Plastica Belgravia Manual

WPM002 March 2016 Edi ion www.plas icapools.com
Self Build Ins all Ins ruc ions
S re ched Pools
(Belgravia, Bayswa er, Wes mins er)
Oc agonal Pools
(Knigh sbridge, Hampstead, Kensing on)

1
Contents
Introduction: Recommendations for Storage after Delivery
General Safety Precautions
Required Tools
it Contents
Section A: Preparation of the Base
Option I: Subsoil Base
Option II: Concrete Base
Section B: Assembly of the Shell
Decide on the Layout of your P ool
Assemble the Pool Walls
Install the Return and Low Suction
Install the Skimmer
Build the External Wooden Ladder
Fitting the Wooden Vertical Support Planks
Fitting the Top Shelving Support Brackets
Section C: Fitting the Liner
Fitting the Linerlock
Levelling the Floor
Fixing the Wall Foam Underlay
Laying the Floor Felt Underlay
Preparation for Liner Fitting
Fitting the Liner
Cutting in the Pool Flow Fittings
Section D: Filtration Equipment
General Description
Positioning the Equipment
Cutting and Joining Pipes
Plumbing the Pipe Work
Fill the Pool and Fit the Cover
Section E: Fitting the Top Shelving
Position the Top Shelving
Fix the Top Shelving Corner Brackets
Fix the Top Planks to the Metal Corner Brace
Secure the Top Shelving to the Hidden Fixing Plates
Fix the Plastic Corner Covers
Section F: Fitting the Ladders and End Capping Channel
Fitting the External Wooden Ladder
Fitting the Internal Metal Ladder
Fitting the End Capping Channel

30
Notes

29
* Minimum size underlined.
* Consider extending the base on one side for the External Ladder.
*Consider extending another side for placing the Filteration Enclosure.
* Note that the Skimmer can not be on the same side as the Ladder or filtration Enclosure.
8.1m Pool Concrete Base Layout Drawing

2
A DVD is available upon request that illustrates
many stages in this book. The film shows a project
from start to finish as an informative guide which
supplements this book. For detailed instructions
please primarily use this book. You are advised to
watch the entire DVD and read this whole book
before starting your project.
In the event of any problems please contact your
dealer immediately. Warranty claims will not be
entertained if there is delay in reporting a problem or
these instructions have not been followed.
A copy of the installation DVD is also available at
http://goo.gl/1f7y8w
Introduction
• Do not store the wood in direct sunlight or under a
black cover as this will cause distortion which will
make installation extremely difficult.
• Assemble the structure as soon as possible after
receipt.
• Assemble the structure in one go, preferably in the
morning while the temperature is cool.
• If the pool must be stored then use a cool well-
ventilated place, sheltered from sun and rain. If
possible keep the pool in its original packaging.
• Components that are damaged, cracked or
distorted due to bad storage and/or handling on
site are not covered by warranty.
In the pre-assembly period the wood is sensitive to
variations in temperature and humidity. It is
therefore necessary that you take the following
precautions immediately after delivery.
Wood is a living material and once cut the
appearance of cracks, slight movements or
changes in colour are normal and the planks
(except in extreme circumstances) do not need
replacing. The planks will have been recently
treated and may be delivered to you still moist. In
case of a rapid change in temperature; these planks
can dry very quickly and lose 1 or 2mm of height.
This might give you the impression that they are
lifting up while they are actually shrinking.
Recommendations for Storage after Delivery
• Unless your filtration kit (filter, pump and any
optional heating) is housed within a secure
waterproof enclosure, it should be placed at least
2m from the shell, you may need to purchase extra
pipe and fittings for this.
• It is important to ensure the electricity supply for
the pump or any other electrical item has 30mA
RCD protection and conforms to present electrical
regulations.
• Never leave children unattended around the pool
when completed or at any stage of construction.
• The pool is designed for domestic use. Running
along the top rail, diving or jumping into the water
from the edge must not be allowed under any
circumstances. The pool is not suitable for the
addition of diving boards.
General Safety Precautions
Both the equipment box and the pallet of wooden
planks contain a packing list detailing the contents.
As you unpack your pool check that you have all
parts required and that their condition is satisfactory.
Contact your dealer immediately if you are in any
doubt or believe parts may be missing/damaged.
it Contents
For octagonal pool models please ignore information given for metal bracing.
This is not relevant to the model you have purchased.
Important Note
There are no specialist tools required but in addition
to regular hand tools the following will be useful.
• Heavy mallets for assembling walls.
• Large spirit level and set square.
• Quality battery drill with screw driver bits, drill bits
and counter sink.
• Wet & dry type vacuum cleaner for fitting the liner
• Clamps for holding components.
• Large mitre block with 90 & 22½ degree slots for
cutting pipes and liner lock.
• Large scissors for cutting underlay felt.
Required Tools

3
SECTION A: Preparation of the Base
OPTION I: Subsoil Base
• Although the recommended base is concrete (see
Option II below) you may choose to construct your
pool on undisturbed subsoil. You must satisfy
yourself that your site conditions are suitable. If
your site is wet and prone to ground water or
flooding use a concrete base.
• Never construct your pool on made up ground,
always dig down to undisturbed subsoil.
• Clear an area at least the size of the appropriate
concrete base.
• Ensure that the cleared area is flat, level and
smooth and that all vegetation has been removed.
• Ensure that all stones, sharp objects and roots are
removed. Failure to prepare the ground will result
in a damaged liner. Any damage caused to the
liner by not using the recommended concrete base
is specifically excluded from any warranty.
• The long sides of stretched octagonal swimming
pools need to be braced to keep them stable. This
is achieved by steel braces on each side. [See
Figure A01 & A02].
• Refer to the laminated pool structure layout
drawing for your size of pool to determine the
positioning on the braces.
• Lay the braces on your dug out area in the
positions indicated on the layout drawing. Mark
their outline on the soil and move the braces.
• Dig out the marked area to a depth of 100mm / 4”.
• Place the braces into the dug out area(s). Make
sure that no metal protrudes above the base. Use
a spirit level to make sure the sides of the braces
are vertical and they are not leaning sideways.
• Bracing positions may need to be corrected, for
example if an area was over dug, the brace is not
vertical or leaning. In this case use either concrete
or a 5:1 dry mix of sand and cement.
• If you are installing 4 or 6 braces make sure they
are lined up with each other.
• When you are satisfied with the braces backfill
over them with a 5:1 dry mix of sand and cement
to re-level the floor.
• Please refer to the later section Levelling the Floor
(in Section C) as extra work may be required at
that stage if a concrete base has not been used.
Figure A01 Figure A02

28
* Minimum size underlined.
* Consider extending the base on one side for the External Ladder.
*Consider extending another side for placing the Filteration Enclosure.
* Note that the Skimmer can not be on the same side as the Ladder or filtration Enclosure.
6.5m Pool Concrete Base Layout Drawing

27
5.5m Pool Concrete Base Layout Drawing
* Minimum size underlined.
* Consider extending the base on one side for the External Ladder.
*Consider extending another side for placing the Filteration Enclosure.
* Note that the Skimmer can not be on the same side as the Ladder or filtration Enclosure.

4
• The recommended minimum base is a 100mm (4”)
thick concrete pad. Using a steel reinforcing grid in
the concrete will greatly increase its strength and
is recommended. Every site is different so give
due consideration to increasing this specification if
you have unstable ground or any other concerns.
If in doubt seek the advice of a ground working
contractor or a civil engineer.
• Never construct your pool on made up ground,
always dig down to undisturbed subsoil.
• The minimum size concrete base for the Stretched
pools are shown in the Base Layout drawings.
• Ensure that your finished concrete is absolutely
level over the whole pool area. If your base is not
level the pool water level will show this after filling.
• The long sides of stretched octagonal swimming
pools need to be braced to keep them stable. This
is achieved by steel braces on each side. [See
Figure A01 & A02].
• Refer to concrete base layout drawing to
determine the positioning of the braces.
• Lay the braces on your base area in the positions
indicated on the laminated pool structure layout
drawing.
• Use a spirit level to make sure the base of each
brase is horizontal and that the verticals are not
leaning sideways.
• If you are installing 4 or 6 braces make sure they
are lined up with each other.
• If a brace is not vertical or is leaning this must be
corrected. In this case use either concrete or a 5:1
dry mix of sand and cement to correct the brace.
• When you are satisfied with the braces secure
them with a small amount of concrete around each
end.
• Lay your concrete base over the steel bracing
ensuring that the horizontal parts are completely
covered with concrete. Make sure the braces do
not move while pouring the concrete or while it is
curing.
• Ensure that your finished concrete is absolutely
flat over the whole pool area. Any high and low
areas will cause difficulties with construction and
spoil the finished look of the liner floor.
• Ensure that your finished concrete is absolutely
smooth. Rough concrete can damage the pool
liner. The swimming pool liner and felt will not hide
imperfections; tamp lines or trowel marks will show
through when the pool is filled.
• Allow your concrete to cure before assembling
your pool.
OPTION II: Concrete Base
Please see pages 27-29
for Pool Base Layout Drawings

5
• Refer to the laminated Pool Layout drawing
suitable for your sized pool.
• Decide where you would like the pool ladders.
Choose a convenient side to have your ladders
that will suit your long term pool usage.
• Decide which end of the pool you would like the
skimmer, low suction and return flow fittings.
Please refer to Section D: Filtration Equipment
and Pipes which will help you decide. The skimmer
is best fitted facing into the prevailing wind so that
floating debris is blown into the skimmer. These
fittings can not go on the same sides as the
internal and external ladders.
• If you are planning to use an underwater light
decide which side to install it on. A light would
usually be sited in the middle of one side, not
behind the ladder and where the external wires will
not appear unsightly.
• You may find it useful to sketch your equipment
positions onto the laminated Pool Layout drawing.
SECTION B: Assembly of the Shell
Decide on the Layout of your Pool
• Carefully unpack the pallet of wooden planks and
stack them in the middle of your pool area.
Assembly will be faster if you sort the planks into
their different types at this stage.
• Wooden knocking blocks are provided; these are
small untreated blocks of wood which protect the
pool wall planks as they are knocked together.
Place the knocking block so its grooves align with
the tongues of the plank being hit. Never hit a
plank with mallet or hammer but always use the
grooved blocks provided.
• Each plank must have 2 tongues facing upwards
and 2 grooves facing downwards.
• Each plank must be fully tapped home along its
entire length. [See Figure B01 & B02]
• If a plank is difficult to fit first make sure no object
like a small stone has become lodged in any
groove.
• If a plank is still difficult to fit try it in another
location.
• If a plank is warped start fitting from one end and
using the tongue and groove as rails “zip” the
plank down by gradually working along the length
striking firmly with a mallet and the wooden
knocking block. Using a clamp may be helpful.
• Do not start a new layer of planks without making
sure every preceding plank is full interlinked.
Assemble the Pool Walls
Figure B01 Figure B02

26

25
• Locate the “U” section end capping channels and
fixing pins.
• Cut a small section of end capping channel to suit
the end of each extended plank wall top plank. Nail
into position with the nail passing through the hole
left free in the metal corner brace..
• Cut longer sections to suit the two rows of planks
ends on each corner of the pool. Note you will
need 8 shorter lengths of trim and 8 longer lengths
to allow for the half planks on alternate walls.
• Nail the trims into place. [See Figure F06]
Fitting the End Capping Channel
Figure F06

6
• Find the 4 bottom half planks that have a flat
under side and two tongues facing upwards. Place
these flat side down on your pool base as shown
below [See Figure B03]
• Using 4 standard planks you can now form the first
layer of the Pool walls. The 45 degree interlocking
slot at each plank end will form the shape of your
octagonal pool. [See Figure B04]
Please note that we have used an Octagonal pool in
the diagrams, as even the stretched pools and
execise pool are of an octagonal form
• Fit the next layer of planks so each side has two
layers. [See Figure B05]
• At this stage and after every couple of plank layers
check that the pool shell is correctly aligned on the
concrete base and that the diagonal
measurements across the corners are equal to
ensure that the structure is square. Also use a
spirit level to check the pool is level.
• Fit the plank which has the inlet and low suction
holes on. The end wall that you have determined
will have the skimmer. This starts with a bottom
half plank. It is usual to position the inlet plank as
the third whole plank up, e.g. a half plank on the
concrete base, two standard planks and then the
inlet plank. [See Figure B06]
• Continue to build up the walls checking alignment
as you go.
• The hole for the skimmer is formed on the wall that
you started with a half plank and where the inlet
and low suction plank is fitted. There are two
planks that have a “U” shape cut out. One of these
skimmer planks is standard length, fit this on the
forth layer above the low level suction and inlet
plank, with the “U” facing up. [See Figure B07]
Figure B03
Figure B04
Figure B05
Figure B06
Figure B07

7
• Locate the return and low level suction fittings.
Ensure that all screws, rubber gaskets and other
parts are carefully stored. [See Figure B09]
• The main body of each fitting is the same, there is
no need to decide which fitting will be return or
suction at this point.
• Take the main body of each fitting and fit it into the
pool wall from the inside so the flat face is against
the inside pool wall and the 1½” pipe fitting is
pointing to the outside. [See Figures B10 & B11]
• From inside the pool fix each main body to the pool
wall with two 3.5mm x 20mm screws from the
fixings kit. Do not use the screws that come with
the flow fittings, they are used later for the liner
face plates. The screws should not protrude above
each fitting’s face and be careful not to form sharp
edges on the screws.
Install the Return and Low Suction
• At this stage check what type of skimmer has been
supplied. If it is a preassembled (one piece) type fit
the skimmer between the planks now. If the
skimmer “throat” is separate it can usually be fixed
into place when the pool wall is complete. In both
cases refer to the instructions supplied with the
skimmer. [See Figure B08]
• The top skimmer plank is extra long and has a flat
top. Fit this with the “U” facing downwards.
• The top layer of planks are extra long and have flat
tops. Once these are in place the pool wall is
complete and should be an equal height all round.
Figure B09 Figure B10
Figure B11
Figure B08

24
SECTION F:
Fitting the Ladders
and End Capping Channel
Fitting the External Wooden Ladder
• Offer up the wooden ladder to your chosen pool
wall and position by laying a spirit level on a ladder
tread. [See Figure F01]
• On the majority of pools we manufacture, the
ladder will fit tight against top shelving brackets,
however you may have a pool where it fits against
a vertical support plank. This is perfectly normal.
• Use a 10mm drill to make holes through the ladder
and top shelving bracket/vertical support plank.
• Take the 10mm coach bolt and pass it through the
hole from the inner side. Fix on the washer and nut
from the outer side so that people do not catch
their feet on the protruding fixings whilst using the
ladder. [See Figure F02]
Figure F01
Figure F02
• Assemble the stainless steel ladder in accordance
with its own supplied instructions.
• Remember to fit the ladder cushions to the bottom
of the ladder or you will damage your liner.
• Place the ladder on the top shelf directly above the
wooden ladder. [See Figure F03]
• Use a spirit level to position the ladder vertically
and make sure the ladder cushions are resting
against the pool liner.
• Mark positions of the 6 holes in the fixing flanges.
• Remove the ladder and drill 8mm holes through
the top shelving.
• Reposition the ladder and fit the 6 ladder bolts
down through the ladder flange and top shelf. [See
Figure F04]
• Underneath the top shelving fit a washer and nut
onto each bolt and tighten.
Fitting the Internal Metal Ladder
Figure F03 Figure F04

23
Fix the Top Shelving Corner Brackets
Option 2 – Hidden Fixings
• Use the wooden pellets supplied to hide the
screws. To do this drill approximately 10mm deep
using the plug cutter supplied.
• Once you have drilled out a deep enough hole you
can fix the top shelving in to position using the 5 x
70mm screws (use a slow drill speed to avoid
overheating the stainless screws which will cause
them to snap). [See Figure E04]
• Break off one of the wooden pellets supplied and
insert into the hole ensuring the grain in the pellet
runs in the same direction as the top shelving
timber.
• Use a hammer to tap the pellet firmly down. The
pellet is tapered to give a tight fit. [See Figure E05]
• Repeat this procedure on the rest of the fixings in
the top shelving.
• Once all the pellets are located, use a sharp chisel
upside down to trim off the excess pellet which is
still exposed. [See Figure E06]
• Finally use some sandpaper to smooth off to a
lovely finish. [See Figure E07]
Figure E04
Figure E05
Figure E06
Figure E07
Figure E08

8
• If a one part skimmer has been supplied it will
need to be fitted during assembly of the pool walls.
• Refer to the instructions that came with your
skimmer and ensure that all screws, rubber
gaskets and other parts are carefully stored.
• Pay particular attention to making sure that the
skimmer is the correct way up, look for the marking
“top”. Also ensure the skimmer is mounted
horizontally by checking with a spirit level during
fixing. [See Figure B12, B13, B14]
• Drill four holes in each corner of the skimmer [see
figure B13] Locate the screws from the pool fixings
kit and secure the skimmer into the pool wall [see
figure B14] Do not use the screws that come with
the skimmer, they are used later for the liner face
plate The screws should not protrude above where
the skimmer faceplate should finish, and be
careful not to form sharp edges on the screws.
• If a two part skimmer has been supplied it is worth
considering waiting until you have installed the
liner and created a vacuum seal, before you glue
the main skimmer body to the skimmer throat that
you have fixed to the pool. This is a large glue joint
and is a two person job. Hold the skimmer body in
position while the glue sets.
(above shows a picture of the skimmer with one of
two self adhesive gaskets provided in place)
Install the Skimmer
Figure B12
Figure B13
Figure B14
Figure B15

9
• Locate the wooden ladder treads and wooden
ladder sides. [See Figure B16]
• The stretched pools have 4 ladder treads.
• From the fixings kit locate the sixteen x 5mm x
70mm screws used to secure the ladder treads to
the ladder sides.
• Using a 4mm drill bit make holes through the
ladder sides to accept the screws, two holes in
each slot. [See Figures B17 & B18]
• Place one ladder side on a flat surface with slots
facing upwards. You may wish to protect the wood
surface by padding it with cardboard or similar.
[See Figure B19]
• Fit each ladder tread into a slot and tap home. Do
not hit the ladder sides or treads directly but use a
wooden block.
• Place the second ladder side over the top and tap
home so the treads are firmly in place. [See Figure
B19]
• Fit two screws through the ladder side into each
tread using the holes drilled earlier.
• Turn the ladder over and fit the remaining screws.
• The ladder is not connected to the pool now but is
needed to check the Top Shelving support
spacings later.
Build the External Wooden Ladder
Figure B16
Figure B18
Figure B19
Figure B17

22
• The top shelving comes as 16 pieces, 8 inner
planks and 8 outer planks.
• Lay the inner planks around the pool, resting them
on the wall and top shelving brackets, inserting
stainless steel biscuits supplied in fixing kit as you
proceed. [See Figure E01]
• The inner planks are designed to slightly overhang
the installed liner (by approx 20mm). Ensure that
this overhang is consistent all around the pool.
• Take your time to position the top shelving
carefully.
• Continue to lay the outer planks leaving a gap of
approximately 4mm between the inner and outer
planks.
• Once you are satisfied with the positioning you can
then mark out the screw positions on the centres
of the top shelving brackets, vertical supports and
in the eight corners. Mar out your screw
positions on the flat areas of the top shelving
(not the reeded pattern area). This will allow you
to finish your fixings using either of the options
below.
Option 1 – Exposed Fixings
• Leave the screw head exposed by using the plug
cutter bit supplied to countersink the stainless
steel screws (5 x 70mm). [See Figure E02 & E03]
SECTION E: Fitting the Top Shelving
Position the Top Shelving
Figure E01
Figure E03
• When the pipe work has been completed and the
glue set the pool can be filled.
• The usual operating level is the water level half
way up the skimmer opening.
• Once there is water in the pool start water
treatment, refer to the booklet Operating and
Maintaining your Wooden Swimming Pool.
• Float the solar cover on the water, bubbles facing
downwards.
• Allow a couple of days for packing creases to
come out and then use scissors to cut to shape.
Fill the Pool and Fit the Cover
Figure E02

21
• Fit a Male Threaded Union to the filter valve
marked “pool” or “return”.
• If you are using a heater fit a Male Threaded Union
to the heater inlet. [See Figure D07]
• Fit pipe between the Unions on the filter and
heater.
• On the outlet of the heater fit a Male Threaded
Union and then a Double Union Ball Valve. [See
Figure D08]
• Fit a male threaded union into the back of the
return inlet that you have fitted into the pool wall.
[See Figure D09]
• Fit pipe between the return union and the heater
valve. [See Figure D10]
• If you are not using any heating fit the valve just
after the filter and run pipe directly to the return
inlet union.
• When you have assembled the above pipe work
and are happy with the layout glue the joints as per
the instructions. [See Figure D11]
• Fit a hose tail pipe fitting into the connection on the
filter valve marked “waste” or “backwash”. Use a
jubilee clip and fix the flexible backwash hose onto
the hose tail. [See Figure D12]
• Allow the glue to set over a few hours or overnight
before allowing water into it and turning on the
pump. Refer to the Wooden Pool Operating and
Maintenance Manual.
Figure D10
Figure D11
Figure D12
Figure D07
Figure D08
Figure D09