laying the reinforcements and the consequent concrete pouring.
The various rows of formwork, to be connected to each other, must be positioned staggered by at least 50 cm (2 modules), exactly as you would with Lego.
The formwork units are arranged for a length of 1.25 m, each block consists of 5 separable 25 cm modules, thus ensuring that they interlock perfectly with each other and allow for obtaining the desired overall length.
The openings at the ends must be closed using the special sealing keys. Two for each formwork unit, positioned at an angle, so as to prevent concrete from leaking out during pouring.
Then position the double horizontal reinforcement bars inside each row of formwork. Ensure that the courses of the horizontal irons overlap by at least 50 cm with each other. In the presence of perimeter corners, the horizontal bars must be appropriately bent by 90 degrees and continue on the next side to ensure maximum strength.
N.B.: Avoid overlapping horizontal irons at the same points.
Once the horizontal and vertical reinforcement is completed, it is advisable, to fix the pool and the surrounding paving that will be built, to position the external screed anchors:
Once the formwork is laid, the built-in parts can be installed: skimmers, jets, lights, filter wall (if present), etc.
Also prepare the support for the level control (if present).
Position the accessories at the desired point and mark their dimensions with a marker, then make the cuts in the affected formwork units, following the trace. Once the positioning phase is over, if you are sure you no longer want to move the special parts, you can proceed to fix them with polyurethane foam, which, by drying and solidifying on contact with air, fixes the part almost immediately.
Do not overdo the polyurethane foam; the flow of concrete must be guaranteed.
Position the patented Zavatti profile, interlocking, before pouring the walls. The Zavatti profile will be the zero point (starting point) of the reinforced PVC lining and the zero point (support point) of the external paving of the tank.
Before proceeding with the concrete pour, recheck that the structure is level and square.
With high-density EASYBLOK formwork, it will not be necessary to reinforce the structure either before or after pouring, thus saving time and money.
Then we will see in detail, depending on the chosen filtration system, how to proceed with its installation.
In the meantime, let's finish explaining the concrete pouring phase.
The concrete used (cement, sand, and fine gravel) must have a consistency that is neither too liquid, to avoid excessive pressure inside the formwork, nor too dense, to avoid the formation of aggregate lumps that prevent the proper propagation of the concrete inside the EASYBLOK formwork.
Therefore, fine-grained concrete with a slump consistency class S4 > 160 mm and a maximum aggregate size between 10 and 12 mm (maximum aggregate diameter 20 mm) is recommended, taking care to compact it well.
During pouring with mechanical means, such as a concrete pump, etc., it is advisable to distribute the pouring load along the perimeter without staying in the same spot, so as to uniformly distribute the thrust.
Furthermore, as indicated in the figure, the correct pouring direction consists of letting the concrete fall directly onto the formwork reinforcement and not directly into the cavity.
With EASYBLOK, pouring can be done in a maximum of two passes.
It is not necessary to vibrate the concrete pour as the vibrator itself could damage the integrity of the EPS formwork. Adjacent to the installed accessories, in order to allow the correct flow of concrete, manual operations must be carried out with the aid of a tool (e.g., an iron rod) to ensure that the pour remains completely in contact with the accessory itself.
At the end of the process, smooth the surface with a trowel and clean the site. Then check that the top of the perimeter is perfectly level using a spirit level. Once the structure has been poured, wait at least 10 days for the concrete to cure before proceeding with further work.
Backpack filtration system installation
The backpack filtration system is truly very simple to install; just leave a space next to one side of the pool during excavation for the technical compartment (or more, depending on how many backpacks will be installed).
With the backpack filtration system, it is possible to create completely closed-circuit pools.
The backpack will be both the pool's filtration and its lighting.
It is also possible to include a counter-current swimming system or a salt electrolysis system.
Once the pool is filled, before starting the motor, it is necessary to fill the system with water.
5 – Laying the reinforced lining membrane and finishing
The last thing left to do is to internally line the pool with the reinforced PVC lining membrane. The membrane supplied in the kit comes in rolls and will need to be heat-welded on-site with special heat-welding guns.
Thanks to the perfection of the EASYBLOK formwork, skimming the inner walls can be avoided; it will be sufficient to install the polyurethane PVC mat on the walls with adhesive.
In the case of internal steps and stairs, plasticized corner pieces are provided for a perfectly executed heat-welding.
Customizations
It is possible to customize the EASYKIT pool kit with a staircase or a beach area:
EASY KIT STAIRCASE already pre-assembled, quick and easy to install.
Supplied with plasticized corner pieces for a perfect membrane installation. Includes a roll of anti-slip safety PVC reinforced membrane.
EASY KIT BEACH to be assembled on site.
Supplied with plasticized corner pieces for a perfectly executed membrane installation. Includes a roll of anti-slip safety PVC reinforced membrane.
Suitable for creating a beach area with a maximum size of 10sqm.
STAIR AND BEACH REINFORCEMENT: it is necessary to cut the last row of formwork by 10 cm, on the inside of the staircase or beach, to lower them compared to the level of the plasticized profile, placed on the edges of the steps. Then proceed with the laying of the iron and, finally, with the pour. This is necessary so that the cement best binds the entire structure. The supplied plasticized profile is necessary to create perfect angles that last for years and for correct laying of the lining membrane.
Pool products and accessories
For the maintenance and upkeep of your pool, there are essential products and accessories, which you will always find on ZavattiShop.com
Dolphin Maytronics automatic pool cleaners
Solar showers
Winter and summer covers
Disinfection and filtration
You can watch the assembly tutorial video here: