How to build a DIY swimming pool
Easykit Pool Installation Manual with Easyblok
Your dream has finally come true. You're building your own pool with the system, a do-it-yourself pool with high-quality materials—easy, simple, and fast. Let's look at the construction steps together.
EASYKIT was born from an idea by Danny Zavatti, the swimming pool expert.
Danny will always be by your side at every stage:
- Choosing the EASYKIT solution that best suits your needs;
- During the purchase;
- During installation, step by step;
- Commissioning;
- Use and maintenance.
Danny is always available; you can contact him by phone or WhatsApp at +39 334 1491755, or by email at info@zavattishop.com.
INSTRUCTIONS FOR INSTALLERS
PREMISES
This manual provides general construction instructions and guidelines for installing skimmer pools using disposable polystyrene formwork blocks, completed on site by installing reinforcing bars and then pouring the concrete mix.
The artefacts must comply with the following dimensional limits:
- maximum height from the bottom of vertical walls: 1.52 ml;
- maximum height of the liquid head: 1.45 ml;
and the following constraints related to the geographical location of the artefacts:
- low seismicity areas: locations in zone 4 or zone 3
- foundation soil with medium or good geotechnical characteristics (permissible pressure not less than 0.9 kg/cm2)
This document does not refer to any specific site or to the geotechnical parameters and characteristics of a specific foundation soil; therefore, verification of compliance with the above limits and constraints remains the responsibility of the client or his designated design engineer and/or works manager.
Failure to comply with even one of these limits and constraints renders the indications and provisions, however general, contained herein ineffective, and releases the author of this document from any liability.
REGULATIONS
The following indications and prescriptions are provided in compliance with current legislation and specifically:
- Ministerial Decree on Infrastructure of 17 January 2018 and attached "Technical standards for construction".
- Circular of the Ministry of Infrastructure and Transport of 21 January 2019, no. 7 - Instructions for applying the update to the "Technical standards for construction" pursuant to the Ministerial Decree of 17 January 2018.
MATERIALS REQUIREMENTS
In carrying out the works in question, the following material resistance classes are prescribed:
a) CONCRETE STRUCTURES FOUNDATION AND ELEVATION
- Minimum characteristic resistance: R'ck = 300 daN/cmq
b) STEEL FOR REINFORCED CONCRETE
- Class B450C, or equivalent class for electro-welded mesh
REINFORCING IRON QUANTITY INDICATIONS
As an indication, the methods for calculating the quantities of reinforcing iron required for a rectangular pool with an internal shoreline and a wall height of 1.52 m are set out.
Calculation parameters:
- Pool area (m2): internal pool area + 50 cm on each side (e.g. 4x8 pool = 5x9 excavation);
- Internal perimeter of the tank (ml): perimeter of the vertical walls in contact with the water;
- External perimeter of the tank (ml): perimeter of the vertical walls in contact with the ground.
In the case of a pool with an external shoreline, the protruding dimensions of the shoreline itself must also be taken into account in these parameters.
1) Foundation slab: D.8/20”x20” electro-welded mesh; quantity in m2: slab area x 2 + 20% (mesh overlap of at least 2 meshes)
2) Walls: horizontal iron rods D.10 of 6.00 m; n. = internal perimeter of the tank x 2
3) Vertical irons pos.1 D.12 L=1.60 ml; n. = internal perimeter of the tank x 8
4) Horizontal corner irons pos.3: D.10 L=2.00 ml; n. = n. corners x 10
5) Sidewalk connection brackets pos.2: D.8 L=1.00 ml; n. = external perimeter of the tank x 4
All of this as shown in the construction details below, for illustrative purposes only:
ATTENTION: during the execution phase, any variation to this sizing must refer to the actual values of the characteristics and design parameters, assessed by the professional on the basis of real operating conditions.
The following indicative table summarizes the horizontal and vertical reinforcement required for the construction of swimming pools using the EASYBLOK isothermal formwork system as a function of the seismic acceleration at the construction site of the structure.
1 - Tracking
The first step in building a pool is choosing the right location. Choose an area free of trees or obstructions, wells, or foundations.
You need to find a reference square, which could be the house or the garden fence. Based on this, draw the dimensions of the excavation on the ground.
For example, in the case of a swimming pool with a water surface measuring 4.00 x 8.00 m, we will have a footprint of 4.50 x 8.50 m (the depth of the formwork is 25 cm), therefore we will excavate a 5.00 x 9.00 m excavation (thus leaving another 25 cm to facilitate the work and the space required for any recirculation pipes).
In the case of a pool with a water surface of 5.00 x 9.00, we will excavate a 6.00 x 10.00 hole, and so on…
By calculating accurately, you will save money on excavation and the slab, and you will also have less backfill and less settlement.
So, once the area and precise dimensions have been chosen, we begin to trace the pool itself on the ground.
What you need:
- sharp wooden stakes or irons;
- a rope;
- white powder (lime, plaster or cement);
- measuring wheel;
- wire beater.
Once the four outermost stakes have been fixed, we stretch out the string and effectively trace the excavation of the pool, distributing the white powder following the string.
Then remove the string and move the stakes outside the excavation to quickly report the pool measurements once the excavation is complete.
At this point all that remains is to measure all the sides and diagonals again, which must be equal, to verify the correctness of the dimensions and the squareness of the traced shape.
NB: If present, at this stage, it is also a good idea to choose where to position the technical room.
A distance of 3 to 5 meters is recommended, and the excavation should be approximately 10 cm deeper than the room itself. Therefore, also mark out the footprint for the utility room excavation.
2 - Excavation
Once the tracing is complete, we proceed with the excavation using an excavator.
ATTENTION: the excavation must be made at least 20/25 cm deeper than the planned depth of the pool, in preparation for the construction of the foundation slab 20/25 cm thick (depending on the characteristics of the soil) reinforced with double mesh D.8/20”x20” supported on spacers of appropriate height.
So, if our pool needs to be 1.50 m deep, we'll dig to a total depth of about 1.70 to 1.75 m. We'd also consider a few extra centimeters for the formwork feet (about 2 cm), the liner profile (about 1.5 cm), and the paving (1 or 2 cm thick). However, we deliberately recommend that the pool be a few centimeters above ground level, so that rainwater drains into the surrounding soil and not into the pool itself.
Always consider the highest point near the pool as the zero point.
NB: At this stage, if present, install the bottom socket at the correct height.
3 – Preparation of the area and casting of the slab
Once the excavation is complete, we'll re-trace the pool's interior. This is a very quick process, thanks to the previously placed pegs. At this point, we can proceed with laying the double-layer electro-welded mesh. This operation is done by raising the mesh surface off the ground with spacers, so that the mesh is at least 5 cm above the ground.
Next, lay the second layer of mesh over the first, maintaining proper spacing between the two layers. Numerous spacers are required to ensure optimal stability during pouring. Meshes in the same layer should overlap by at least 40 cm to ensure stability. It's also a good idea to place reference points between the mesh to align the concrete slab. Then, insert metal stakes onto which the reference levels will be hammered to ensure a perfect level. Once the base reinforcement is complete, use the pump truck for pouring.
WARNING : check that the metal pegs on the bottom are perfectly level, so that you can keep the dimensions under control at all times.
Then proceed with pouring the slab. We recommend using a good-consistency concrete grade (S3-S4) to facilitate operations and distribution.
When pouring, give priority to the outer part of the slab, where we will lay the pool walls, then proceed with the innermost part.
We recommend using a straight edge to level the slab and then a sander for quartz smoothing.
It's very important that the surface is perfectly level and smooth. Even the smallest imperfections will be highlighted by the PVC coating, and water will highlight them like a magnifying glass.
4 – Installation of Easyblok formwork and pouring of concrete
We wait for the necessary time for the floor to dry completely.
Using a tape measure, locate the four internal vertices of the tub's perimeter and mark them with nails. Then, anchor a marking line to these, redefining the tub's shape. It's a good idea to check the actual squareness of the resulting shape by measuring the diagonals and sides. The diagonals must be identical, as must the long and short sides.
Now begin installing the EASYBLOK formwork in a clockwise or anticlockwise direction, with the feet facing downwards, interlocking.
Once the first round is finished and the structure is squared, we can prepare the vertical reinforcement by creating, with a drill, holes in the base ∅16, 10/11 cm deep, 25 cm apart, in a zig-zag pattern.
The vertical bars will then be positioned before installing the last row of formwork.
The D.12 vertical bars should then be inserted into ∅16 holes, 100-110 mm deep, cleaned and filled with fine-grained cement mortar, single-component Basf Masterflow 960, or two-component chemical adhesive. Alternatively, insert the reinforcing bars into ∅12 holes, 100-110 mm deep, using simple mechanical compression.
In the formwork positioned in the corner, cut a small side window in the upper part with a hacksaw, so as to obtain a continuous space for the installation of the reinforcement rods and the subsequent pouring of the concrete.
The various rows of formwork, to be linked together, must be positioned staggered by at least 50 cm (2 modules), exactly as you would do with Lego.
The formworks are arranged over a length of 1.25 m, each block is made up of 5 25 cm modules that can be sectioned, ensuring that they fit together perfectly and allowing the desired overall length to be obtained.
The openings at the ends must be closed using the appropriate plugs. Two plugs must be used for each formwork, positioned at an angle to prevent the concrete from leaking during pouring.
Then, place the double horizontal reinforcing bars inside each row of formwork. Make sure the horizontal bars overlap by at least 50 cm. At perimeter corners, the horizontal bars must be bent 90 degrees and extended to the next side to ensure maximum strength.
NB: Avoid overlapping the horizontal rows in the same places.
Once the horizontal and vertical reinforcement has been completed, it is recommended to position the external screed supports to secure the pool and the flooring that will be built around it:
Once the formwork has been laid, you can proceed with installing the pieces to be walled in: skimmers, vents, lights, filter wall (if present), etc.
Also prepare the level control stand (if applicable).
Position the accessories in the desired location and mark their dimensions with a marker, then cut the relevant formwork, following the outline. Once the positioning phase is complete, if you are certain you do not want to move the special pieces, you can proceed to secure them with polyurethane foam, which dries and solidifies upon contact with air, securing the piece almost immediately.
Do not overdo the polyurethane foam; the flow of the concrete must be guaranteed.
Position the patented Zavatti profile , interlocking, before pouring the walls. The Zavatti profile will be the starting point for the reinforced PVC cladding and the supporting point for the pool's external flooring.
Before proceeding with the concrete pouring, double check that the structure is level and square.
With the high-density EASYBLOK formwork, it will not be necessary to reinforce the structure either before or after pouring, thus saving time and money.
We will then see in detail, based on the filtration system chosen, 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 lumps of aggregate that prevent the correct propagation of the concrete inside the EASYBLOK formwork.
We therefore recommend fine-grained concrete with a slump consistency class of S 4> 160 mm and a maximum aggregate size of between 10 and 12 mm (maximum aggregate diameter 20 mm), taking care to compact it well.
When casting with mechanical means, such as a fire engine, etc., it is advisable to distribute the load of the casting along the perimeter without stopping in the same point, so as to distribute the thrust evenly.
Furthermore, as shown in the figure, the correct pouring direction is to drop the concrete directly onto the formwork reinforcement and not directly into the cavity.
With EASYBLOK you can cast 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. To allow the concrete to flow properly, manual operations must be performed adjacent to the installed accessories using a tool (e.g., a rebar) to ensure the concrete remains in complete contact with the accessory itself.
Once the process is complete, smooth the surface with a trowel and clean the site. Then, use a level to ensure the top of the perimeter is perfectly level. Once the structure has been poured, wait at least 10 days for the concrete to cure before proceeding with the work.
Easy Kit – available filtration systems
The EASY KIT do-it-yourself pool construction kits are available with the following filtration systems (click on the image to link to the specific manual for the kit you are interested in):
The Basic kit is fully equipped, with the filtration system and any lighting included in a single "backpack." This backpack is easy to install in the pool and requires no plumbing expertise; it simply straddles the structure, ensuring top performance with minimal labor. With backpack filters, you don't even need to drill holes or puncture the structure. This type of system is highly recommended for pools up to 35/40 cubic meters and for homeowners who want to build their own in-ground pool.
The Design kit, on the other hand, uses the innovative filter wall for pool filtration and lighting. This kit is currently the best-selling among both private individuals and installers. The filter wall, combined with the EASYBLOK formwork, allows for professional installation without the risk of pipes or other installations running around the pool. It can also be equipped with salt systems or bypasses for dosing pumps or heat pumps.
The Skimmer Kart kit is an industrial filter cartridge directly integrated into the skimmer. This provides excellent filtration quality with a significantly simplified filtration system (less piping, eliminating the need for hoses connecting the skimmer to the filter). The skimmer's aesthetic appeal is enhanced by its wide, high-mouth design, creating an effect similar to an infinity pool.
Finally, there's the Sand Line kit, with which we've strived to offer the highest quality at the absolute best price on the market. This kit is designed for those with manual and plumbing skills, whether private individuals or professionals. Skimmers, nozzles, and hoses will be positioned at the installer's discretion; therefore, the appropriate knowledge and skills are required.
Instructions and advice for the company responsible for external work
Once the pool walls have been poured, wait at least 10 days for the concrete to cure before proceeding with external work such as drainage, drains, plumbing and electrical connections, gravel backfilling, and pouring the floor slab.
5 - Level control
If present, finish installing the level control near the pool and prepare a sump pit, if necessary. Then connect the water supply.
6 - Biological dechlorinator (required in case of sand system)
Position the biological dechlorinator well (with the well for the submersible pump supply next to it) approximately 1 meter from the pool's technical room and make all the hydraulic and electrical connections.
NB: In the case of an industrial cartridge filter system, it is not necessary to prepare the chlorine removal well.
7 - Backfilling with fine aggregate
As soon as all the manholes, drains, outlets and hydraulic and electrical pipes have been correctly positioned, proceed with backfilling with fine aggregate (gravel, sand or recycled material).
8 - Pool light connections
Before pouring the slab, make the electrical connections for the pool lights.
9 - Paving slab casting
Next, you can pour the reinforced concrete slab for the flooring (about 15 cm high), taking into account a 1% slope every 1 meter toward the outside of the pool. Then, considering the ground level corresponding to the wall level, leave about 25-30 cm of backfill (which will be made of aggregate/sand/gravel/recycled material); about 15 cm of reinforced concrete slab; and finally about +3 cm of glue, flooring, and edging.
Instead of the classic pool edge, you can use floor tiles which could have a height varying between 2 and 3 cm.
NB if there are visible pipes or fittings (not flushed) on the outside of the pool wall, cover them with sand.
Wait until the slab is perfectly dry and complete the flooring by laying the chosen tiles and arranging the garden.
NB: Before installing the inner liner, make sure to thoroughly dry and clean the bottom and walls of the pool. Fill and smooth any cracks if necessary.
10 – Laying of the reinforced covering sheet and finishing touches
The last thing left to do is line the inside of the pool with the reinforced PVC liner. The liner provided in the kit is in rolls and will need to be heat-sealed on site using special heat-sealing guns.
Thanks to the perfection of EASYBLOK formwork, you can avoid smoothing the internal walls; simply install the glued PVC polyurethane mat on the walls.
For internal steps and stairwells, plastic-coated corners are provided to allow for proper heat sealing.
Once the sheet has been laid, proceed to flange all the accessories into the tank.
11 - Pool start-up
As soon as the liner has been laid and the accessories have been flanged, you can immediately proceed with filling the tank, possibly with mains water.
Wait until the water level reaches half of the skimmer mouth (about 7 cm from the edge in the case of an overflow skimmer).
After that, turn on the filter system and proceed with the first water treatment with specific chemicals.
Customizations
You can customize the EASYKIT pool kit with a ladder or a beach:
EASY KIT SCALA already pre-assembled, quick and easy to install.
Supplied with plastic-coated corners for proper installation. A roll of non-slip PVC safety tarpaulin is included.
EASY BEACH KIT to be assembled on site.
Supplied with plastic-coated corners for proper installation. A roll of non-slip PVC safety tarpaulin is included.
Suitable for creating a beach of maximum size 10m2.
STAIRS AND BEACH REINFORCEMENT : The last row of formwork must be cut by 10 cm, on the inside of the stairs or deck, to lower it compared to the height of the plastic-coated profile placed on the edges of the steps. Then proceed with the installation of the rebar and, finally, with the pouring. This is necessary to ensure the concrete binds the entire structure properly. The plastic-coated profile provided is necessary for creating perfect corners that will last for years and for proper installation of the covering sheet.
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 robot cleaners
Solar showers
Winter and summer covers
Disinfection and filtration
