NGCC/NCN Case Review 07/06: FRP Swimming Pools

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Case Review 07/06
FRP Swimming Pools.


Introduction

Domestic swimming pools are big business in the USA and Australia. It is estimated that the US
pool and spa industry is worth $8 billion alone. However, FRP swimming pools account for only 3%
of this, despite offering distinct social, economic and environmental advantages over the concrete
and vinyl liner pools that dominate the market.

The FRP shell structures have now overcome blistering problems encountered on their introduction,
thanks to the development of vinyl ester resins. At present this application is pertinent in those
countries with warmer year round climates. However, the economic benefits offered by FRP pools
could help expand the market in other countries, particularly the UK.

The sports industry has also taken advantage of the property and construction benefits offered by
FRPs. A recent high profile example is the Sydney Olympic training pool, situated in Homebush,
Australia. The pool harbours the largest fully removable FRP floor in the world.



The application is a good example of synergy combining 22 tonnes of FRP with 30 tonnes of
corrosion resistant metal. The use of FRP made installation possible in 8 months, at an average
cost of $1750/m
2
compared to $3000/m
2
previously. The lighter weight of the floor allows it to be
raised or lowered (range 2.5m to zero) to cater for a range of activities, thus increasing the
functionality and appeal of the pool.


NGCC/NCN Case Review 07/06: FRP Swimming Pools
e-mail: ngcc@netcomposites.com Web: www.ngcc.org.uk


Key properties
The higher strength/stiffness to weight ratio of FRP materials means that less material is
required in the structure, and provides greater impact resistance as a result of these
properties.
Vinyl-liner pools are prone to cuts and other damage.
The FRP shells can be pre-fabricated, minimising site assembly and installation times.
The flexibility of composites allows the design and manufacture of almost any shape.
A standard product range can be developed, maximising the efficiency of the
ordering/delivery/installation process
The shell construction method provides an opportunity for synergy with other materials to
achieve desirable functional properties. For example, the addition of a ceramic core
provides greater stiffness and thermal insulation.
The shell can be completely finished and quality controlled before delivery.
Through life costs are significantly less than for conventional pools due to a number of
contributory factors:
o Site installation is typically 1-5 days, compared to 4-8 weeks for a concrete or liner
pool
o The light weight reduces personnel and site equipment requirements during
installation
o No periodic maintenance/re-painting is necessary
o Power consumption is less due to better thermal properties.
o It is claimed that they require fewer water treatment chemicals than conventional
pools due to less microbial contamination.
FRP shells can be sold direct to the homeowner for D-I-Y installation.
Electrical and chemical usage is about half that of a concrete or liner pool, meaning
extraction and processing benefits for the environment.
There is no leaching of chemicals from the shell into the surrounding earth.
Rapid installation causes minimal disruption to the domestic routine.
Pools can be manufactured to the specification of the customer.
The pool can be moved to a new place of residence.
The pools can be installed all year round, unlike gunite pools which cannot be installed in
cold weather.
FRP shell pools are the least dependent of all pool types on the skills of the installation
crew.

Opportunities for FRP and potential market size

This is a predominantly market driven leisure product. Less significance is placed on the structural
performance as would be in industrial applications. Therefore there is little 'pure' research behind
the products, manufacturers have taken up the use of FRPs because of their production benefits,
long term durability and negligible maintenance requirements. The leisure industry has taken a lead
from the marine and offshore industries, where FRPs have been proven to provide high
performance in aqueous and corrosive environments. Long term cost effectiveness is the major
driver for this domestic product.

The main competitors for FRP pools are gunite (concrete) and vinyl liners. A comparison of key
characteristics can be made:


NGCC/NCN Case Review 07/06: FRP Swimming Pools
e-mail: ngcc@netcomposites.com Web: www.ngcc.org.uk


FRP
Pools
Concrete
(Gunite) Pools

Vinyl Liner
Pools
Warranty

Lifetime by the
Manufacturer

1-5 years by contractor

Liner seams only
Installation
Time

5-13 days, ready for
decking using few (if
any) subcontractors.

8-12 weeks using many
different subcontractors.

2-3 weeks using few
subcontractors.
Shapes of
Pools

Limited to the models of
the manufacturer.

Unlimited

Limited to the models of
the manufacturer.
Price of
Pools

Average

High

Average
Estimated
Chemical
Usage

Surface does not alter
water's chemical
balance. Substantially
fewer chemicals used.

Plaster reacts with water
to raise pH levels. Uses
substantially more acid
& chlorine to
counterbalance this
chemical reaction.

Surface does not alter
waters' chemical balance.
Substantially fewer
chemicals used.
Estimated
Electricity Use

Circulate Water 4-6
hours daily.

Circulate Water 8-10
hours daily.

Circulate Water 5-7 hours
daily.
Surface
Texture

Smooth, non-abrasive to
skin or swim suits,
walking and seating
areas are textured for
slip resistance.

Rough, causes skin
abrasions to feet, hands
and swim wear.

Slippery, easily punctured
or torn by toys, pets, or
surfacing rocks.
Algae
Penetration

Algae sweeps off with
wall brush.
Algae grows and is
harbored in pores of
gunite. Acid baths and
scrubbing required to
remove algae.

Seams of liner harbor
algae.
Estimated
Maintenance
Time


1/2 hour per week
maximum


4-5 hours per week


2-3 hours per week
Major
Renovation

None

Re-marcite or re-plaster
at 5-7 years.

Vinyl Liner needs to be
replaced every 7- 9 years.
Quality
Control

Manufactured in
controlled factory to
quality control
standards.

Manufactured on-site.
No environmental
control.

Kit manufactured in
factory. Quality of on-site
assembly varies by
installer.
NGCC/NCN Case Review 07/06: FRP Swimming Pools
e-mail: ngcc@netcomposites.com Web: www.ngcc.org.uk




Installation of FRP pool

Flexible design
As well as small domestic pools, FRP materials are used for many applications in large public and
competition swimming pools, such as starting blocks, end walls, water polo goals etc. The
application of FRPs offers greater flexibility in the use of the pool than would be achievable using
other materials. Two important features are moveable bulkheads and moveable floors these allow
the pool size to be tailored to meet varying requirements of its use.

Moveable bulkhead
The moveable bulkhead is designed to function as a
substantial stable pool divider which can be fitted
with starting blocks and used for national and
international level competitions. The bulkhead spans
the width of the pool and allows the pool to be
programmed for maximum utilisation and revenue
generation.

The motorisation option comprises battery powered
transport trolleys which can be stored away from the
pool. This system eliminates the hazards of wiring
built into the bulkhead.

Bulkheads are built using a unique modular component system which ensures high standards of
engineering and allows for the detailed customisation to meet the needs of each installation. This
means that tolerances can be exceedingly fine while costs are kept under control.

Moveable floor
The Variopool system is based on a floating floor which is pulled to the desired depth using a pulley
system of stainless steel cables and hydraulic cylinders. This is a proven concept that is
characterised by its simplicity and a minimum of moving parts resulting in high reliability and low
maintenance costs. Moreover, a unique feature is that it is unnecessary to empty the pool for
regular maintenance or repair.

Movable pool floors can be made from various materials or combinations of materials. The choice
of material is determined by the customer, the set requirements and the functionality.
Variopool supplies three different types of floor:
- Glass-fibre reinforced plastic
- Stainless steel frame covered with glass-fibre reinforced polyester
- Stainless steel frame covered with polypropylene panels.
NGCC/NCN Case Review 07/06: FRP Swimming Pools
e-mail: ngcc@netcomposites.com Web: www.ngcc.org.uk

All three types have an anti-slip surface as described in the latest version of NEN 13451-11.

A GRP floor consists of elements between 9 and 15 metres long and 2 to 2.5 metres wide. The
buoyancy is guaranteed as it is permanently integrated into the elements. When making these
elements, at an early stage an indication must be given of whether the movable floor must have
competition lines, coloured areas or logos. The advantage of this is that they do not wear.


Photos courtesy of Variopool

The advantage of the glass-fibre reinforced floor is that it is completely self supporting, the mould
imparts an anti-slip structure to the floor surface and the floor can be installed very quickly, meaning
that the swimming pool only needs to be closed for a limited time.

The stainless steel frame with GRP panels moveable floor is built using a 316L stainless steel
frame that is joined together using nuts and bolts. Glass-fibre reinforced anti-slip plastic panels are
attached to the frame.



The advantage of this type of floor is that the parts can be brought in through a small access
opening. The parts of the structure are also light, meaning that there is no need for hoists or other
tools.



Future developments

It is inevitable that manufacturers will start adding FRP pools to their product portfolios as
consumers become aware of their functional benefits and economic savings. The products will
become more readily available and cheaper as manufacturing systems develop.

Internet ordering of 'standard' pools is already available and will become a large market over the
next 5-10 years as the concept filters from the main markets in the US and Australia. The ability for
self installation will also attract a wider market due to associated financial savings.
NGCC/NCN Case Review 07/06: FRP Swimming Pools
e-mail: ngcc@netcomposites.com Web: www.ngcc.org.uk


There is the potential for development of indoor FRP pools in the UK. A total FRP 'system',
including covering structure, would reduce costs and promote the product to a wider market.


Further information

Companies

Variopool B.V., Netherlands
http://www.variopool.nl

Oasis Swimming Pools - California - Advanced Composite Pool (ACP)
www.deluxepool.com/acp.html

Advanced Composite Technology Company Ltd - Australia
www.adcomp.comp.au

Antiwave - FRP pool components
www.dibro.co.nz/antiwave
http://www.anti.to/Pdf/BWBrochure.pdf


Research Papers
"FRP swimming pools' low maintenance, high quality make a splash". Feature in "Composites
Technology Magazine", July/August 2001.






Acknowledgements
Acknowledgement is given to the NGCC steering group for their valuable contributions to the
document.

Disclaimer: Whilst NGCC has endeavoured to ensure the information in this document is accurate, NGCC
makes no warranties or guarantees, actual or implied, and bears no responsibility for the use of information
from this document. NGCC cannot accept any liability for any loss or damage, whether direct, indirect or
economic, as a result of the use of information in this document.