The present embodiments are directed to the field of swimming pools, and more particularly, to swimming pool construction and related methods.
A swimming pool is a relatively popular structure for swimming or other leisure activities. One type of swimming pool is an in-ground swimming pool. In one type of in-ground swimming pool, walls, typically metal or plastic are installed into an excavated area. The walls each typically have a same height. In other words, the walls do not vary in height to extend to a “deep end” depth. Foam padding may be placed over the walls to define the inside walls of the swimming pool. Sand may be positioned and smoothed to define the floor of the pool. A liner, typically vinyl, is installed over the foam or inside walls of the pool, and floor of the pool over the sand.
Another type of in-ground swimming pool includes the use of cement for forming the walls and floor. More particularly, a minimal wood frame is constructed within an excavated area. Metal or steel rebar, for example, in an interlaced or wire mesh fashion, is used to define the walls and floor of the pool (i.e., define the form). Gunite, shotcrete, or sprayed concrete is sprayed into form or floor and walls and permitted to harden. A pool finish is then added, for example, sprayed, over the sprayed concrete.
A method of constructing an in-ground swimming pool may include positioning a plurality of outer form panels in side-by-side relation defining an outer form wall within an excavated area of ground corresponding to a desired in-ground swimming pool shape. Each outer form panel may have opposing inner and outer sides and a support member bracket extending from the outer side. The method may also include positioning a plurality of inner form panels in side-by-side relation and in spaced relation from the inner side of the plurality of inner form panels to define an inner form wall. The inner and outer form walls may define a wall space therebetween, and each inner form panel may have opposing inner and outer sides. The method may further include coupling a plurality of support members over the wall space and to an outer side of the plurality of inner form panels and to respective ones of the plurality of support member brackets.
The method may further include removing the plurality of outer and inner wall panels, for example. Each of the plurality of support members may include a base member and a plurality of arms extending outwardly from the base member.
Coupling the plurality of support members to respective ones of the plurality of support member brackets may include slidably positioning one of the plurality of arms within a corresponding one of the support member brackets. Coupling the plurality of support members to an inner side of the plurality of inner form panels may include clamping one of the plurality of arms to a respective one of the plurality of inner form panels, for example.
The method may further include positioning a plurality of spacers within the wall space to maintain spacing between the plurality of inner and outer wall panels. The method may also include excavating the ground prior to positioning the plurality of outer and inner form panels to define the excavated area, for example.
The method may also include injecting cement within the wall space to partially fill the wall space. The method may further include allowing the cement to cure to support filling remaining portions of the wall space with the cement and filling the remaining portions of the wall space with the cement, for example.
The method may also include removing the plurality of inner and outer wall panels based upon curing of the cement within the remaining portions of the wall space. Positioning the plurality of outer and inner form panels may include positioning the plurality of outer and inner form panels to be spaced above the ground in the excavated area.
Injecting the cement within the wall space to partially fill the wall space may include injecting cement within the wall space to permit the cement to flow from a bottom thereof to define a floor of the in-ground swimming pool, for example. The method may further include forming a plurality of post openings in the ground adjacent a perimeter of the desired area, inserting a plurality of support posts within the plurality of post openings, and coupling the plurality of outer form panels to the plurality of support posts.
An apparatus aspect is directed to a form system for an in-ground swimming pool. The form system may include a plurality of outer form panels in side-by-side relation defining an outer form wall within an area of ground corresponding to a desired in-ground swimming pool shape. Each outer form panel may have opposing inner and outer sides and a support member bracket extending from the outer side. The form system may further include a plurality of inner form panels in side-by-side relation and in spaced relation from the inner side of the plurality of inner form panels to define an inner form wall. The inner and outer form walls may define a wall space therebetween, and each inner form panel may have inner and outer sides. The form system may also include a plurality of support members over the wall space and coupled to an outer side of the plurality of inner form panels and to respective ones of the plurality of support member brackets.
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
Referring initially to
At Block 106, the method includes forming post openings within the ground 22 adjacent a perimeter of the desired area and inserting support posts 23 (e.g., vertically) within the post openings (Block 108). As will be appreciated by those skilled in the art, the area of ground 22 is excavated to be slightly larger than the desired size of the in-ground swimming pools so as to permit the support posts 23 to be positioned therein.
The support posts 23 may be wood, for example, 2×4. The support posts 23 may be another type or size of material.
The method further includes positioning outer form panels 30 in side-by-side relation to define an outer form wall 31 (Block 110). More particularly, each outer form panel 30 includes a smooth rigid panel 32 defining the inside of the outer form panel and spaced apart ribs 34 laterally coupled along a length of the smooth rigid panel defining the outer side of the outer form panel. The smooth rigid panel 32 and spaced apart ribs 34 may be steel, for example, galvanized steel. The smooth rigid panel 32 and spaced apart ribs 34 may each be another or different materials. Each of the spaced apart ribs 34 is illustratively in the form of a square tube, for example, having a 2″×2″ size. Each of the spaced apart ribs 34 may be a different size, and the amount of spaced apart ribs may be based upon the size and shape of each outer form panel 30. For example, longer or deeper (e.g., for deeper excavated areas of the ground 22) outer form panels 30 may have four spaced apart ribs 34, while outer form panels for more shallow excavated areas, such as, for example, spas or sun-shelves, may have less than four spaced apart ribs.
Angled brackets 35 are coupled to the spaced apart ribs 34 and have an L-shape. The positioning of the outer form panels 30 in side-by-side relation to define the outer form wall 31 includes coupling, for example, using fasteners, each outer form panel to respective support posts 23. As will be appreciated by those skilled in the art the angled brackets 35 are positioned from the ends of each outer form panel so that adjacent panels are coupled to a support post 23 without spacing therebetween (e.g., sized for a 2″×4″ support post).
The outer form panels 30 are coupled to the support posts 23 so that the outer form panels 30 are spaced above the excavated ground 22. In other words, there is a space 25 between the excavated ground and the bottom of each outer form panel 30. In some embodiments, fasteners, for example, threaded fasteners and nuts, may be also used to further secure adjacent outer form panels 30.
Referring additionally to
Each outer form panel 30 may have a different size and shape so as to be coupled together to form a desired shape of an outer form wall 31 of an in-ground swimming pool. In other words, outer form panels 30 may be selected from a kit of many different sized and shaped inner form 40 panels to create a desired in-ground swimming pool shape. Moreover, while flat or planer outer form panels 30 are illustrated, those skilled in the art will appreciate that an outer form panel 30 may be curved or rounded.
Referring additionally to
Each inner form panel 40 includes a smooth rigid panel 44 defining the inner side 42 of the inner form panel and spaced apart ribs 45 laterally coupled along a length of the smooth rigid panel defining the outer side 43 of the inner form panel. The smooth rigid panel 44 and spaced apart ribs 45 may be steel, for example, galvanized steel. The smooth rigid panel 44 and spaced apart ribs 45 may each be another or different materials. Each of the spaced apart ribs 45 is illustratively in the form of a square tube, for example, having a 2″×2″ size. Each of the spaced apart ribs 45 may be a different size, and the amount of spaced apart ribs may be based upon the size and shape of each inner form panel 40. For example, longer or deeper (e.g., for deeper excavated areas of the ground 22) inner form panels 40 may have four spaced apart ribs 45, while inner form panels for more shallow excavated areas, such as, for example, spas or sun-shelves, may have less than four spaced apart ribs.
In some embodiments, each inner form panel 40 may include angled brackets 46 coupled to the inside of the smooth rigid panel 44 between adjacent ribs 45. The angled brackets 46, similar to the angled brackets 35 on the outer wall panels 30, may have an L-shape. The positioning of the inner form panels 40 in side-by-side relation to define the inner form wall 41 may include coupling, for example, using fasteners 47, adjacent inner form panels using by way of the angled brackets 46. As will be appreciated by those skilled in the art the angled brackets 46 are positioned from the ends of each inner form panel 40 so that adjacent panels are coupled together in side-by-side relation without spacing therebetween.
Each inner form panel 40 may have a different size and shape so as to be coupled together to form a desired shape of an inner wall 41 of an in-ground swimming pool and to match the shape of the outer wall 31. In other words, inner form panels 40 may be selected from a kit of many different sized and shaped inner form panels to create a desired in-ground swimming pool shape. Moreover, while flat or planer inner form panels 40 are illustrated, those skilled in the art will appreciate that an inner form panel may be curved or rounded.
The method further includes, at Block 114, coupling support members 50 between the outer side 43 of respective inner form panels 40 and respective support member brackets 38. More particularly, each support member 50, which includes a base member 51 and a pair of arms 52a, 52b extending outwardly from the base to define an inverted U-shape or hump-shape, is positioned over the wall space 60. Each support member 50 may include or be formed of metal, for example, steel, and more particularly have a square tubular base member 51 and arms 52a, 52b. The square shape of the arms 52a, 52b matches the shape of the support member bracket 38 so that the arm can be received, for example, slidably, therein, or engaged with the support member bracket 38. Accordingly, one of the arms 52b is secured to an uppermost rib 45 of the respective inner form panel 40, for example, using a clamp 56 (e.g., a c-clamp) (
Each support member 50 may include a further base member 55 spaced from the base member 51. In use, each support member 50 may be positioned over the corresponding outer and inner form panels 30, 40 and lowered so that the arm 52a engages the support member bracket 38 (which may also be referred to as an angle-iron) from the topside. The support member 50 may also be rotated or tilted so that the arm 52a engages the support member bracket 38 from the side (i.e., the open side of support member bracket). The support member bracket 38 secures the support member 50 so that the outer and inner form panels 30, 40 remain level and so that the support member can be secured more easily to the inner form panel. Thus, the support member 50 may be considered a type of anchor for the outer and inner form panels 30, 40. Without the support member bracket 38, the support member 50 may not sit level. For example, the arm 52a may be spaced from the outer form panel 30, and more particularly from the one of the ribs 45, so that the form panels will not remain level. Removal of the support member 50, for example, when desirable to remove the form panels, may include removing the clamp 56 and sliding the support member 50 upwardly or outwardly from the support member bracket 38.
As will be appreciated by those skilled in the art, the use and configuration of the support members 50 advantageously secures the inner form panels 40 and also levels the inner form wall 41 relative to the outer form wall 31. In some embodiments, support posts 23 may be inserted into the excavated ground 22 and coupled to the inner form panels 40 similar to the coupling arrangement between the support posts 23 and the outer form panels 30.
Referring additionally to
Rebar 65 configured as a mesh may be positioned in the wall space 60 and along the excavated area bottom to define what will be the floor of the in-ground swimming pool (Block 118). Referring briefly to
The shape or layout of and sizing of the risers 72 corresponds to either or both of an inner and outer form panel 30, 40. The recesses 73 are sized to receive individual rebar rods 75 therein. The rebar forming panel 70, as will be appreciated by those skilled in the art, permits the rebar 65 to be pre-fabricated (i.e., not in the field or at the construction site as is conventionally done) into mesh panels. The spacing of the individual rebar rods 75 is thus done in accordance with desired building specifications and/or codes, which in turn, corresponds to quicker installation and may also reduce an amount of inspection rejections.
Referring additionally to
Referring additionally to the continuation of flowchart 100 in
At Block 126, upon curing of the remaining portions of the cement, the inner and outer form panels 30, 40 are removed exposing cement walls of the in-ground swimming pool 20, the inner side facing pool water and the outer side facing the ground. The space between the outer side of the cement pool wall and the excavated ground may be backfilled to remove that space. The method ends at Block 128.
As will be appreciated by those skilled in the art, the inner and outer form panels 30, 40 may be different sizes and shapes so that they can be configured to a desired pool shape or design. In some embodiments, the inner and/or outer form panels 30, 40 may be have numbers, letters, or other indicia thereon. The indicia may provide a reference to an installer so as to setup the inner and outer form panels 30, 40 for a particular configuration. For example, a given configurations from among a plurality thereof may be selected and correspond to a panel arrangement, for example, provided by reference guide. The inner and outer form panels 30, 40 may be configured according to the guide and corresponding to the selected configuration. This may further reduce installation time.
Accordingly, the method, and system, described herein may advantageously reduce a construction duration for an in-ground swimming pool. For example, a typical in-ground swimming pool 20 may take about three to four months to complete. The method described herein using the inner and outer form panels 30, 40 may reduce in-ground swimming pool construction to about a week. In particular, the method of constructing an in-ground swimming pool 20 using the form system described herein advantageously permits the floor and walls to be poured or constructed at what may be considered the same time (i.e., with the outer and inner form panels 30, 40 in place and, for example, on a single given day). This is in contrast to other conventional form systems that require the floor and walls to be poured or constructed over a 4-5 day period, which typically involves pouring the walls then removing the forms and then subsequently pouring the floor.
A system aspect is directed to a form system for an in-ground swimming pool 20. The form system includes outer form panels 30 in side-by-side relation defining an outer form wall 31 within an area of ground 22 corresponding to a desired in-ground swimming pool shape. Each outer form panel 30 has opposing inner and outer sides 36, 37 and a support member bracket 38 extending from the outer side. The form system also includes inner form panels 40 in side-by-side relation and in spaced relation from the inner side 42 of the inner form panels 40 to define an inner form wall 41. The inner and outer form walls 31, 41 define a wall space 60 therebetween, and each inner form panel 40 has inner and outer sides 42, 43. The form system also includes support members 50 over the wall space 60 and coupled to an outer side 43 of the inner form panels 40 and to respective ones of the support member brackets 38.
Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.
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Frank Wall Enterprises, LLC; “What is the Aquaform Difference?;” Website: www.frankwall.com/aquaforms/; pp. 1-18; retrieved Feb. 18, 2019. |