Patent Application
20250207419
The present disclosure relates to insulated pools and improved construction methods for use in constructing insulated pools such as swimming pools, hot tubs, or fountains.
Some traditional methods of constructing a pool often involve the steps of excavating a hole for the pool, building a form inside the hole (often of wood) with bracing as necessary to support the form, filling the form with concrete (sometimes adding scaffolding elements, such as rebar, to give the concrete additional tensile strength), and letting the concrete set. After this, the form is traditionally removed and the gap between the concrete pool and the surrounding earth is filled (e.g., with gravel or dirt). Although these methods are effective at producing functional pools, such pools often lose a significant amount of heat energy through their uninsulated bottom and sides, making maintaining a pleasant swimming temperature much more costly.
In short, while there are existing methods for creating pools, some such methods have substantial drawbacks, as discussed above. For this and other reasons, there exists a need to improve or even replace certain methods.
The systems and methods disclosed herein provide improved insulated pools, and improved methods for creating the same, which address some deficiencies in the current insulated pool and insulated pool construction industry.
Some implementations of the systems and methods disclosed herein use less concrete, less rebar, or less insulation than do some current insulated pools. Consequently, in some implementations, construction materials used for building the improved insulated pools weigh less than those construction materials used in current methods. In some cases, installation of the improved insulated pools is accomplished more easily than other insulated pools. In some cases, these attributes of implementations result in less labor, thereby increasing the efficiency and profitability of construction crews, while also decreasing wait times and costs to the consumer.
In some implementations, the decreased material requirements and increased efficiency of construction crews allow for construction of improved insulated pools at a lower cost, thereby increasing the accessibility of insulated pools while providing all the energy-saving, structural, and cost-efficient benefits that insulated pools have over non-insulated pools. Moreover, in some cases, the improved insulated pools last longer and require less maintenance by allowing for the insulation to be embedded in concrete, thus protecting the insulation from wear and tear and environmental damage, while simultaneously allowing the concrete to be decorated, textured, or otherwise embellished.
According to some implementations of the disclosed systems and methods, an insulated, in-ground pool, such as a swimming pool, hot tub, fishpond, water feature, fountain, cooling ponds, decorative ponds, or any other suitable place where water pools (or is held) is formed from construction panel components within a concrete structure. The pool includes at least one of an insulated basin floor and one or more insulated basin walls. In some instances, the insulated basin floor is generally horizontal. In some cases, the floor includes inclines, grading, drop-offs, or other features. For the purposes of this disclosure, “generally horizontal” may mean at least as horizontal as it is vertical, meaning no more than 45 degrees tilted from the orientation parallel with flat ground (although, if further specified, “generally horizontal” can mean any angle less than 45 degrees from parallel with flat ground, such as less than 35 degrees, 30 degrees, 25 degrees, 20 degrees, 15 degrees, 10 degrees, 5 degrees, 3 degrees, 2 degrees, or 1 degree).
In some implementations, the wall includes a single wall (e.g., in a generally circular or other smoothly curving shape). In some instances, the walls include multiple straight or curved walls that join with each other at one or more corners. In some cases, the walls or floor of the pool contain drains, jets, lights, filters, or any other swimming pool features. The walls or floor are, in some cases, tiled, covered, textured, or otherwise embellished to increase the aesthetic or practical value of the pool.
According to some implementations, the insulated basin floor and one or more insulated basin walls are formed of one or more of the following: a first outer layer of concrete, a second outer layer of concrete, and an inner insulating core. In some cases, the inner insulating core is sandwiched or otherwise positioned generally between the outer layers of concrete. Thus, the concrete on either side of the insulating core, in some cases, provides structural support, and the insulating core, in some cases, insulates the walls from temperature change such as heat loss. In some implementations, the layers of concrete and the insulating core are affixed together in such a manner that they form a unitary whole.
In some implementations, the insulating core is made from one or more insulating materials, such as a foam, which, in some cases, is capable of providing insulation while generally retaining its shape and structure. In some cases, the foam is configured to be cut or burned away at places as needed, such as to provide a passage for a plumbing or electrical feature. In some implementations, the foam is configured to be bent to conform to a particular shape.
In some implementations, the pool includes a rebar construction joint, with such rebar construction joint forming straight or curved pieces of rebar tied into a scaffold, which in some instances increases the strength of the concrete used in the basin walls and floor. In some cases, the rebar construction joint generally corresponds with the size and shape of the pool, and it provides additional structural integrity to the pool.
In some implementations, the rebar construction joint includes a generally horizontal floor section and a generally vertical wall section. In some cases, the generally horizontal floor section is at least partially embedded in the insulated basin floor and the generally vertical wall section is at least partially embedded in the basin wall or walls. These sections of the rebar construction joint, are, in some iterations, embedded in the concrete of the walls and/or floor (e.g., if the concrete mix is poured or otherwise applied over the rebar construction joint). In some cases, they are embedded in (or otherwise attached to) the insulating cores. In some implementations, the rebar construction joint includes pieces of rebar. In some implementations, the pieces of rebar are inserted through the insulating core or attached to the insulating core. The rebar construction joint of some implementations passes through the insulating core and the inner and outer layers of concrete to help hold the components of the basin walls and floor together.
In some implementations, the first outer layer of concrete has a thickness of at least 0.5-20 inches (or any subrange thereof, such as at least 3-4 inches). In some cases, the second outer layer of concrete has a thickness of at least 0.2-10 inches (or any subrange thereof, such as at least 0.5-2 inches). In some cases, one of the layers of concrete is optionally omitted. In some cases, the inner insulating core has a thickness of at least 0.5-20 inches (or any subrange thereof, such as at least 3-4 inches). In some implementations, at least one of the first outer layer of concrete, the second outer layer of concrete, and the inner insulating core has a thickness at least two times a thickness of at least one other of the first outer layer of concrete, the second outer layer of concrete, and the inner insulating core. In many implementations, the wall and floor components are not required to have any particular thickness, but rather the layers of concrete and insulation can be adjusted to match the specifications of the desired insulated pool.
In some implementations, the pool includes one or more of a shelf, stairs, ramps, waterfall features, interior walls, or other pool features that can add variety, accessibility, or aesthetic value to the pool. In some cases, these pool features are constructed in accordance with traditional swimming pool construction practice. In some cases, they are constructed with improved insulation in the same or a similar manner to the construction of the basin walls and floor. As an example, the pool features of some implementations include two outer layers of concrete and an inner insulating core, with such components joined together to form a unitary whole. Additional pool features of some implementations include lights, jets, or any other pool features, in some cases attached to a rebar construction joint. In many implementations including such pool features, it is desirable to include a shelf that is positioned at a height less than the height of at least one of the basin walls. Indeed, in many instances, such a shelf has a height such that it is submerged when the pool is filled, but is still higher than the floor of the pool to allow for persons to sit or stand on the shelf, thereby enjoying a shallower area of the pool.
In some implementations, the inner insulating core used in the basin floor and walls includes a piece of insulating material that is generally disposed in a gap between two grid mats.
One or more grid mats includes, in some cases, longitudinal and transverse wires crossing one another, with the wires attached together at the points where the wires cross. The grid mats are, in some cases, separated by a gap, which in some cases is wider than a thickness of the insulating material that is disposed between the two grid mats. In some implementations, there are spacer wires that are cut to length and attached (e.g., by welding) to the points of cross of the spacer wires with the respective grid mats. The spacer wires of some implementations cross through the insulating material, joining the grid mats and the insulating material into one unitary whole.
In some iterations, the insulating core and the grid mats are provided as a plurality of segments spliced together to form a unitary whole. In some instances, these segments are spliced together using splice mesh, a piece of which is configured, in some implementations, to be attached to two or more segments to join them together. In some instances, the splice mesh is configured to be attached to the segments by clipping, stapling, welding, tying, or otherwise attaching it. Like the grid mats, splice mesh in some instances is formed of longitudinal and transverse wires crossing one another, with the wires attached together (in some cases) at all or some of the points where the wires cross.
In some iterations, splice mesh is bent to create an edge mesh, whereby it is configured to be attached to a floor insulating core and a wall insulating core or extending between adjacent wall cores. Splice mesh is some cases is configured to be bent in a U-shape to create a U-mesh, a horseshoe shape, a V-shape, or any other suitable shape that can fit over the end of one or more segments, thereby coming into contact (in some cases) with both of the grid mats of at least one single segment of the basin floor or wall.
Some implementations of the disclosed systems and methods include a method for constructing an insulated, in-ground pool, such as a swimming pool, hot tub, fountain, or another structure. Such a method includes, in some cases, excavating an in-ground space such as a hole, a pit, a trench, or another space configured to fit a pool or water feature. The in-ground space formed by such excavation includes, in some cases, a generally horizontal floor and one or more generally vertical walls. The in-ground space so excavated is, in some iterations, deeper than the intended depth of the in-ground pool an amount generally equal to an intended floor thickness of the in-ground pool, and, in some iterations, it is wider than the intended width of the in-ground pool (in any particular direction/dimension) an amount generally equal to approximately twice an intended wall thickness of the in-ground pool. Indeed, in some implementations, the width of the in-ground space does not exceed the intended width of the in-ground pool plus twice the intended wall thickness of the in-ground pool. According to some implementations, the method includes installing rough plumbing and electrical features to the in-ground space once it has been excavated.
According to some implementations, the method includes placing, assembling, tying, or otherwise building a rebar construction joint in the in-ground space. As described above, the rebar construction joint of some implementations includes a generally horizontal floor section and a generally vertical wall section. In some cases, the generally horizontal floor section is configured to be at least partially embedded in the basin floor and the generally vertical wall section is (in some cases) configured to be at least partially embedded in the basin wall or walls. Some iterations of these sections of the rebar construction joint are configured to be embedded in the concrete of the walls and/or floor (e.g., if the concrete mix is poured or otherwise applied over the rebar construction joint). In some cases, they are embedded in (or otherwise attached to) the insulating cores that will be installed. The rebar construction joint includes (in some cases) pieces of rebar that can be inserted through the insulating core or attached to the insulating core. The rebar construction joint of some iterations passes through the insulating core and the inner and outer layers of concrete in order to help hold the components of the basin walls and floor (that will eventually be formed) together.
According to some implementations, the method includes applying a first layer of floor concrete. In some cases, the first layer of floor concrete at least partially overlaps with the generally horizontal floor section of the rebar construction joint. Consequently, the rebar construction joint acts, in some cases, partially as a scaffold for the concrete that then generally covers the bottom of the in-ground space and will eventually form part of the bottom of the pool. The rebar construction joint becomes, in some implementations, part of a unitary whole with the first layer of floor concrete, increasing the strength of the floor concrete.
In some implementations, the method includes laying at least one generally horizontal insulating core on the first layer of floor concrete before the first layer of floor concrete has set. Thus, the insulating core is, in some cases, suspended on top of and/or partially embedded in the first layer of floor concrete. If needed, some implementations of the method include vibrating (such as by using a plate compactor) or applying pressure to the insulating core to cause it to better settle on and/or embed itself in the first layer of floor concrete. Such vibration or pressure is sometimes effected until the insulating core has reached a desirable depth and position (generally, with a lower grid mat fully embedded in the concrete and a lower surface of the insulating core fully resting on the concrete).
According to some implementations, the method includes securing one or more generally vertical insulating cores to the generally vertical wall section of the rebar construction joint. This securing is, in some cases, accomplished through any method of securing. In some cases the securing includes a permanent attachment (whereas in some cases it includes a selective attachment). For example, the generally vertical insulating cores can be welded, tied, or clipped to the rebar construction joint, but they can also be (at least initially) removably attached through such means as sliding the insulating core onto at least part of the generally vertical wall section of the rebar construction joint, such that at least part of the rebar construction joint becomes generally contained within the insulating core.
The generally vertical insulating cores, in some implementations, have an inner surface (e.g., facing generally toward the inside of the pool) and an outer surface (e.g., facing generally toward the outside of the pool). In some implementations, the generally vertical insulating cores are placed in such a position so as to create a gap between the outer surface of the generally vertical insulating cores and the wall or walls of earth that make up the wall or walls of the in-ground space.
In some implementations, the method includes applying an outer layer of wall concrete. In some cases, the outer layer of wall concrete is applied between the outer surface of the generally vertical insulating cores and the surrounding wall of earth. As an example, the outer layer of wall concrete is, in some cases, poured into the gap defined by the wall(s) of earth and the generally vertical insulating cores. Consequently, in some implementations, the wall and the cores together act as a form, holding the concrete in place as it sets. In some implementations, as necessary, appropriate bracing extending between the generally vertical insulating cores and/or between the generally vertical insulating cores and the at least one generally horizontal insulating core secures the insulating wall(s) in place while the outer layer of wall concrete is poured and at least partially cures.
In some iterations, the outer layer of wall concrete fills the gap substantially or completely, thus leaving little to no space between the pool wall and the earth wall that would later need to be back filled. In some cases the concrete adheres to or partially envelops the generally vertical insulating cores to become part of a single structural element. In other words, in at least some implementations, the outer layer of wall concrete envelops an outward-facing grid mat of the generally vertical insulating cores. In some implementations, the outer layer of wall concrete envelops or partially envelops the generally vertical wall section of the rebar construction joint.
In some implementations, bracing is placed on the inside of the pool before the outer layer of wall concrete is applied. For example, Gates clamps, “grasshoppers,” or similar devices can be used to secure walers to the inner grid mats of the wall formed of insulating generally vertical insulating cores for bracing. Sometimes such bracing holds the generally vertical insulating cores in place (relative to other wall(s) or to the floor) while the outer layer of wall concrete is being poured and setting, and consequently it can be effected in any manner that would accomplish this purpose. In some implementations, such bracing is removed after the outer layer of wall concrete has set sufficiently.
According to some implementations, the method includes applying an inner layer of wall concrete to the inner surface of the one or more substantially vertical insulating cores. For example, the applying is, in some cases, done with a projectile applicator, which causes concrete to be projected onto a surface at a high velocity, causing the concrete to adhere to the surface and consolidate from the impact. Projectile application is often known as shotcrete, gunite, or sprayed concrete, and any such projectile application methods can be implemented in connection with various implementations of the disclosed systems and methods.
According to some implementations, the method includes applying a second layer of floor concrete. In some cases, the applying includes pouring concrete or applying concrete with a projectile applicator, and the resulting second layer of floor concrete substantially covers (in some cases) the generally horizontal insulating core. In some implementations this second layer of floor concrete adheres to or partially envelops the generally horizontal insulating core, thereby forming a unitary whole with the generally horizontal insulating core (and the other components attached thereto). In other words, in at least some implementations, the second layer of floor concrete envelops an upper grid mat of the floor's generally horizontal insulating core(s).
According to some implementations, the insulating cores used in the method are each comprised of two grid mats of longitudinal and transverse wires crossing one another, the wires attached together at a point of cross (e.g., by welding or in any other suitable manner), the grid mats spaced apart from each other by a gap, and a piece of insulating disposed within the gap between the grid mats. In some implementations, the gap between the grid mats is greater than a thickness of the heat insulating material, thus creating a space between each grid mat and the piece of insulating material. In some implementations, the grid mats become embedded in the concrete applied during the construction of the pool. In some implementations, the insulating cores are removably attached to a rebar construction joint by sliding a part of the rebar construction joint (e.g., a piece of rebar, a protrusion, part or all of the rebar construction joint's generally vertical wall portion) into the space between one of the grid mats and the piece of heat insulating material.
According to some implementations, the method includes (prior to laying any generally horizontal insulating cores on the first layer of floor concrete) securing together at least two generally horizontal insulating cores using at least one piece of bottom wire mesh (e.g., splice mesh). In some cases this is done by securing the bottom wire mesh to a bottom side of each of the cores desired to be secured together, such as by clipping (attaching a staple or other clip), adhering, tying, or otherwise attaching the mesh to each core. As an example, the mesh of some iterations is clipped to one of the grid mats on each insulating core. According to some implementations, the bottom wire mesh becomes embedded within the first layer of floor concrete when the generally horizontal insulating cores are jointly laid on the first layer of floor concrete.
According to some implementations, the method includes (e.g., after laying the generally horizontal insulating core or cores on the first layer of floor concrete) attaching at least one piece of a top wire mesh to a top side of at least two of the generally horizontal insulating cores. Similar to the above-described bottom wire mesh, the top wire mesh in some instances is splice mesh, and it is (in some instances) clipped to the now-generally upward-facing grid mats of the generally horizontal insulating cores (or otherwise attached to such insulating cores). This can be done in such a manner that the top wire mesh becomes (at least partially) embedded in the second layer of floor concrete with the upper grid mats of the generally horizontal insulating cores after the second layer of floor concrete is poured (or otherwise applied) on the generally horizontal insulating cores. Accordingly, some implementations include a plurality of generally horizontal insulating cores that are attached together on both sides with splice mesh.
According to some implementations, the method includes (prior to applying the outer layer of wall concrete), securing together at least two of the generally vertical insulating cores using at least one piece of an outer wire mesh by securing the at least one piece of outer wire mesh to the outer surface of at least two of the generally vertical insulating cores (generally before the generally vertical insulating cores are placed in the in-ground space), such that when the outer layer of wall concrete is applied, the at least one piece of outer wire mesh becomes at least partially embedded in the outer layer of wall concrete with the outer grid mats of the generally vertical insulating cores). In some cases, this includes clipping splice mesh to the grid mats on the outer surface of the insulating cores, or by otherwise attaching the outer wire mesh.
According to some implementations, the method includes (prior to applying the inner layer of wall concrete) attaching at least one piece of an inner wire mesh to the inner surface of at least two of the generally vertical insulating cores, such that when the inner layer of wall concrete is applied, the at least one piece of inner wire mesh becomes at least partially embedded in the inner layer of wall concrete with the inner grid mats of the generally vertical insulating cores). In some cases, this includes clipping splice mesh to the grid mats on the inner surface of the insulating cores, or by otherwise attaching the inner wire mesh to each insulating core desired to be secured.
According to some implementations, the method includes attaching at least one piece of corner wire mesh between at least one of the generally vertical insulating cores and at least one of the generally horizontal insulating cores, such that when the second layer of floor concrete is applied, the at least one piece of corner wire mesh becomes at least partially embedded in the second layer of floor concrete with the upper grid mat(s) of the generally horizontal insulating core(s), and such that when the inner layer of wall concrete is applied, the at least one piece of corner wire mesh becomes at least partially embedded in the inner layer of wall concrete with the inner grid mats of the generally vertical insulating cores. The corner wire mesh in some instances includes a piece of splice mesh that has been bent to generally a right angle, such that it has a generally horizontal floor section that becomes at least partially embedded in the second layer of floor concrete, and a generally vertical wall section that becomes at least partially embedded in the inner layer of wall concrete. Thus, some implementations of the corner wire mesh join together the insulating cores in the walls and the floor.
According to other implementations, the insulated, in-ground pool includes an insulated basin floor and one or more insulated basin walls, with such insulated basin floor and insulated basin walls each including an outer layer of concrete, and inner layer of concrete, and an insulating core, where the insulating core is comprised of two grid mats of longitudinal and transverse wires, the wires crossing one another and attached together at a point of cross. In some cases, the grid mats are spaced apart from each other by a gap, and a piece of insulating material is disposed within the gap between the grid mats.
According to some implementations, the piece of insulating material is positioned generally between the two layers of concrete. In some cases, each of the grid mats is at least partially embedded in one of the respective layers of concrete. Thus, some implementations include a piece of insulating material with a grid mat on either side of the insulation, with each grid mat at least partially embedded in a layer of concrete, forming a panel of a piece of insulation sandwiched between two layers of concrete. In some cases, each layer is reinforced by one of the grid mats such that the layers of concrete and the insulating core form a unitary whole.
According to some implementations, the insulating core also includes a plurality of linking structural elements at least partially embedded in the piece of insulating material disposed within the gap between the grid mats. In some cases, the plurality of linking structural elements are generally attached to each of the grid mats to join the grid mats and piece of insulating material into a unitary whole. For example, the linking structural elements can include spacer wires that are attached to each of the grid mats and pass through the piece of insulating material. Thus, the spacer wires of some implementations hold the grid mats in a parallel (or any other desired) configuration and prevent them from sliding, twisting, or moving toward or away from one another. In some implementations, the spacer wires are cut to length and welded to the points of cross on the respective grid mats. According to some implementations, the spacer wires extend between the grid mats at an oblique angle.
According to some implementations, the linking structural elements include rebar segments inserted between the grid mats proximate to and affixed to one or the other of the grid mats.
According to some implementations, the pool includes a rebar construction joint having a generally horizontal floor section and a generally vertical wall section. In some cases, the generally horizontal floor section is at least partially embedded in the insulated basin floor and the generally vertical wall section is at least partially embedded in the one or more insulated basin walls such that the rebar construction joint, the insulated basin floor, and the one or more insulated basin walls form a unitary whole. In some implementations, the rebar construction joint is tied, welded, clipped, glued, or otherwise attached to one or more grid mats, or pieces of the rebar construction joint can slide in between grid mats and the attached piece of insulating material in order to secure an insulating core. The rebar in some cases also traverses (e.g., being embedded or partially embedded in) the insulating material, adding additional structural strength or anchoring elements of the pool in their proper places.
In some implementations, the insulating core is comprised of an insulating wall core that is joined to an insulating floor core. In some implementations, they are joined together by attaching them together through clipping, welding, or another method, or they are joined together using another material that attaches to both the insulating wall core and the insulating floor core. As an example, one or more pieces of splice mesh is used in some cases. In some implementations, the splice mesh includes transverse and longitudinal wires that cross each other and are attached at the points of cross, and it is clipped, tied, twisted, spliced, glued, welded, or otherwise attached to the insulating cores. For example, in some implementations, the splice mesh is clipped to a grid mat on the insulating wall core and to a grid mat on the insulating floor core. In some implementations, the splice mesh is bent at generally a right angle to form a corner splice mesh, wherein there is a generally vertical section (which is attached to the wall core) and a generally horizontal section (which is attached to the floor core).
According to some implementations, the insulated basin floor and/or the insulated basin walls are formed of a plurality of panel segments attached together to form a unitary whole. As an example, in some implementations, the segments are attached together directly or by attaching another material to two or more segments. For instance, the segments of some implementations are attached together by clipping (or otherwise attaching) a piece of splice mesh to two adjacent panels.
According to some implementations, one or more additional pieces of wire mesh is added for stability. The additional piece(s) of wire mesh include(s) two generally-right-angle bends, so as to form a general U-shape, forming a U-mesh. The U-mesh is placed over the edges of the panels or cores, thus coming into contact with the grid mats on either side of the piece of insulating material. The U-mesh is then secured in place (such as through clipping, welding, tying, or otherwise attaching).
According to some implementations, the wire mesh such as the splice mesh, edge mesh, U-mesh, or any combination of the above, becomes at least partially embedded in one or more of the layers of the concrete. Thus, the wire mesh adds structural integrity to the concrete while helping to hold various components in place.
According to some implementations, the cement or concrete, used includes green concrete, Portland concrete, ashcrete, blast furnace slag, micro silica, fibrous concrete, plastic waste concrete, or any other concrete alternative.
According to some implementations, the piece of insulating material includes foam, fibrous materials, polymer insulators, thermoplastics, cork, or any other insulating material. In many implementations, however, the material comprises a foam that is sufficiently rigid to retain its shape, is capable of being cut or burned away at certain locations as desired. In some cases, the insulating material is lightweight.
Any of the implementations can include elements of any of the other implementations. For example, the methods described herein can include making or combining any of the various structures recited herein, and the structures can include anything included in the methods described. The implementations discussed are for illustrative purposes only and are not meant to be interpreted as limiting the claims in any way.
The objects and features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments and are, therefore, not to be considered limiting of its scope, the systems and methods will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
A description of embodiments will now be given with reference to the Figures. It is expected that the disclosed systems and methods may take many other forms and shapes, hence the following disclosure is intended to be illustrative and not limiting, and the scope of the systems and methods should be determined by reference to the appended claims.
Insulated swimming pools can retain their temperature significantly better than some traditional, uninsulated pools. The ability of insulated pools to conserve heat energy can significantly reduce the costs of operating a pool, particularly costs relating to electricity and heating. Insulation can also increase the durability and structural integrity of a pool.
Some current methods of insulating swimming pools include ICF (Insulated Concrete Form) construction, which entails making a form out of polystyrene foam or another insulating material instead of making a form out of wood. Concrete can then be poured into the insulating form, and then the form and the concrete become part of a unitary whole and the foam form encasing the concrete does not need to be removed. The foam on either side of the concrete can provide insulation, and the concrete in between the foam sheets can provide the necessary pool structure.
However, some current methods of constructing insulated swimming pools can be time-consuming and costly. The added time and effort of constructing an insulated swimming pool, in addition to the added costs of the insulating materials, can make constructing an insulated swimming pool significantly more expensive than constructing an uninsulated swimming pool. The current methods can be particularly costly because of the costs associated with using two layers of insulation, as well as the materials needed to join the layers of insulation together to create a form. Additionally, a large amount of concrete is then used to fill the form. For these reasons, constructing an insulated swimming pool can be more costly, significantly more difficult, and take significantly longer than constructing a traditional swimming pool with no insulation.
Some pools insulated in such a manner can also be heavier than non-insulated pools, putting added strain on the foundational earth in which the pool is set. This can create the necessity of building additional structural elements or performing additional engineering work to ensure the pool will withstand the environmental stresses it will be subject to. Furthermore, insulating the bottom of a pool using current methods can present unique challenges that arise from the need to have highly smooth ground for the necessary insulating form to lie flat so a smooth pool bottom can be formed. Moreover, the insulation in such pools can then be subject to wear and tear, as the insulation may be exposed to chemicals in pool water, the bare earth outside the pool, insects, fungus, plants, and other environmental factors, as well as scratching, tearing, or other physical damage that can occur from being exposed to pool users or other forces. Additionally, it can be difficult to create insulated pool features such as stairs or seats using current insulating techniques because of the necessity of building custom insulating forms for unique features.
According to some embodiments of the described systems and methods, an insulated, in-ground pool, such as a swimming pool, hot tub, fountain, fishpond, water feature, cooling pond, pond, or any other structure (or pool) capable of holding liquid and insulating such liquid against temperature change (a pool) is provided. According to some embodiments, the pool has a basin floor 20 (a floor) and one or more basin walls 22 (walls). Although the floor and walls can have any configuration for holding a liquid, some embodiments are configured such that at least a portion-and in some cases, an entirety-of the floor or walls 22 is insulated. Although such insulation can be accomplished in any suitable manner, some embodiments utilize insulated construction panel components within a concrete structure, as will be shown and described in detail in a later portion of the specification. By way of non-limiting illustration,
In some embodiments, the pool contains one or more auxiliary features, such as one or more: shelves 24 (or other platforms for standing, sitting, placing objects, or fulfilling other purposes, which in some cases have a height that is lower than a height of the basin walls, so that the shelf or other feature can be submerged or partially submerged when the pool contains liquid); stairways 26; ladders; slides; dock areas; waterfalls; water features; climbing walls; plumbing access points 28 (which can be used for drains, jets, filters, or other relevant pool plumbing devices); electrical access points (which can be used for lights, speakers, filters, jets, or other electrical features); or any other features that may be used in connection with pools. By way of non-limiting illustration,
Although the pool can be built in any suitable environment, some embodiments of the pool are built in one or more in-ground spaces (e.g., an excavated space or another depression in the ground). In some cases, the in-ground space has a shape similar to the desired shape of the pool (e.g., a floor area 120 on which the basin floor 20 is configured to be built, and a wall area 122 on which the basin walls 22 are configured to be built). By way of non-limiting illustration,
According to some embodiments, the pool includes one or more reinforcement components 30. The reinforcement components can include any suitable reinforcement components as used in construction, including one or more of: rebar (e.g., carbon steel rebar, stainless steel rebar, galvanized rebar, epoxy coated rebar, glass-fiber-reinforced-polymer (GFRP) rebar, welded wire fabric (WWF) rebar, expanded metal rebar, high strength deformed (HSD) rebar, composite bars, or any other type of rebar made of any metal, alloy, or other material); reinforcement shards, such as metal fiber or other shards (of any material, shape, or size); or tension strands (e.g., pretension strands or post-tension strands).
The reinforcement component 30 can be included in any suitable position or configuration within the pool. In some embodiments, the reinforcement component is coupled to one or more other components of the pool (e.g., the basin floor 20, floor area 120, walls 22, wall area 122, auxiliary components, or other components yet to be discussed, such as layers of concrete 36, insulating cores 38, grid mats 42, panels 45, wire mesh 46, or any other components discussed herein).
Where the reinforcement component 30 includes rebar, the rebar (or any other suitable reinforcement feature) can be included in any suitable configuration. By way of non-limiting illustration, some embodiments include rebar in an insulating core 38. In some cases, the strength of the pool can be increased by including rebar close to the center of a layer of concrete 36. Accordingly, some embodiments include rebar (or any other reinforcement component) near the center of one or more layers of concrete. In some cases, rebar is positioned inside a grid mat 42 (such that the rebar is between the grid mat and a piece of insulating material 40), and in some cases, rebar is positioned outside a grid mat (such that the grid mat is between the rebar and the piece of insulating material). In some embodiments, rebar is positioned substantially parallel to one or more grid mats (e.g., parallel to a plane of the grid), and in some cases, rebar is positioned substantially orthogonal to one or more grid mats. Accordingly, in some cases, rebar extends through multiple layers (e.g., through insulating material as well as through layers of concrete).
According to some embodiments, rebar (or another reinforcement component 30) is used to form a scaffold (also known as a construction joint) upon which other components of the pool can be built. In some cases, the construction joint is tied, built, constructed, or placed according to engineers' specifications, and in some cases, it acts as a skeleton for other parts of the pool, as discussed herein. While the scaffold can have any suitable feature, shape, configuration, size, and other characteristics, some embodiments of the scaffold include a portion generally configured to align with the basin floor 20 (such portion being referred to as a generally horizontal section 32) and a portion generally configured to align with the basin walls 22 (such portion being referred to as a generally vertical section 34). Despite the terms ‘generally horizontal’ and ‘generally vertical’ it is understood that such terms are merely used for convenience to orient the reader to understand that one portion (the generally horizontal section) is typically associated with the pool floor and one portion is typically associated with the pool walls (the generally vertical section), although the generally horizontal section can include vertical components (or otherwise angled or non-horizontal components) and the generally vertical section can include horizontal components (or otherwise angled or non-vertical components). Moreover, the generally horizontal section and the generally vertical section can each be incorporated into various parts of the pool (e.g., they are not necessarily limited to being used to strengthen and reinforce the structural integrity of the basin floor or the basin walls). That said, in some embodiments, the generally horizontal section is incorporated (or partially incorporated) into the basin floor, and the generally vertical section is incorporated (or partially incorporated) into the basin walls. It is worth reiterating that some embodiments have sloping or graded floors or walls (or portions thereof), and the walls and floors of pools can accordingly take many shapes. Thus, in some embodiments, the construction joint has a size and shape that generally corresponds with the size and shape of the pool desired to be built. Thus, there is flexibility for the generally horizontal section 32 and the generally vertical section 34 to take on different forms.
By way of non-limiting illustration,
Where the reinforcement component 30 includes reinforcement shards (e.g., instead of or in addition to rebar), the reinforcement shards can include any pieces of any material configured to provide strength to the pool. For example, small pieces of material can be mixed in with the layers of concrete 36, embedded in the insulating core 38 (e.g., partially embedded in the insulating core, such that a portion protrudes into a layer of concrete when the concrete is poured), attached to a grid mat 42, or otherwise included. The reinforcement shards can be metal or any other material (e.g., alloys, wood, glass, plastic, carbon fiber, polymer material (e.g., polyvinyl alcohol (PVA), polypropylene), or any other material). The reinforcement shards can be any size, but in some cases they are relatively small (e.g., 1 cm to 20 cm in length, or any subrange thereof, such as 1 cm to 10 cm, 3 cm to 8 cm, or any other suitable subrange). In some cases, reinforcement shards are small enough to fit through the holes in the grid structure of the grid mat (e.g., if the grid size is approximately 2 inches, then the reinforcement shards can be under 2 inches). Reinforcement shards can also be any suitable shape, such as rods, helices, spikes, strands, plates (e.g., square, rectangular, triangular, circular, hexagonal, polygonal, or otherwise shaped flat or semi-flat plates), or any other shape. In some cases where reinforcement shards are embedded in the insulating core, the reinforcement shards are configured to be retained within the insulating core when the concrete is poured, but in some cases, at least some of the reinforcement shards are configured to come free of the insulating core when the concrete is poured so as to be mixed in with (e.g., randomly dispersed within) the concrete. In some embodiments, including reinforcement shards decreases the amount of rebar necessary to provide the desired strength.
Where the reinforcement component 30 includes one or more tension strands (e.g., in addition to or instead of rebar or reinforcement shards), any suitable tension strands can be used. Some embodiments include one or more pretension strands, in which a strand is attached to bulkheads on either side of the applicable portion of the pool (e.g., a layer of concrete 36) and placed under a great amount of tension prior to pouring the concrete. Then, after the concrete is set, the tension is released and the strand constricts, thereby placing the structure under compression, thereby adding strength. Some embodiments include one or more posttension strands, in which a strand is placed under tension after the concrete has set to place the structure under tension, thereby adding strength. The strand can be any suitable strand capable of withstanding the amounts of tension necessary, such as steel cable or any other high-load capacity strand.
With further respect to the basin floor 20 and walls 22 of some embodiments, the floor and walls can have any suitable component useful for forming an insulated, water-tight barrier. For example, some embodiments of the floor or walls are formed of one or more outer layers of concrete 36 (e.g., a first outer layer disposed on a first side, and a second outer layer disposed on a second side, along with any number of additional layers), sandwiching an inner insulating core 38. In this respect, in some embodiments, the pool has great structural integrity (stemming in part from the double layer of concrete), as well as excellent insulation properties (stemming in part from the insulating core), all while (in many cases) using less concrete, steel, insulation, and other materials than other methods of construction of insulated pools, such as those utilizing insulated concrete forms. Additionally, this configuration allows the concrete 36 to be exposed and the insulation 38 to be protected (in some cases). Thus, in some implementations, the insulation is shielded from damage due to water, chemicals, insects, plants, fungus, or physical damages, such as scratching or tearing. At the same time, the pool-side or otherwise exposed concrete is freely available to be painted, coated, decorated, embellished, textured, tiled, or otherwise modified to increase the aesthetic or functional value of the pool. By way of non-limiting illustration,
In some embodiments, the walls 22 or floor 20 (or both) include a single, unitary piece of insulation 38 (e.g., sandwiched between layers of concrete 36 as discussed). That said, some embodiments include one or more panels 45 (as discussed in more detail below), with each panel including its own piece of insulating material. Thus, the components discussed herein are, in some cases, components of the basin floor or walls in general, and in some cases they are components of one or more panels. By way of non-limiting illustration,
According to some embodiments, the insulating core 38 includes one or more pieces, slabs, sections, or bodies of insulating material 40 (insulation). The insulation can include any suitable insulation, such as foam, fiberglass, mineral wool, cellulose, natural fibers, polystyrene (e.g., expanded polystyrene or EPS), polyisocyanurate, polyurethane, perlite, cementitious foam, phenolic foam, materials with air pockets, or any other suitable type of insulation.
According to some embodiments, one or more grid mats 42 are affixed to the insulation 40. In some cases, the insulation is disposed between two or more grid mats. The gird mats can include any structural component that is capable of assisting in coupling concrete to the insulating core. For example, a grid mat can, in accordance with some embodiments, include any assembly of wires, planks, beams, stakes, cables, rebar, fibers, or any other structural elements useful for coupling concrete to the insulating core. Moreover the structural elements can have any suitable configuration (e.g., running parallel with each other, forming a grid shape, running diagonally, intersecting each other, or any other suitable pattern). The grid mats can include any type of grid (e.g., a lattice, a net, a honeycomb, or another grid of any shape, such as a grid with a triangular, square, diamond, hexagonal, X-shaped, alternating pentagonal and triangular, or any other tessellating or non-tessellating regular or irregular grid pattern) formed of any type of material (e.g., wood, metal, glass, plastic, carbon fiber, polymer material, cardboard, paper, nylon, fabric, netting, or any other material). Strands of material (e.g., wires, bars, or other strands) can be coupled together in any suitable manner, such as via one or more welds, adhesives, staples, wire couplings, eyelets, magnets, hook-and-loop fasteners, interference fits, friction fits, tongue-and-groove connections, snaps, ties, rivets, stakes, wire ties, clamps, clips, or any other couplers. The grid mats can be parallel or non-parallel to each other, planer, non-planar, curved, wavy, or otherwise configured. For example, the grid mats of some embodiments include longitudinal and transverse wires crossing each other and attached together at the points of cross. According to some embodiments, the wires are attached via welding, but in some embodiments they are attached via tying, bending the wires around each other, clipping, or another method for binding the wires together to form a grid mat.
The grid mats of some embodiments are spaced apart by a gap, and the gap in some cases is greater than a thickness of the piece of insulating material 40. The piece of insulating material of some embodiments is disposed within the gap between the grid mats 42, such that there is a space between each of the grid mats 42 and the piece of insulating material 40.
Additionally, the grid mats 42 of some embodiments are attached to each other, such as by one or more linking structural elements 44. In some embodiments, these linking structural elements 44 comprise spacer wires that are attached to each of the grid mats (such as by clipping, tying, welding, or otherwise coupling). In some cases, they are cut to a length that corresponds with the gap between the grid mats 42. The linking structural elements 44 of some embodiments traverse through the piece of insulating material, thus binding the grid mats 42 and the piece of insulating material 40 into a unitary whole, which (in some cases) provides the insulating core 38 and structural steel to secure the outer layers of concrete 36 to the insulating core 38. In some embodiments, the linking structural elements 44 cross through the piece of insulating material 40 perpendicular to the grid mats 42, and in some embodiments they are longer than the gap between the grid mats 42 and cross through at an angle. In some embodiments, the linking structural elements include materials other than spacer wires, such as rebar or other materials capable of linking the grid mats 42 together. Additionally, in some embodiments, other materials, such as rebar or other structural reinforcement materials, occupy the space between the grid mats 42 and the piece of insulating material 40, as may be desired for strengthening the construct.
As discussed above, the piece of insulating material 40 can be made of any insulating material, in single layers or in multiple layers attached together in any reasonable manner. That said, in some embodiments, the piece of insulating material 40 comprises a material, such as a foam (e.g., EPS), that can easily be cut, melted, and/or burned away to change the shape of the insulating core 38 or to allow for objects (such as rebar, plumbing, electrical components, structural elements, or other objects) to pass through the insulating core 38.
The insulating core 38 of some embodiments comprises a sheet-like or rectangular-prismatic (e.g., cuboid), but it can also be any other shape that would allow for the pools disclosed herein to be constructed or the methods disclosed herein to be carried out. By way of non-limiting illustration,
According to some embodiments, when the insulating core 38 is used in connection with layers of concrete 36, the grid mats 42 are configured to become at least partially embedded in the respective layers of concrete 36, thus binding the layers of concrete 36 and the insulating core 38 together into a unitary whole (which in some embodiments then forms the basis for the basin floor 20, basin walls 22, basin shelf 24, or another structure). The grid mats of some embodiments not only help to hold the layers of concrete in place next to the piece of insulating material 40, but they help (in some embodiments) to increase the structural integrity of the layers of concrete (e.g., acting somewhat like rebar or other reinforcement components, thereby decreasing the amount of rebar necessary and correspondingly decreasing the weight of the pool). By way of non-limiting illustration,
Additionally, some or all of the linking structural elements 44 of some embodiments extend past the grid mats 42, deeper into the layers of concrete 36 to further strengthen the unitary whole. Moreover, in some cases, rebar or another structural element is embedded in the unitary whole, such as by passing through both layers of concrete 36 and the insulating core 38 at certain locations. In some cases, the concrete entirely or almost entirely covers (e.g., encases) the insulation, thereby protecting it from environmental damage (e.g., more than 90%, 95%, 99%, or any other suitable percentage of a surface area of the insulation is covered by concrete and is thus not exposed to water, dirt, sun, wind, or other damaging environmental conditions).
In addition to the grid mats 42, some embodiments include one or more pieces of mesh 46. Like the grid mats, the mesh can include any component configured to help a surfacing material stick to the surface or to help couple other components together, such as one or more grids, nets, lattices, fabrics, weaves, textures, wires, rods, or any other suitable components that could aid a surfacing material in sticking to a surface or could help couple other components together. Although the mesh can be formed of any suitable material (such as wires, rods, bars. metal, wood, glass, plastic, carbon fiber, polymer material, cardboard, paper, nylon, fabric, netting, or any other suitable material to which a surfacing material can adhere), in some embodiments, the mesh is formed of the same material as the grid mats. By way of non-limiting illustration,
Where the pool includes multiple panels 45, the panels can be coupled together by any means, but according to some embodiments, the panels 45 are attached together using wire mesh 46 acting as sections of splice mesh. In this regard, according to some embodiments, wire mesh 46 is attached to two or more panels 45 desired to be attached together. In other words, mesh 46 is used (in some embodiments) to join multiple segments of the basin floor, basin walls, or other components together. For example, in some embodiments, one or more pieces of mesh is attached to adjacent panels thereby coupling such panels together.
The wire mesh 46 can be attached to the panels 45 by any means, but in some embodiments the wire mesh is attached to the grid mats 42 on each of the respective panels. For example, the wire mesh can be attached to the grid mat on one panel such that the wire mesh 46 extends past the edge of the panel, and then the portion that extends past the edge of the panel 45 can be attached to the grid mat on a different panel, thus coupling the panels together. In some embodiments, another piece of wire mesh is attached to the other grid mat on each of the respective panels, thus coupling the panels together on both sides.
For example,
The wire mesh 46 can be attached by any reasonable means, such as clipping (securing a small piece of metal to a part of the grid mat 42 and a part of the wire mesh), stapling, tying, welding, or any other reasonable means. In some embodiments, wire mesh is applied to both sides of adjoining panels to provide increased structural stability. In some embodiments, wire mesh of at least an outwardly directed side of the panels (e.g., a bottom of the generally horizontal panels or an outward surface of the generally vertical panels) is applied before the panels are placed in the in-ground space (although in some cases, applying the mesh after the panels are in the in-ground space is also possible by temporarily moving the panels away from the floor 120 or walls 122 of the in-ground space), while wire mesh of an inwardly directed side of the panels (e.g., a top of the generally horizontal panels or an inward surface of the generally vertical panels) is applied either before or after the panels are placed in the in-ground space.
According to some embodiments the mesh 46 is substantially planar (e.g., as shown by a representative embodiment in
According to some embodiments, U-mesh 50 is used on one or more edges of insulating cores 38 or insulating core panels 45, particularly at a top of walls of the pool. As an example, the U-mesh 50 can be attached to each of the grid mats 42 on a single insulating core 38 (or panel 45), or it can be attached to each of the grid mats 42 on multiple insulating cores 38 (or panels 45), thus aiding in joining the insulating cores 38 (or panels 45) together. Any of the wire mesh 46, edge mesh 48, or U-mesh 50 can attach such that they become embedded in one or more layers of concrete 36 when the concrete is poured or otherwise applied (e.g., via projectile application) and allowed to set.
According to some embodiments, one or more methods for constructing a pool (as discussed herein) are provided. According to some embodiments, the method includes assembling or placing a scaffold or construction joint 30 (e.g., as described above) in an in-ground space (or in any other suitable location). According to some embodiments, the method includes applying a first layer of floor concrete 136, wherein the first layer of floor concrete 136 at least partially overlaps with the generally horizontal floor section 32 of the construction joint 30. In many embodiments, this results in the bottom 120 of the in-ground space being covered or substantially covered in the first layer of floor concrete 136 (i.e., to thereby provide a foundation for the pool and protect the insulation against insects or other damage caused by the ground). By way of non-limiting illustration,
According to some embodiments, the method includes placing a generally horizontal insulating core 138 (including any feature of any insulating core 38 discussed herein) on the first layer of floor concrete 136 before the first layer of floor concrete 136 has set. In some embodiments, the generally horizontal insulating core 138 is weighted, walked on, pressed down, vibrated (e.g., with a plate compactor), or otherwise mechanically stimulated to help ensure that it settles in the first layer of floor concrete 136 and reaches the proper depth, allowing any lower grid mats 42 or wire mesh 46 of the generally horizontal insulating core 138 to become embedded in the first layer of floor concrete 136 such that the space between the lower grid mats 42 and the piece of heat insulating material 40 is substantially, mostly, or fully occupied by the first layer of floor concrete 136. Thus, according to some embodiments, a generally horizontal insulating core 138 substantially covers (e.g., completely covers or substantially covers, such as by covering at least 90%, 95%, or 99% of) the layer of concrete 136 on the bottom 120 of the in-ground space. In some cases, the top side of the generally horizontal insulating core 138 has an exposed grid mat 42 (e.g., facing upwards), while the bottom side of the generally horizontal insulating core 138 is at least partially (and in some cases, completely or substantially) embedded in the first layer of floor concrete 136 that is below it. In some cases, the grid mat on the bottom side is coupled to the generally horizontal portion 32 of the construction joint 30. By way of non-limiting illustration,
According to some embodiments, the method further includes securing one or more generally vertical insulating cores 238 to the generally vertical wall section 34 of the construction joint 30. This step can occur either before or after the first layer of floor concrete 136 cures, or while the first layer of floor concrete 136 is curing (or at any other suitable time). Such securing can be done in any reasonable manner, and it can (but does not necessarily) constitute a permanent attachment. For example, the generally vertical insulating core 238 can be welded, tied, or clipped to the construction joint, but it can also be removably attached through such means as sliding the insulating core 238 onto at least part of the generally vertical wall section 34 of the construction joint 30, such that at least part of the construction joint 30 becomes generally contained within the generally vertical insulating core 238. In some cases, the insulation 40 of the insulating core is coupled to the construction joint (e.g., by stabbing the construction joint into the insulation), and in some cases, the construction joint is slid into the gap between the insulation and the grid mat 42 or the joint is formed in any other suitable manner. In some cases, the insulation is cut, burned, or otherwise resected to make room for the generally vertical section of the construction joint. By way of non-limiting illustration,
In some embodiments, the generally vertical insulating core 238 has an inner surface (e.g., facing generally toward the inside of the pool) and an outer surface (e.g., facing generally toward the ground outside of the pool). In some embodiments, the generally vertical insulating core 238 is placed in such a position so as to create a gap between the outer surface of the generally vertical insulating core 238 and the wall of earth 122 of the in-ground space. According to some embodiments, the generally vertical insulating core 238 will eventually become the insulation portion of the basin wall 22, and the gap between the insulating core and the wall 122 of the in-ground space is configured to be filled with concrete. Thus, in some embodiments, the generally vertical insulating core acts as a barrier or a form such that concrete can be poured into the gap and cure while being held in place by the insulating core.
According to some embodiments, the method optionally includes bracing the generally vertical insulating core 138 with appropriate bracing 52 in order to ensure that it is not displaced as the concrete (as described in additional detail below) is poured and allowed to set. The bracing can include any suitable bracing for holding the generally vertical insulating core in place, including one or more scaffolds (e.g., including scaffolding of wood, metal, or any other material), braces, clamps, wedges, walls, boards, beams, or any other types of bracing. By way of non-limiting illustration,
According to some embodiments, the method includes applying a layer of concrete 236 to the space between the generally vertical insulating core 238 and the wall 122 of the in-ground space, thus creating an outer layer of wall concrete 236. In some embodiments, the concrete is then allowed to set. In some cases, the generally vertical insulating core 238 forms one side of a form for the outer layer of wall concrete 236, and the wall of earth 122 forms the other side of the form for the outer layer of wall concrete 236. Thus, in some embodiments, no backfilling around the pool after construction is required. By way of non-limiting illustration,
According to some embodiments, an inner layer of wall concrete 237 is applied. In some embodiments, this is done after the aforementioned portions of the method, although in some embodiments it is done concurrently with or before other portions of the method (or at any other suitable time). According to some embodiments, the inner layer of wall concrete 237 is applied with a projectile applicator, which causes concrete to be projected onto a surface at a high velocity, causing the concrete to adhere to the surface and consolidate from the impact. Projectile application is often known as shotcrete, gunite, or sprayed concrete, and any such projectile application methods can be implemented in connection with embodiments. In some embodiments, a form is built such that the inner layer of wall concrete (or any other suitable portion of the pool) can be poured according to cast-in place methods of creating an inner layer. By way of non-limiting illustration,
According to some embodiments, the method includes applying a second layer of floor concrete 137. This second layer of floor concrete 137 (in some cases) completely or substantially covers the generally horizontal insulating core 138, such that the upward-facing grid mat 42 of the generally horizontal insulating core 138 becomes embedded in the second layer of floor concrete 137. By way of non-limiting illustration,
According to some embodiments, the method includes installing plumbing and/or electrical features. In some embodiments, rough plumbing, including pipes and plumbing access points 28 are installed. The installation of plumbing access points 28 of some embodiments occurs after excavating the in-ground space 120, but it can occur after or before building or installing the rebar construction joint 30. As shown in
According to some embodiments, after the second layer of floor concrete has sufficiently set (or at any other viable point during the construction of the pool), water features are installed. In some embodiments, such water features include fountains, drains, jets, filters, or any other water features, and they are installed on or near plumbing access points 28 and/or in other locations, with connections to plumbing access points 28.
According to some embodiments, electrical features are installed (e.g., in like manner as plumbing features). In particular, some embodiments include installation of electrical features in similar manner and location as pipes, and electrical access points can be installed in like manner and location as plumbing access points 28. Thus, in some embodiments, wires and/or electrical access points line the wall(s) 122 and/or floor 120 of the in-ground space, and in other embodiments they are embedded in such wall(s) 122 and/or floor 120.
According to some embodiments, electrical features such as lights, speakers, filters, jets, pumps, and other electrical features are configured to connect to the electrical system through the electrical access points.
According to some embodiments, before, after, or concurrently with the installation of wall insulating core 238 or floor insulating core 138, such insulating cores (including either just the piece of insulating material 40 or the piece of insulating material 40 and the grid mats 42) are cut, burned away, or otherwise altered in order to accommodate the plumbing and electrical systems. Accordingly, in some embodiments the plumbing and electrical systems are at least partially embedded in the basin floor 20, basin wall(s) 22, or other basin features. Moreover, in some embodiments, the plumbing and electrical systems pass through each layer of the basin components, such as through the bottom layer of floor concrete 136, floor insulating core 138, and top layer of floor concrete 137 (or through the outer layer of wall concrete 236, wall insulating core 238, and inner layer of wall concrete 237).
The described systems and methods can be varied in any suitable manner that allows for the formation of the pool. Indeed, any suitable portion or portions of the described systems and methods can be reordered, omitted, substituted, replaced, performed at least partially in series, performed at least partially in parallel, or the described systems and methods can otherwise be modified in any suitable manner. For instance, while some embodiments of the described pools are formed in the ground, in some embodiments, one or more portions of the pool are formed on or above ground, with forms used to form some portion of the pool (e.g., a portion of a wall that extends above the ground or any other suitable portion of the pool).
In some embodiments, one or more walls or other portions of the pool are formed in a form and then lifted up or otherwise moved into place (e.g., to serve as a wall or any other suitable component of the pool). For instance, in some embodiments, a form is placed or formed on the ground and concrete is placed in the form. In some such embodiments, the method includes laying at least one generally horizontal insulating core on the first layer of floor concrete before the first layer of floor concrete has set. Thus, the insulating core is, in some cases, placed on top of and/or partially embedded in the first layer of floor concrete. If needed, some implementations of the method include vibrating (such as by using a plate compactor) or applying pressure to the insulating core to cause it to better settle on and/or embed itself in the first layer of floor concrete. Such vibration or pressure is sometimes effected until the insulating core has reached a desirable depth and position (generally, with a lower grid mat fully embedded in the concrete and a lower surface of the insulating core fully resting on the concrete). In some cases, concrete is then added on top of the insulating core (e.g., to cover an upper grid mat). In some cases, when the concrete is dried, the resulting structure is then lifted or otherwise moved and put in a desired location (e.g., as a wall). In some such cases, one or more sealants (e.g., types of caulking, tar, concrete, silicon, grout, a liner, or any other suitable type of sealant or sealants) are optionally applied to the pool or any cracks or gaps between the various portions of the pool (e.g., to gaps around a floor formed in place and a wall placed and secured on or next to the floor).
As used herein, the singular forms “a”, “an”, “the” and other singular references include plural referents, and plural references include the singular, unless the context clearly dictates otherwise. For example, reference to a panel includes reference to one or more panels, and reference to grid mats includes reference to one or more grid mats. In addition, where reference is made to a list of elements (e.g., elements a, b, and c), such reference is intended to include any one of the listed elements by itself, any combination of less than all of the listed elements, and/or a combination of all of the listed elements. Moreover, the term “or” by itself is not exclusive (and therefore may be interpreted to mean “and/or”) unless the context clearly dictates otherwise. Furthermore, the terms “including”, “having”, “such as”, “for example”, “e.g.”, and any similar terms are not intended to limit the disclosure, and may be interpreted as being followed by the words “without limitation”.
In addition, as the terms “on”, “disposed on”, “attached to”, “connected to”, “coupled to”, etc. are used herein, one object (e.g., a material, element, structure, member, etc.) can be on, disposed on, attached to, connected to, or otherwise coupled to another object—regardless of whether the one object is directly on, attached, connected, or coupled to the other object, or whether there are one or more intervening objects between the one object and the other object. Also, directions (e.g., “front”, “back”, “on top of”, “below”, “above”, “top”, “bottom”, “side”, “up”, “down”, “under”, “over”, “upper”, “lower”, “lateral”, “transverse”, “longitudinal”, “right-side”, “left-side”, “base”, etc.), if provided, are relative and provided solely by way of example and for ease of illustration and discussion and not by way of limitation.
The disclosed systems and methods may be embodied in other specific forms without departing from their spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the systems and methods is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
This application claims the benefit of U.S. Provisional Application No. 63/612,733 (attorney Docket No. 30588.8, entitled Insulated Pools and Methods for the Construction Thereof, filed Dec. 20, 2023, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63612733 | Dec 2023 | US |
