Kafko DIY Installation Manual 05.p65
Contents
1. ring is in place and tighten open valve and return multiport valve handle to filter and switch the pump on The pump should prime within a few minutes if not repeat the above process if this still fails call your pool sup plier Filter amp 6 Way Multiport Valve The filter Sand unit is placed by the side of the circulation pump The multiport valve will found on top of the filter easily identified by a black selector valve handle The sand filter takes soiled water from the pump and under pressure enters the top of the filter this is then forced down through the sand the sand traps debris and fine particles within it allowing clean filtered water out of the bottom of the filter back to the pool see dia below The pressure gauge found on the multiport valve records the back pressure on the sand thus as the sand becomes dirty the pressure will increase When the pressure gauge has increased by approximately 20 30 a backwash cycle Is required see dia 2 below REGARDLESS WHETHER YOUR FILTER IS DIRTY OR CLEAN IT IS IMPERATIVE THAT YOU BACK WASH AT LEAST ONCE A WEEK TO REMOVE CHEMICAL RESIDUE Filter cycle Backwash cycle 6 Way Multiport Valve2. 4 Installation of electric cables and gas pipesis costly therefore the shorterthe run from your electric and gas meters tothe pump and heat source the cheaper itis 5 The pool has to be level therefore either choose a level site or be prepared to extend the level by using some of the excavated earth Itis a mistake to cutinto the slope or to have the pool absolutely level with the garden The pool should be raised by atleast 4 6 to enable the paving to slope away from the pool taking splashed water and rain water away from it tis often preferable to raise the pool byas muchas 18 using the soil to build a patio around it finished with either a retaining wallor gradually sloping turf This may be done to save onthe costof earth removal and the time and effort involved in excavation especially when hand digging is involved orwhen the water table is high enough to interfere with the installation BUILDING MATERIALS TO BUY This checklist is only approximate and depends on individual siting arrangements soil conditions etc andis intended asa guide only PoolSize SoftSand Ballast Cement 40mmShingle cubicmetres cubicmetres 25KgBags cubic metres 20x12 2 4 40 11 24x12 2 4 13 40 28x12 3 5 55 14 55 30x 14 3 5 15 Amount required for optional 5 depth pool cubicmetres cubicmetres 50 Kg Bags cubic metres 20x12 2 5 4 45 11 24x12 2 5 4 45 13 28x12 3 5 5 60 14 60 30x14 3 5 5 15 Please read all of t
3. ad z are made f A ams hal pe its wh 4 5ft DIY Swimming Pool lnstallation Manual Ne D I Y CD VIDEO STAGE INDEX A useful Interactive CD or Video film guide is available from your swimming pool dealer The CD amp Video is designed to help and guide you throughout the various stages of a Kafko D I Y Panel Pool Installation The CD amp Video has been filmed and edited to have the same Stage Index numbers as listed below VIDEO KAFKO INSTALLATION MANUAL STAGE PAGE NUMBER INTRODUCTION LOCATION amp MATERIALS 3 STAGE 1 MARKING OUT EXCAVATION 4 Dic DIMENSIONS STAGE2 Excavation 4FT DEPTH 6 EXCAVATION OFT DEPTH T STAGE 3 INSTALLING THE POOL PANELS amp OPTIONAL STEP UNIT 8 STAGE4 SeEcuRING Poot WALL PANELS 10 STAGES NSTALLING ALUMINIUM COPING RECEPTOR 11 STAGE6 THE CONCRETE RINGBEAM 12 STAGE THE FLOOR SCREED 13 STAGE8 INSTALLING THE CIRCULATION FITTINGS amp OPTIONAL U W LIGHT 14 STAGEQY LINER INSTALLATION 16 STAGE 10 PLUMBING 20 STAGE 11 BACKFILLING 22 STAGE12 CONCRETERING BEAM 20 WARNING Do not use this Installation Manual CD Video as guide for any other type of panel pool system as recommended installation methods will differ and compromise the warranty safety and structural integrity of the pool structure SECTION 1 PRELIMINARY PREPARATIONS LOCATION Itis extremely importantto give due consideration to the pool location Remember that once installed a pool cannotbe moved
4. these panels have to be cut manually by the manufacture If when joining the panels together you experience a incorrect alignment or gaps appear you may find that you either have to plane down the side of the panel or fill a gap using a car body filler If you are unsure what to do please contact your dealer Due to the manufacturing process using injection moulding some pool panels may not be manufactured to an exact size Your pool build is not an exact science so do not be too concerned if the overall pool size is not exact 0 5 1 00 tolerance is not uncommon Like any DIY project work to the best of your ability If you have any doubts call your dealer 2 When all braces have been fixed it is important to make sure that the pool construction is put in level and square To do this run string lines along length and width of pool construction panels for alignment and set to correct height Check diagonal measurements are equal Check Diagonals 3 Making sure that the pool is correctly aligned drive the Steel Aligning Pins provide through the holes in the bottom flange of the panels leaving approx 6 exposed If it is necessary to raise some of the panels they should be packed underneath with odd pieces of slate tile brick etc DO NOT ATTEMPT TO MAKE UP ANY VOIDS WITH SAND OR SOIL 4 Drive the Polymer Stake attached to Polymer brace through bottom of the Brace into the ground as far as you are able Inthe event that the
5. and plumbing to be installed etc See fig 3 Tip PoolSize Length 20x12 24x12 28x12 30 x 14 Stake position to A B 20 24 28 30 Figure 1 Marking Out 24 form 24 radius Width A C B D 12 12 12 14 Diagonal A D B C 23 a 4 26 10 30 51 2 33 11 4 Figure 2 Creating 24 radius corners H Pi at F F Fy Figure 3 Pool size showing working trench 24 TR EE HH Ft Hi Fi Hh KE HH KE FE RE KE FE KE KE HE RE KE KE KE HE FE EE E na fe Ka sa G sa p Sa aa E sa A J b ut When you have marked the out the working trench as fig 3 it is a good idea to mark another rectangle 4 longer and wider than the working trench Insert a Steel Pin into each corner of the marked area You will now be able to run string lines at a later stage in the installation that will help you to check alignment when the pool walls are in stalled EXCAVATION DIG DIMENSIONS 2 5 Coping Receptor Pool Size 4 21 2 46 coping Screed ALTERNATIVE 5 POOL DEPTH An optional 5 pool depth is also available at no extra cost The same liner that is used for a 4 depth pool can also be used for a 5 depth pool The liner material is expandable and will stretch into position as long as the excavation is carried out to the dimensions specified below Please make sure your dealer is aware of your intentions to increase the Pool Size depth of the pool
6. as this may alter plumbing configuration and heater sizing that is required for your pool Coping Receptor coping Screed EXCAVATION STAGE 2 SEE PAGE 7 FOR 5 DEPTH EXCAVATION Drawing fig 4 below shows the finished excavation Toreach this stage proceed as follows 1 Fixalevelstringline to stakes ata height equal to top of Wall panels and Coping Receptor i e finished pool amp surround level around the marked outarea 2 Using back hoe of the excavator start digging to the depth of 4 21 2 from the intended top level ofthe pool surround This height and level is mostimportant thus check your levels frequently using either an optical builders level or water level Itis unlikely that sufficiently good results could be obtained with a spiritlevel If earth is to be removed leave iton the side easiestfor removal Atthis stage the whole area is to be excavated to a constant depth of 4 21 2 Remember The pool has been marked out allowing fora 24 overdig This area is also to be excavated it willact as a working trench and willreceive the Polymer Braces Excavation should be undertaken extremely carefully especially underneath the walls since any over digging will have to be made up with bricks and cement One hours careful work at this stage with the machine can count for halfto a whole days manual work after the excavator has left ae _ String Line s Panels 24 Overdig Figure 4 Finished exca
7. digging will have to be made up with bricks and cement One hours careful work at this stage with the machine can count for halfto a whole days manual work after the excavator has left Figure 5 Finished excavation 4 2 4 2 5 2 1 2 Figure 6 Bank detail EXCAVATION FOR OPTIONAL STEP UNIT Make sure that you have excavated the right amount of soil to allow access for installation of the Step Unit Two examples aredrawnbelow Line of Line of Excavation Excavation Backfill using 15 SS a parts Ballast 1 part Soe AENEAN Concrete 6 Cement oe BEES parts Ballast 1 Ei partCement TEETE ee Concrete Aea E TA TET TATATA TET EEEn Support l ee ee nn m n n n n n n ee ee n n o o o o o o o o o i o o i o o o o Foam Backed Step Unit Step Unit with Leg Support System ERECTION OF POOL WALLS anp OptTIonaL Step UNIT STAGE 3 Start by creating the four 24 radius corners Tocreate a radius corner a Multiflex Panel is used A 3 Multiflex Panel has been designed so thatit can be flexed to create a internal radius Tomake sure thatthe right radius is applied when flexing the panel a Strap Set is used The Straps are marked and pre drilled by a computer at the factory to determine the correct radius an identification sticker showing radius dimension is applied to each individual strap Each panel will require 2 straps Each strap is simply pushed
8. ground conditions do not allow the brace to be inserted easily Steel Aligning Pins should be used leaving approx 3 of steel exposed When the Stake has been driven home CHECK the panel is upright using a Spirit Level If adjustment is required tap the top of the brace to align the panel The pool structure is now to ready to receive the Aluminium Coping Receptor Kafko Polymer Brace Katfko Panel Polymer Use pieces of Slate Brick to raise panels if height adjustment is re quired DO NOT make up voids with Steel Aligning Pin 4 Undisturbed Ground INSTALLING ALUMINIUM COPING RECEPTOR Stage 5 Snap Aluminium Coping onto top of pool panels and secure with Liner Lock Screws provided at intervals of approximately 6 8 apart The extrusion will help with alignment prior to pouring the bottom concrete ring beam and also acts as a receptor to receive the liner beading that is attached to the liner Coping for radius corners are preformed and may need slight adjustment when securing In the middle of every Coping straight and joint an Aluminium Support Bracket should be inserted approximately every 4 Note Support Brackets may have to be removed when paving surround is laid Front facia Cover Clips are also provided to cover Coping Joints Kafko use a patented Snap Lock System to prevent the liner from coming out of the Liner Lock extrusion Set aside Snap Lock extrusion and fit when liner has been fully
9. installed APPLY PROTECTIVE SHEETING TO COPING WHERE ACCESS IS REQUIRED TO POOL STRUCTURE Support Bracket Aluminium Coping Polymer Panel Snap LockExtrusion TIP It is a good idea to leave one section of Aluminium Coping off the pool surround to enable access for building materials i e Floor Screed GRP Trim for Roman Steps only For Roman Step units a GRP trim is supplied in place of an Aluminium extrusion It is sup plied in two sections Fix each section to the top of step unit as per the diagram The return straight trim will have to be cut down to make sure that is in line with the inside of the plastic faceplate Butt the Aluminium coping up to the plastic trim Cut down GRP trim in line with inside of faceplate _ F GRP Trim su pplied in two sections W Note no groove a Faceplate Diagram of Panel Pool Construction Kafko Panel PolymerBrace Sera NNN 7 SUNS V i TON F a Steel Aligning Pin POURING BOTTOM CONCRETE RING BEAM Stage 6 IMPORTANT NOTE due to the nature of the product if the polymer panels are exposed to extreme heat or sunlight panels may begin to distort or bulge Therefore we recommend that a protective white sheeting is used to reflect the suns rays or wait until a cooler climate arises DO NOT POUR CONCRETE RINGBEAM OR BACKFILL IF PANELS ARE DISTORTED As Polymer has a structural memory in general all panels wi
10. n a n n n n a n n n n n n nn a a a a n a a a a a a a a i A ee a a a a a es a n n n n a n n n n n n nn n an n n a n n n n n n n n nn nuun u u u af ee n nunn num mmm RRR n n n n nnn nuun mumm mfy RRT n n nunn nuun mmm O RRR S a Le Le Be Concrete a a A AEE RE Support Fes eS Sooo Se aaa eae REE ee me n n nonon nm n n m m o o o o o o o o o o o o o o i o i o o o o o m o o o Kafko Step Unit with Leg Support System Country Leisure Foam Backed Step Unit Side Flange s can be cut Note Installation notes for 6ft Kafko Square Step Unit Only To prevent a large mortar joint when laying paving slabs decking against a Kafko Square Step the side flanges may be trimmed Make sure that adequate concrete is placed under flanges after they have been trimmed to fully support top of step unit J Make sure that Concrete is placed underneath trimmed flanges SECURING POOL WALL PANELS STAGE 4 1 When all wall sections are temporarily in place 7 No Bolts are to be placed through the pre drilled rectangular holes on each panel joint and brace Polymer Braces are to be fixed every PANEL JOINT Braces are NOT placed in between panel joints but at the side If 5 amp 6 panels have been supplied intermediate Braces supplied must be placed in the middle of the panel Where a 1 or 2 panel is required for an infill i e between a step unit and corner
11. on what type of step you have bought either Kafko or Country Leisure will pre determine what level you set the step to see diagram below Fix temporarily into position using G Clamps Mark the Step Unit through the holes that are already located in the panel Remove panel and drill Step Unit Level front and back of Step Unit and concrete into position please note Step units are made of Glass Fibre when the step is released from the mould slight contraction shrinkage arises therefore the step unit may not be exactly level from front to back to start with Polymer or Galvanised Bracing is required either side of the Step Unit to prevent the Step being pushed forward when concrete support is poured Country Leisure Step Country Leisure Step Kafko Step should be 2 5 should be level should be level higher that pool panel Country Leisure Country Leisure Kafko Roman End Step Unit Square Step Unit Square Step Unit Install Country Leisure steps level with the top of the polymer panel to A Kafko step is 2 5 higher than a enable coping trim to run along rear of step unit Country Leisure step This is to allow the coping trim to butt up against the step Concrete Line of Cemeptraci 2 e penennnmm Support Foam Infill Concrete 6 a 1 pm parts Ballast 1 Toor PERRNERENE partCement ee a n n n n saaa E eee Pn a a a a a es ss aa a a n a es ss aaa a a a a a a a a a a h2ozo20207 na n n n n a n n n n n
12. sheet in between Timber Frame D and Liner Lock Tape a Polythene sheet Liner Wicca PRE to top of Step Unit and EEG ee Liner to prevent air ee escaping Clamp Plate a ae Foam Gasket either Bolt On or Screw Fix ae already applied eo by manufacturer 19 POOL PLUMBING STAGE 10 Prior to installing the filter and pump please study the plumbing layout plan as shown on page 21 Included in the pool kit is a small amount of plumbing fittings and pipework see list below to enable you to site the filtration unit approximately 3 metres away from the pool However plumbing configurations may vary in accordance with site conditions ancillary equipment etc Therefore extra plumbing may be required and purchased from your dealer Your pool plumbing consists of a simple circulating system drawing water from the pool at one point the Skimmer This is the suction side of the system The suction is provided by an electric pool pump which passes the pool water under pressure to the filtration unit to cleanse the water before returning back to the pool via the two Return Inlet Fittings All pool plumbing pipes are maufactured in A B S or P V C and are 1 5 in diameter DO NOT USE WASTE OR OSMA PIPE When using the pipe and fitting adhesive make sure that both pipe and fitting are absolutely clean and dry All plumbings lines to and from the pools should ideally be laid 18 below ground level to protect from frost It is also advisable to c
13. that form either the length or the width of the pool including the radius corners multiflex using 3 no Nuts amp Bolts and placing them into the front three round holes these will temporarily fix the panels together while lowering the wall sections into the hole and also enable extra joint tightening where required NOTE Some Multi flex Panels MAY NOT have pre drilled location holes for temporary fixing Either install the Polymer Braces at this time or using a 10mm drill piece drill the location holes A 1 Polymer Insert must be inserted on each side of radius corner panel before attaching the straight panels These require 2 5 Long Fixing Bolts provided 3 5 bolts maybe required where a corner brace 12 panel are required 3 Lower panel assembly into excavation and position on shelf Continue erecting all wall sections 8 INSTALLING OPTIONAL STEP UNITS A Step Unit takes the place of a Polymer Panel and is simply bolted to the panel structure Steps may be supported by a Leg Bracing System KAFKO or have a Reinforced Foam Backing COUNTRY LEISURE utilising the shape of ground to give support Either way make sure that you have excavated the right amount of soil to allow access for installation of the Step Unit Two examples are drawn below Step Units are manufactured for all types of pool construction and therefore will be not predrilled to accept Polymer panels Line up the Step Unit against the panels and depending
14. water level rises very slowly and may therefore carry out your plumbing sequence and finalise your fittings TOP CONCRETE RING BEAM Stage 12 When backfilling has been completed pour a concrete ring around perimeter of pool structure Minimum depth required is 4 minimum width required is 24 but in most cases it is desirable to pour a 3 oversite to cater for paving slabs Make sure that concrete is applied around Skimmer Body and Extension Throatfor support Apply desired deck surround FITTING LADDER OR GRAB RAILS STAGE 13 1 Assemble ladder rails and treads 2 Bolt Ladder to paving concrete ringbeam 3 If Wedge Anchors have been supplied these must installed when pouring the Concrete Ringbeam see manufacturers instruction ELECTRICAL CONNECTIONS STAGE 14 AN EARTH LEAKAGE Circuit BREAKER ELCB SHOULD BE INCLUDED IN YOUR ELECTRICAL SYSTEM AND WE STRONGLY RECOMMEND THAT ALL ELECTRICAL WORK IS CARRIED OUT BY A QUALIFIED ELECTRICIAN It is advised that a electric control panel is used that will contain a pump contactor 24hr time clock and 3 switch type fuses Micro Circuit Breakers Swim EP Enjoy You deserve it QUICK GUIDE THROUGH YOUR EQUIPMENT Surface Skimmer the skimmer draws water and surface debris off the pool over a floating weir debris is caught in the skimmer basket with the water being filtered The skimmer basket will need to be checked and cleaned of debris on a regular basis The water level must be mai
15. withoutvery high cost Before deciding on a site itis advisable to draw a scale plan of your garden on graph paper marking the position of fences buildings footpaths water pipes etc cutting a template of the proposed pool ideally of different coloured paper you can then superimpose this on your plan until the ideal position isfound The following points should be borne in mind when deciding onthe right position 1 Ensurethatno electric cables water pipes gas or drainage pipes run under the proposed site Moving any of these is time consuming and costly 2 Keep away from trees and shaded areas TOOLS YOU WILL REQUIRE This checklisthas been compiled assuming thatthe normal handyman s tools are available i e an electric drill and an extension lead to reach the pool site obviously ten men hand digging a pool will require more shovels and wheelbarrows Wood floatand Steel Float Cowley or water level Club hammer Adjustable spanners Phillips screwdriver Shovels Forks Spades Rake Pick SoftBroom Wheelbarrow Industrial vacuum cleaner Ball of string and stakes Stanley knife Garden Hose Chain wrench or Stilsons to tighten 17 Hacksaw Tape measure 50 2 masking or packing tape Electric drill G Clamps Angle Grinder may be hired PLANT EQUIPMENT TO HIRE Excavator Concrete Mixer Dumper Truck Tipper Lorries if spoil being removed from site 3 Itis advisable to choose a location with a fair degree of privacy
16. TO THE FOLLOWING UNDER WATER LIGHT rig 8 Make sure that the water line is just under the light and that the liner has stretched firmly onto the floor of the pool With your finger tips feel through the liner to locate two of the 12 holes and make a small hole with one of the screws it will be easier to do this in the pool Nowalign Clamp Plate with the two holes you have justmarked in the liner Insertthe twoscrews and tighten halfway Insert and tighten the remaining screws Start by tightening one screw at 12 o clock then one at 6 o clock to enable the Clamp Plate to secure evenly Using a sharp Stanley Knife cut the liner inside the Clamp Plate Push on light Face Plate to cover screw holes INLET FITTINGS Fig 9 Make sure thatthe water line is just under each Inlet Fitting and thatthe liner has stretched firmly onto the floor ofthe pool With yourfingertips feel through the linerto locate one ofthe 8 holes Make asmallhole with one of the screws itwill be easierto do this inthe pool Using asharp Stanley Knife make a star incision into the middle of the fitting Now align the inlet Clamp Plate with the hole you have justmarkedin theliner Insertthe three remaining screws andtighten evenly The incision willallowthe Clamp Plate tofitsecurely into the inletfitting Nowscrewon the directional eye ball plate The skimmercannowalsobe cut SKIMMER FITTINGS Fic 10 With your finger tips feel through the liner to loc
17. adius corners should be formed as perfig 7 Steel Pin Inserted to finished pool depth do not leave Steel EEE Pin in finished Screed Figure 7 24 Radius Corners INSTALLING CIRCULATION FITTING S amp OPTIONAL U W LIGHT Stage 8 The skimmeris supplied in two parts 1 Skimmer Body 2 Skimmer Extension Throat 2 No Gaskets are also supplied Only 1 x Gasket is required put aside for the liner installation Toinstalla Skimmer carry outthe following Check that a Skimmer opening has been cut out ofa pool panel thatwill receive the Wide Extension Throat and that 6 No Locating holes have been pre drilled This would be carried out prior to delivery Place W Mouth Skimmer Throat into opening MAKE SURE THAT THE SKIMMER BODY WILL SLIDE DOWN ONTO THE SKIMMER THROAT Place 6 No Bolt fixings through Extension Throat and Polymer Panel and apply Nut fixing Remove Skimmer Body from packaging The Skimmer Body has an option of using Imperial or Metric pipe fittings apply correct stop plug Supplied into correct socket thatis notrequired Apply ABS Glue not PVC LIBERALLY to Skimmer Body and Extension Throat Slide Skimmer Body onto Extension Throat Once in position be careful not to disturb Skimmer until glue has fully set 24Hrs Using necessary plumbing fittings plumb skimmer line back to plantroom GLUE fittings into Skimmer Body When plumbing has been completed place a mix of concrete under not around 90 deg elbow that is plumbe
18. along the opening of the Square Step Whenthelinerhas been installed into the correct position as perthe instructions on page 13 apply asheetof polythene overthe top ofthe Step Unit using packing tape This willsealthe top of Step Unitand preventany airescaping whenthevacuumisswitchedon BOLT ON CLAMP PLATE When the liner is installed take great care not to puncture the liner when positioning around the step area Once the vacuum has removed all the creases and the water level is up to the underside of the Clamp Plate use a Sharp Stanley Knife and very carefully make a small incision over each protruding bolt Apply the Clamp Plate over the bolts starting at the top Tighten with a socket wrench Cut and remove liner in the step area Any excess Foam Gasket is best left on as this will naturally peel off when the pool is up and running SCREW FIX CLAMP PLATE Make sure that the vacuum has removed all the liner creases and the water level is up to the underside of the Clamp Plate Using your finger tips feel through the liner to locate the top two holes on one side of the Step Unit and make a small hole with one of the screws it will be easier to do this in the pool Now align the Clamp Plate with the holes you have just marked in the liner Insert the remaining screws and tighten working your way down and around the Clamp Plate one screw ata time T Section Timber Frame Liner Lock Place Polythene
19. ate two of the 16 holes and make a small hole with one ofthe screws it willbe easier to do this inthe pool Nowalignthe Skimmer Clamp Plate withthe holes you have justmarked inthe liner Insertthe remaining screws andtighten Startby tightening the Clamp Plate evenly Using asharp Stanley Knife cutthe liner inside the Skimmer Clamp Plate Push onlight Face Plate to coverscrewholes i Cover Plate ClampPlate a Eyeball cake Plate Back Nut Cover Plate Fig 8 eA Panel Fig 9 Liner Panel See page 19 if a Step Unit is Installed Gasket Skimmer Throat veal Plate ey Liner Fig 10 Panel 18 STEP UNIT A Step Unit can be supplied with two methods of fixing the Clamp Plate 1 Bolt on Clamp Plate The Bolt on Clamp Plate must be removed prior to installing the liner 2 Screw fix Clamp Plate The Screw Fix Clamp Plate mustbe removed priorto installing the liner Construct a temporary T Shape Frame Section out of wood and attach a strip of Liner Lock approximately oft long Make sure that when the T section is located in the Step Unit that the Liner Lock is level with the extruded receptor in the Aluminium Coping i e where liner beading is inserted The idea of the T Section is to allow the liner to be temporarily fixed into position in the Square Step Use G Clamps to secure timber framework to the Step Unit You should now be able toinsertthelinerallthe way around the perimeter ofthe pool structure and
20. d into bottom of Skimmer Body Good supportis required to preventthe Skimmer Body from subsiding Concrete will also surround and supporttop of Skimmer Body once backfill has commenced _ Skimmer Lid Collar Height Adjustment Concrete Top Ring Beam when backfill has commenced Concrete Support for Skimmer Concrete Bottom Ring Beam INLET FITTINGS Push each Inletfitting into the predrilled holes inthe Polymer panels Apply the Backnut onto fitting and hand tighten the back nut Use a wrench to tighten one additional full turn there is no need to over tighten no water can leak throughout this fitting NOTE Putaside the Faceplate Clamp plate 4no Screws and 1 x self adhesive gasket until you are ready to instal the liner IMPORTANT when installing the plumbingline utilisethe Polymer Braces by placing the pipeworkthrougheachbrace this willprevent any pipemovementwhenbackfillcommences When Backfilling commences makesure thatthe inletfittings are supported by concrete Apply concrete underneath notaround theinlet fitting Inlet Fitting Inlet Gasket 1 x required only CERTIKIN UNDERWATER LIGHT IF SUPPLIED The main body or niche of the underwater lightis installed in the same way as the inlet fittings Install the Light Housing into the precuthole using the four locating screws Connect Cable Conduitto Light Housing and Deck Box electric junction box Temporarily tape the Deck box tothe top of the pool st
21. ed If gaskets are not self adhesive useasmallamountof silicone sealant or tape to apply with EXTREME CAUTION mustbe used atall times when handling the liner Take utmost care to avoid rips tears and punctures DO NOT SMOKE Keep clear of all sharp objects including rose bushes brambles etc DO NOT WEAR ANY FOOTWEAR BARE FEET ONLY Leave the liner in the box when lifting into the pool 5 Unfold the liner in the pool structure NEVER DRAG THE LINER ACROSS THE POOL FLOOR Starting atthe onecorner ofthe pool insert the white beading thatis attached to the liner into the coping receptor See dia below Continue inserting the beading along the width of the pool to the othercorner Itisimportantatthis stage to make sure thatthe liner is installed squarely into the two corners Make sure thatthe pattern material is also vertical and not diagonal Coping Receptor Liner Bead Snap Lock Insert prior to filling pool 6 Insertthe remaining beading tothe two remaining corners The lineris nottailor made to the exact size of the pool structure therefore you may find that when you are trying to insert the liner into the last corner that you may be short of material If this happens you will need to stretch the liner evenly along the length and width of the pool of the pool sides to gather more liner material to enable you to insert the liner Tip If required the beading and liner can be made more pliable by pouring a small quantity of hot NOT boi
22. felt underlay which will iron out any trowel marks and roughness in the screed Note an all patterned lineris supplied with your pool kit The benefit to having an all pattern liner material is that it willcover most imperfections e Trowel marks etc in the finished screed application Therecommended method forlaying the screed is as follows 1 A2 screed depth is required for the pool floor To help you achieve this itis agood idea to use a chalkline to mark aline all around the pool structure 2 up from the bottom of the panel Some panels will have a score line already marked on the panel The finished pool depth after screeding should be 2 less than dimensions C in the Schedule of Dimensions page 4 and should coverthe bottom of the panels by 2 You may find that if you were to run a string line across the pool from the 2 mark line thatthe depth will vary from 2 4 in places This is quite acceptable as some soil conditions willnotenable youto achieve a perfectlevel floorwhen excavating using amechanical digger 2 Startby placing aline approximately 3 of screed material on one side of the pool structure and another line approximately 4 apart see dia below Insert a steel pin to the finished depth of your pool in all four corners of the floor area if you have decided to have the oft depth option Itis a good ideatolevelin 2 x 1 wooden battons across the pool floorin sections to actas a guide and to maintain the correctdepth
23. he Installation Manual before commencing the installation A few minutes spent reviewing each stage ofthe manual could save you timeandmoney MARKING OUT FOR EXCAVATION STAGE 1 Using the ball of string and the stakes 1 Mark line A B representing the length of the pool Marking a line on grass can be achieved by using floor marking spray paint along the line of the string 2 At points A amp B mark 2 arcs in the positions shown using pool width measurement See fig 1 3 Again using points A amp B mark 2 further arcs as shown using the diagonal measurements listed where the arcs cross determine points C amp D points A B C amp D form a true rectangle See fig 1 4 Therectangle youhave marked outrepresents the actual poolsize Now create the 24 radius corners Todothis simply place a mark 24 from each corner along the length and width of the pool From each mark markaline 24 intowards the middle of the pool from each point You should now have formed a square See fig 2 5 Using astring line 24 long and a stake position the stake inthe corner ofthe square and using the string line create an arcto form the 24 radius corner see fig 2 Repeaton the otherthree corners 6 You will now have marked outa rectangle with 24 radius corners Now mark another rectangle 4 longerand widerthan the pool to allow for an 24 working trench thatwill enable the support braces to be fitted to the pool structure
24. ling water on it 7 When the lineris completely inserted most ofthe material should hang vertically along the sides of the pool structure Any obvious diagonal folds should be adjusted by moving the liner bead in the opposite direction to the diagonal you made find thatthe whole liner may have to be repositioned THE LINER AT THIS STAGE WILL HAVE SHALLOW CREASES THROUGHOUT THE POOL A VACUUM IS REQUIRED TO SUCK THE LINER BACK INTO A CREASE FREE FIT 16 LINER INSTALLATION CONTINUED 8 Place a Wet amp Dry vacuum cleaner such as a VAX or HENRY nextto the skimmer Remove allfilters in the vacuum cleaner Check flexible suction hose for any sharp edges that might damage the liner and tape overthem ifnecessary Then shake the hose to remove all gritand dust Slide the vacuum hose through the top opening ofthe skimmer guiding it along the throat ofthe skimmer and down between the wall panel and liner ensuring the bottom of the hose terminates approx 8 above the screed level Apply tape to skimmer lid and hose preventing any suction loss See dia below Vacuum Seal Skimmer lid area with tape Liner Vacuum hose should be approx 8 away from pool floor Floor Screed Hi H EE 9 Switch on vacuum cleaner after about 10 15 minutes the liner should be vacuumed into the correct position 95 of the creases should disappear by the suction ofthe vacuum Any remaining creases should be smoothed outby adjusting manual
25. ll be shrink back to their original shape or size once they have cooled as long as a concrete ringbeam or backfill has commenced To avoid disturbing panel alignment the concrete should be PLACED rather than poured into position A concrete mix of 6 parts ballast 1 part cement is required Two concrete pours are required for a bottom ring beam 1st Pour Approximately 3 of concrete this enables the panels to be secured into position LEAVE 24 HOURS and check panel alignment 2nd Pour Approximately 6 of concrete 12 SCREEDING OF POOL BASE STAGE see also page 14 for 5 depth option A STRONG Screed mixture is required 4 parts sand to 1 part cement The consistency required should allow you to squeeze a ball of screed in your hand and when released the screed should stay together in a ball and not crumble The sand MUST be builders softsand DO NOT USE SHARP SAND liners are microporous and will still allow a very small amount ofwaterthrough theliner overa 7 10 year period If sharpsandis used the chemicals thatare contained inthe water may break down thescreedandexposethe aggergratethatcan cause damagetotheliner This is probably the most difficult stage forthe amateur builder If you are apprehensive aboutthis stage there are two alternatives 1 Youcanemploy alocal plasterer to carry out the work for you or 2 Youcanlaythe screedtothe bestof your abilityandthen purchase from your pool supplier some special pool linerfoam
26. ly orwith the aid of along handled soft broom Packing creases may also be visible for up to two weeks but will disappear Inthe eventthatthere are still creases visible switch off vacuum and reposition liner The liner does nothave to be pulled out of the Coping Receptor to be repositioned Simply remove the corners and pull the liner along inthe Coping Receptor IF YOU ARE NOT HAPPY WITH THE FIT OF THE LINER DO NOT PROCEED ANY FURTHER CONTACT YOUR DEALER FOR ADVICE 10 Insert Snap Lock this is alocking extrusion thatis designed to preventthe liner ever coming out ofthe Coping Receptor Always insert Snap Lock either side of a Step Unit ifinstalled 11 Now you are ready to commence filling the pool Allow the vacuum to run continuously until the water level has risen to 3 above the pool floor Atthis stage the vacuum MUST be turned off and the hose removed from behind the liner otherwise it will become trapped by the water pressure FOR 5 DEPTH INSTALLATIONS TURN VACUUM OFF WHEN WATER LEVEL REACHES THE POOL WALLS 12 When vacuum hose has been removed commence filling until water has risen to the underside of the first pool fitting i e Under Water Light or Inlet Fitting Tip There are Vacuum hoovers specifically designed to vacuum in pool liners Ask your pool dealer if they have one that you may hire apart from having more suction power that a conventional hoover they are also con siderably quieter 17 FIXING THE GASKETS
27. mme UH BWY amp y K oy 7 rt g eee og i EnA f 2 N BALL VALVE TEE GLUE amp P T F E TAPE 20 POOL PLUMBING LAYOUT WHEN THE FILTER SAND HAS BEEN PLACED INTO THE FILTER YOU MUST BACKWASH THE FILTER FOR 90 SECONDS BEFORE LETTING THE WATER GO BACK TO THE POOL THR HOSE TAIL Sa LIP F T SOCKET rai aoe pt FLEXIBLE PLUMBING supped with filter P fi pert ae CKWASH a WASTE HOSE S SAhO FILTER from Skinner HEATER oplional GH RET INLET 1 SHIMMER TIP Dry fit all fittings together prior to gluing fittings Once glue has been applied it will be impossible to remove any fittings Ideally allow 24 hrs for glue to fully cure 21 FINISHED POOL CONSTRUCTION Top Concrete Ring Beam 4 x 3 Coping Receptor Kafko Panel Shingle Backfill Kafko Polymer Brace TEREE y E A A A AA a kathaha hht eee S680 40004 Hechter tty iy Ae er thee theta O08 P0008 pee Later Sa SSeerA 1 nay 82969 696 P e m SS SN 9 Bottom Concrete Ring Beam g WS NN Steel Aligning Pin INS BACKFILLING Stage 11 Once all the liner fittings have been installed itnowtime to start backfilling Backfill using 40 mm shingle up to the level of the water line As the water level rises continue to backfill Keeping in step with the water level and NOT exceeding it Terminate backfilling approximately 4 below top of panel allowing enough depth fora Top Concrete Ring Beam You will find thatthe
28. ntained at least half way up the skimmer opening Be aware that when the pool is in good use and heated evaporation can account for water loss of between 2 to 3 per week even with the summer bubble cover in place when the pool is not in use Return Inlet Found in the wall about 12 underwater This returns filtered water back to the pool Circulation Pump A self priming continuous rated pump with a pre filter strainer pot draws the pool water from the skimmer and delivers it to the filter The strainer pot basket will need cleaning on a regular basis To carry this out ensure the pump Is switched off close the suction valve in front of the pump and turn the multiport valve to closed remove the pump lid usually held on with two thumb knobs or a clamp band Remove the basket and clean out replace basket top strainer pot up with water if required replace lid ensuring that lid O ring is in place and tighten open valve and return multiport valve handle to filter and switch pump on Pump A pump is primed when the strainer pot is full of water If the water level in the pool drops below the skimmer opening or you take an attached vacuum head out of the water you will loose prime To prime the pump Ensure the pump is switched off close the suction valve in front of the pump and turn the multiport valve to closed remove the pump lid fill strainer pot up with water replace lid ensuring that lid O
29. onto the panel by hand and is fixed to the top and bottom of the panel not in the middle Push on Fasteners Multi Flex Corner Panel Top Strap Bottom Strap Erection of pool wall panels 1 Place the panels around the excavation as per drawing supplied at time of pool delivery You may alter the positions of inlets and outlets if desired Make sure that the appropriate panels are located in a position to enable the plumbing lines to take the shortest run possible back to where the filtration plant is to be housed One panel will have a rectangular hole cut into the face of the panel to accommodate a surface skimmer Two panels will have a small round hole cut for a high and alow return fitting 2 Start by bolting one side of pool panels together
30. over pipework with a layer of building sand to protect from sharp stones etc when backfilling The majority of joints are a push fit Cut all pipework with a Hacksaw Clean and de bur edges with sand paper prior to applying glue Apply liberally the A B S P V C adhesive to the inside of the pipe fitting and the pipe push together and hold securely for twenty seconds while the glue fuses the pipe to the fitting Apart from the fittings in the wall do not glue threaded fittings All threaded fittings must have P T F E supplied applied to them Apply a minimum of 20 wraps of P T F E onto a threaded fitting in a clockwise direction As an extra precaution it is a good idea to apply a thin film of Silicone Sealant prior to screwing the fitting into a threaded socket Make sure that all pipework enters all the fittings correctly i e at least 3 4 of pipe should enter fitting It is a good idea to water test all plumbing lines prior to backfilling etc Any water or air leaks that appear when filtration has started will require glued or threaded fittings to be re made A E w l STANDARD 1 5 PLUMBING KIT l a 8 X 3m white pipe 3m x 1 5 ABS PIPE P P SOCKET 90 deg ELBOW 1X PT Socket Union UNION 10 X 90 deg elbows _ 2 X nipple socket it my 3 X p t nipple f W 3 X plain socket a 1 X Ball valve BOCKET P T NIPPLE 1 X tee 4 X PTFE thread seal tape E Hi 1 X adhesive j qa A F oom i Fi Ma
31. ructure Deck Box is to be installed level with the paving surround this cannotbe done until backfilling and concrete top ringbeam has commenced The Bulb Housing can also be installed at this time threading the electric cable through the Conduitto the Deck Box IMPORTANT Usea qualified electrician tocarry outallelectricalconnections NOTE Putaside the Faceplate Clamp plate Screws and 1x selfadhesive gaskets until you are ready to instal the liner Bulb Housing DO NOT SHORTEN LIGHT CABLE Excess cable is supplied to enable the sealed Bulb Housing to be removed under water and the bulb to be changed above the waterline INSTALLATION OF THE LINER STAGE 9 F THE TEMPERATURE IS BELOW 50 DEG F WE RECOMMEND THAT THE FITTING IS POSTPONED UNTIL WARMER WEATHER PREVAILS IF A STEP UNIT IS INSTALLED SEE PAGE 19 PRIOR TO LINER INSTALLATION 1 Atleasttwo people and preferably more are needed to install your liner efficiently 2 IMPORTANT apply packing tape provided to all panel joints Also seal Inlet Fitting plumbing line with tape and anywhere else that air can be sucked in behind the liner and cause loss of suction power If the vacuum is not very powerful you may need to apply tape to the bottom of the Coping Receptor and pool wall 3 Thoroughly Vacuum and sweep the floor structure removing as many fine particles as possible 4 Nowfit one gasketto the Skimmer Inlet fittings and Underwater Light if fitt
32. see dia below The screed should be firmly tamped into place using a Wooden or Plastic float and finished to asemi smooth level surface Itisadvisabletoworkinsmallamounts atatime RemoveWoodenBattonsas you progress along thelength ofthe pool You should now be able to putaspiritlevel across the two screed lines Thelineris nottailor made tothe exactsize of your pool dimensions Therefore atolerance level of 1 2 inthe finished screed is acceptable As with all construction itis advisable to obtain the best results as possible 3 Immediately you have finished screeding a small area a Steel Floatis used to obtain a plaster s trowel finish Applying firm pressure tothe Steel Float use a forward and backward motion to make the screed into a smooth polished finish Wooden Batton Finished Pool Depth Steel Pin REMOVE ALL STEEL PINS AFTER SCREED HAS BEEN APPLIED 13 5 DEPTH OPTION 24 RapIUS CORNERS For 5 flat bottom pool depth you will have to screed the banks first Mark 2 from the bottom ofthe panel andinserta Steel Pin into each corner of the pool floor at the finished floor depth Runa String Line to each corner pin this willbe your finished pool depth guide Using short pieces of battoning as a guide apply screed material to the banks of the pool making sure that the screed does not finish higher than the String line guide or the 2 chalk line marked on the bottom of the panel Wooden Batton s The 24 r
33. vation See page 8 if installing a step unit EXCAVATION STAGE 2 FOR 5 DEPTH EXCAVATION Sketch Drawing fig 5 below shows the finished excavation Toreach this stage proceed as follows 1 Fixalevelstringline to stakes ata height equal to top of Wall panels and Coping Receptor i e finished pool amp surround level around the marked outarea 2 Using back hoe of the excavator start digging to the depth of 4 21 2 from the intended top level ofthe pool surround This height and level is mostimportant thus check your levels frequently using either an optical builders level or water level Itis unlikely that sufficiently good results could be obtained with a spirit level If earth is to be removed leave iton the side easiest for removal Atthis stage the whole area is to be excavated to a constant depth of 4 21 2 Remember The pool has been marked out allowing fora 24 overdig This area is also to be excavated it willact as a working trench and will receive the Polymer Braces 3 Toshape the excavation below 4 21 2 depth proceed as follows a Using string lines mark onthe floor of the excavation across the width and length ofthe pool the 3 6 banks that will form the shape and depth as per excavation drawing below See fig 5 amp 6 b Startatone end of the pool and excavate to dimensions shown in the dig dimension table on page 4 Excavation should be undertaken extremely carefully especially underneath the walls since any over
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