U.S. patent number 3,748,810 [Application Number 05/127,709] was granted by the patent office on 1973-07-31 for method of swimming pool manufacture.
This patent grant is currently assigned to Mattingly, Inc.. Invention is credited to Charles D. Mattingly.
United States Patent |
3,748,810 |
Mattingly |
July 31, 1973 |
METHOD OF SWIMMING POOL MANUFACTURE
Abstract
This invention relates to the structural elements required and
the method of constructing a swimming pool having the ultimate in
design, space efficiency, ease of maintenance, and durability. More
particularly, this invention relates to a means of constructing a
swimming pool through the use of a plurality of interconnected
inside, outside, and step form structures placed in cooperating
positions with the plumbing, electrical, and reinforcing steel
placed therebetween whereupon an entire concrete swimming pool can
be poured in substantially one operation. Still, more specifically,
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.
Inventors: |
Mattingly; Charles D. (Wichita,
KS) |
Assignee: |
Mattingly, Inc. (Wichita,
KS)
|
Family
ID: |
22431538 |
Appl.
No.: |
05/127,709 |
Filed: |
March 24, 1971 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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792047 |
Jan 17, 1969 |
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Current U.S.
Class: |
52/741.12;
52/169.7 |
Current CPC
Class: |
E04H
4/144 (20130101); E04H 4/0081 (20130101); E04H
4/148 (20130101); E04H 4/1272 (20130101) |
Current International
Class: |
E04H
4/12 (20060101); E04H 4/00 (20060101); E04H
4/14 (20060101); E04h 003/16 () |
Field of
Search: |
;264/31,32,35 ;61/5,7,35
;4/172-172.18 ;52/169,742 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Murtagh; John E.
Parent Case Text
This application is a divisional application of the applicant's
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.
Claims
I claim:
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,
b. erecting and interconnecting a plurality of outside form
structures on said surface to form the exterior shape of the pool
structure, and upper 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,
e. 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,
f. 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 corner 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
b. 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 sand and white
portland cement,
b. after all of said concrete material is hardened approximately 12
hours, removing said inside form structures,
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,
g. removing said outside form structures, and
h. installing pool pump and filtering equipment to said plumbing
assembly.
7. The method of swimming pool construction as described in claim
6, wherein:
a. said first, second and third pour section of a concrete material
being of 3,000 to 4,000 pound test rock concrete with a 4 inch
slump,
b. said fourth pour section of a 3,400 to 3,600 pound test concrete
mix of said sand and said white portland cement, and
c. said interior finish being two coats of a white marble dust
paint.
8. The method of swimming pool construction as described in claim
6, including:
a. after the grinding step, grouting all required areas, and
b. setting and grouting tile members within recessed areas left by
said inside form structures to form a water line.
Description
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, non-grainy 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
preformed 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; (11) 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; (14) 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; (15) 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 inside and outside form structures and vibrating the same,
leaving approximately one inch of the deck and coping nose clear of
concrete; (17) 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; (21)
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 pre-constructed 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 3--3 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 6--6 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 interconnecting 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 width and 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 flow
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 pre-engineered 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 pre-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 to be 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 return 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 applicant's co-pending patent application entitled
"FORM STRUCTURE" filed Sept. 9, 1968, Ser. No. 758,255. The "FORM
STRUCTURE" 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
particularly, 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 pre-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
applicant's co-pending application, Ser. No. 759,619, filed Sept.
13, 1968, and entitled "SKIMMER STRUCTURE." It is noted that an
outer ventura 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 manner 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 forms to 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 corners 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 the proper 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 1/8 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 ty-cone
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 pattern 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 form 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 horizontally 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 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 form 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 ty-cone 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 120 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 flotation. 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 invention operates to set forth
precise, simple, easy to follow, 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.
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