Easy Kit Skimmer Kart - how to build a DIY swimming pool with a filter skimmer
INSTRUCTIONS FOR INSTALLERS
PREMISE
This manual provides general construction indications and instructions for the installation of skimmer pools to be built with permanent polystyrene formwork blocks, to be completed on site by laying reinforcing bars and subsequent pouring of concrete.
The structures must comply with the following dimensional limits:
- maximum height from the bottom of vertical walls: 1.52 m;
- maximum liquid head height: 1.45 m;
and the following constraints related to the geographical location of the structures:
- low seismicity zones: locations in zone 4 or zone 3
- foundation soil with medium or good geotechnical characteristics (allowable pressure not less than 0.9 kg/cm2)
This document does not refer to any specific site or to geotechnical parameters and characteristics of a precise foundation soil; therefore, verification of compliance with the above limits and constraints remains the responsibility and full and exclusive liability of the client or their appointed technical designer and/or Works Director.
Failure to comply with even one of these limits and constraints renders the indications and prescriptions, however general, contained herein ineffective, and relieves the author of this document from any liability.
REGULATIONS
The following indications and prescriptions are provided in compliance with current regulations, specifically:
- Ministerial Decree of Infrastructure January 17, 2018 and annexed "Technical standards for construction".
- Circular of the Ministry of Infrastructure and Transport January 21, 2019, n. 7 - Instructions for the application of the update of the "Technical standards for construction" referred to in Ministerial Decree January 17, 2018.
MATERIAL REQUIREMENTS
For the execution of the works in question, the following material resistance classes are required:
a) CEMENT CONGLOMERATE FOR FOUNDATION AND ELEVATION STRUCTURES
- Minimum characteristic strength: R’ck = 300 daN/cmq
b) STEEL FOR REINFORCED CONCRETE
- Class B450C, or equivalent class for electro-welded meshes
INDICATIONS FOR REINFORCING IRON QUANTITIES
As an indication, the methods for calculating the quantities of reinforcing iron needed for a rectangular pool with an internal sunbathing area and a wall height of 1.52 m are described.
Calculation parameters:
- Slab area (sqm): internal pool area + 50 cm for each side (e.g., 4x8 pool = 5x9 excavation);
- Internal pool perimeter (m): perimeter of vertical walls in contact with water;
- External pool perimeter (m): perimeter of vertical walls in contact with the ground.
In the case of a pool with an external sunbathing area, the protruding dimensions of the sunbathing area itself must also be included in these parameters.
1) Foundation slab: electro-welded mesh D.8/20”x20”; quantity sqm: slab area x 2 + 20% (mesh overlap of at least 2 squares)
2) Walls: horizontal bars D.10 of 6.00 m length; n. = internal pool perimeter x 2
3) Vertical bars pos.1 D.12 L=1.60 m; n. = internal pool perimeter x 8
4) Horizontal bars corners pos.3: D.10 L=2.00 m; n. = n. corners x 10
5) Pavement connection stirrups pos.2: D.8 L=1.00 m; n. = external pool perimeter x 4
All as shown illustratively in the following construction details:
ATTENTION: during the execution phase, any variation to this sizing must refer to the actual values of the design characteristics and parameters, evaluated by the professional based on the real operating conditions.
The following indicative table summarizes the horizontal and vertical reinforcement necessary for the construction of swimming pools using the EASYBLOK disposable insulated formwork system, depending on the seismic acceleration at the construction site.
1 - Laying out
The first step in building the pool is choosing the right location. An area without plants or obstructions, without manholes and 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, for a pool with a water surface of 4.00 x 8.00 m, we will have an overall dimension of 4.50 x 8.50 m (the formwork depth is 25 cm), so we will perform an excavation of 5.00 x 9.00 m (thus leaving another 25 cm to facilitate the work and the space needed for any recirculation pipes).
For a pool with a water surface of 5.00 x 9.00 m, we will make an excavation of 6.00 x 10.00 m and so on…
Precise calculation will save money on excavation and slab, and we will have less backfill and less settlement.
So, once the area and precise dimensions are chosen, start tracing the pool itself on the ground.
What you need:
- pointed wooden stakes or iron bars;
- 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 out the pool excavation, distributing the white powder along the string.
Then remove the string and move the stakes to the outside of the excavation to quickly transfer 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 verify the correctness of the dimensions and squaring of the traced shape.
N.B.: If present, at this stage, it is also good to choose where to place the technical room.
A distance of 3 to 5 meters is recommended, and the excavation should be about 10 cm deeper than the room itself. Then, mark the footprint for the technical room excavation as well.
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 constructing the foundation slab, 20/25 cm thick (depending on soil characteristics), reinforced with a double D.8/20”x20” mesh laid on appropriately sized spacers.
Therefore, if our pool is to be 1.50m high, we will excavate to a total height of approximately 1.70 / 1.75m. A few more centimeters 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, deliberately, we recommend 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.
Always consider the highest point in the vicinity of the pool as the zero point.
NB: At this stage, if present, install the main drain at the correct level.
3 – Area preparation and slab pouring
Once the excavation is complete, we will re-mark the pool inside it. This is a very quick process, thanks to the previously placed stakes. At this point, we can proceed with laying the double layer of electro-welded mesh. This operation should be done by lifting the mesh plane off the ground, with spacers, so that the mesh is raised at least 5 cm from the ground.
Then, proceed by laying the second layer of mesh, above the first, maintaining the spacing between the two layers. There should be many spacers to ensure excellent stability during pouring. The meshes of the same layer should overlap by at least 40 cm to create stability. Between the meshes, it is also appropriate to have reference points to which the concrete plane will be aligned. Then insert metal stakes on which the reference levels will be struck, to ensure a perfect plane. Once the bottom reinforcement operations are complete, use the concrete pump for pouring.
ATTENTION: make sure that the metal pegs in the foundation are perfectly level, to keep track of the levels at all times.
Then proceed with pouring the slab. It is recommended to use concrete of good consistency class (S3-S4), to facilitate operations and its distribution.
During pouring operations, prioritize the outer part of the slab, where the pool walls will be laid, then proceed with the inner part.
It is recommended to use a screed for leveling the slab and subsequently a power trowel for quartz smoothing.
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 pouring concrete
We wait the necessary time for the slab to dry completely.
Using a measuring tape, identify the 4 internal vertices of the pool perimeter and mark them with nails, to which a chalk line will then be anchored to redefine the shape of the pool. It is advisable to check the actual squaring 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 course 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 reinforcing bars into ∅12 holes, 100-110 mm deep, with simple mechanical compression.
In the formwork positioned at the corner, cut a side window in the upper part with a saw, so as to obtain a continuous cavity for the placement of the reinforcement and the subsequent concrete pour.
The various courses of formwork, to be connected to each other, must be offset by at least 50 cm (2 modules), exactly as you would with a Lego set.
The formwork units are 1.25 m long, each block consisting of 5 sectionable 25 cm modules, thus ensuring they interlock perfectly and allowing the desired overall length to be achieved.
The openings at the ends must be closed using the appropriate sealing keys. Two for each formwork unit, positioned at an angle, so as not to allow concrete to escape during pouring.
Then position the double horizontal reinforcement bars inside each course of formwork. Verify that the horizontal reinforcing bars overlap by at least 50 cm. At the perimeter corners, the horizontal bars must be appropriately bent by 90 degrees and continue on the next side to ensure maximum robustness.
N.B.: Avoid overlapping horizontal rebar always at the same points.
Once the horizontal and vertical reinforcement is complete, it is advisable, to secure the pool and the paving that will be laid around it, to position the external screed anchors:
Once the formwork is laid, you can proceed with the installation of the embedded parts: skimmers, nozzles, lights, filter wall (if present), etc.
Also prepare the support for level control (if present).
Position the accessories at the desired point and mark their outline with a marker, then cut the affected formwork according to the mark. Once the positioning phase is completed, if you are sure you do not want to move the special parts anymore, you can proceed to fix them with polyurethane foam, which, by drying and solidifying upon contact with air, fixes the part almost immediately.
Do not overdo it with polyurethane foam; the concrete flow must be guaranteed.
Position the Zavatti patented 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 pool.
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 the pour, thus saving time and money.
Then we will see in detail, based on the chosen filtration system, how to proceed with its installation.
In the meantime, let's finish the explanation of 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 correct propagation of the concrete inside the EASYBLOK formwork.
Therefore, fine-grained concrete with a slump consistency class S 4> 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 concrete pumps, etc., it is advisable to distribute the pouring load along the perimeter without staying at the same point, so as to evenly distribute the thrust.
Furthermore, as indicated in the figure, the correct pouring direction involves dropping the concrete 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 concrete to flow correctly, manual operations with the aid of a tool (e.g., rebar) must be carried out to ensure that the pour remains completely in contact with the accessory itself.
At the end of the procedure, level the surface with a trowel and clean the construction 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 the work.
Skimmer Kart Overflow Filtration System
The SKIMMER KART filtration system combines professional cartridge filtration, with a large filtering surface and a porosity of up to 10 microns, with an unbeatable aesthetic and attractive design.
Skimmer filter operation:
The slot ensures water drainage.
The water then passes through the basket designed to stop larger impurities (needles, leaves...).
The water is then filtered by the ultra-fine cartridge (10/15μ porosity).
Clean water is sucked in by the pump and reintroduced into the water.
With this system, we avoid large rooms to house bulky and heavy sand filtration systems.
Various customizations are available; in fact, it is possible to opt for a Bluetooth electrical panel and add level control.
Zavatti also offers the possibility to purchase filtration material in bulk or pre-assembled:
Instructions and advice for the company in charge of external works
Once the pool walls have been cast, wait at least 10 days for the concrete to cure before proceeding with external works such as drainage, waste and hydraulic and electrical connections, backfilling with gravel, and pouring the floor slab.
5 - Level control
If present, finish installing the level control near the pool and prepare any necessary pit. Then proceed with the hydraulic connection for water supply.
6 - Biological dechlorinator (necessary for sand filter systems)
Position the biological dechlorinator pit (with the pit for the submerged pump power supply alongside) approximately 1 meter from the pool's technical room and make all hydraulic and electrical connections.
NB: In the case of an industrial cartridge filter system, it is not necessary to prepare the dechlorinator pit.
7 - Backfilling with fine aggregate
As soon as all pits, drains, waste pipes, and hydraulic and electrical pipes have been correctly positioned, proceed with backfilling using fine aggregate (gravel, sand, or recycled material).
8 - Pool light connections
Before pouring the slab, make the electrical connections for the pool lights.
9 - Pouring the paving slab
After that, you can proceed with pouring the reinforced concrete slab for the paving (approx. 15 cm high), keeping in mind a 1% slope per meter towards the outside of the pool. So, considering the 0 level corresponds to the wall level, keep about 25/30 cm for the backfill (which will be aggregate/sand/gravel/recycled material); about 15 cm for the reinforced slab, and finally about + 3 cm for glue, flooring, and coping.
Instead of classic pool coping, you can use the floor tile, which could have a variable height between 2 and 3 cm.
N.B. if there are visible pipes or fittings (not cast) outside the pool wall, cover them with sand.
Wait for the slab to be perfectly dry and complete the paving with the laying of the chosen tiles and the landscaping of the garden.
NB: Before starting the internal liner installation, be sure to thoroughly dry and clean the bottom and walls of the pool. If necessary, fill and smooth all existing cracks.
10 – Installation of reinforced lining and finishes
The last thing to do now is to line the inside of the pool with the reinforced PVC liner. The liner supplied in the kit comes in rolls, which will need to be heat-welded on-site with suitable heat-welding guns.
Thanks to the perfection of the EASYBLOK forms, it is possible to avoid rendering the inner walls; it will be sufficient to install the polyurethane PVC mattress on the walls using adhesive.
In the case of internal steps and stairs, plasticized angles are provided to ensure a professional heat-welding job.
Once the liner is installed, proceed to flange all accessories in the pool.
11 - Pool commissioning
As soon as the liner installation and accessory flanging are complete, the pool can be filled immediately, preferably with tap water.
Wait until the water level covers half of the skimmer opening (approximately 7 cm from the edge in the case of a skimmer overflow).
Then turn on the filter system and proceed with the first water treatment using specific chemical products.
Customizations
It is possible to customize the EASYKIT pool kit with a ladder or a beach:
EASY KIT LADDER already pre-assembled, easy and quick to install.
Supplied with plasticized angles for a professional liner installation. Includes a roll of anti-slip safety reinforced PVC liner.
EASY KIT BEACH to be assembled on site.
Supplied with plasticized angles for a professional liner installation. Includes a roll of anti-slip safety reinforced PVC liner.
Suitable for creating a beach of maximum 10 sqm.
LADDER AND BEACH REINFORCEMENT: It is necessary to cut the last row of forms by 10 cm, on the inner part of the ladder or beach, to lower them compared to the level of the plasticized profile, laid on the edges of the steps. Then proceed with the iron laying and, finally, with the pour. This is necessary for the concrete to bond the entire structure optimally. The supplied plasticized profile is necessary to create perfect corners that last for years and for a correct installation of the lining.
Pool products and accessories
For the maintenance 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: