ALPOL AQUA PLUS system chart

ALPOL AQUA PLUS system is intended for complete usable and waterproofing courses in swimming pools. The system may comprise the following layers: - external insulation course - underfloor insulation course - thermal insulation course - pressure course - undertile insulation course - cladding layer

Application of the external insulation

Remove any loose material and anti-adhesion coats from the structural slab before getting started. Smooth surfaces, after boarding is removed, and contaminated with boarding protection agents may require additional treatment: shot or sandblasting or milling. To repair large irregularities use ALPOL AZ 130 quick setting mortar, or ALPOL AZ 135 levelling mortar. Properly treated surface of the pool should be sound, even, dry, clean, free from dust and contamination.

Application of the external insulation

Use two products to apply the insulation course: ALPOL AH 740 bitumen insulating and priming emulsion and ALPOL AH 741 bitumen sealing compound. ALPOL AH 740 bitumen emulsion is used for priming. Apply the emulsion with a brush after thinning with water in proportion 1:9 (emulsion:water).

Application of the external insulation

After around three hours, once the ALPOL AH 740 emulsion has dried, apply ALPOL AH 741 bitumen sealing compound and apply the regular waterproofing course. Apply the compound twice in crosswise layers using a brush or stainless steel trowel. One layer takes between 3 and 5 days to dry out.

Application of the underfloor insulation

Remove any loose material and anti-adhesion coats from the structural slab before getting started. In this stage, desired surface slope can be worked (if not shaped on the construction slab yet) and repairs can be done (smoothening irregularities and cavities). It is recommended to use ALPOL AZ 130 quick setting mortar, or ALPOL AZ 135 levelling mortar for that purpose. Properly treated surface of the slab should be dry, clean, free from dust and contamination.

Application of the underfloor insulation

The underfloor insulation should be applied before the thermal and pressure layers. It can be made either of torch-on membrane, ALPOL AH 752 sealing compound, or ALPOL AH 753 waterproof mortar. An excellent underfloor insulation can be made of ALPOL AH 740 bitumen priming and insulation emulsion and ALPOL AH 741 bitumen sealing compound. Insulation using those products is applied in a similar manner as the external insulation. Application of conventional insulation course requires minimum two crosswise layers of torch-on membrane. Then, spread 0.6 mm PE membrane and overlap its edges onto the wall to the pressure course height.

Application of the thermal insulation

It is recommended to make the thermal insulation of extruded Styrofoam (XPS) or EPS 100 - 038 (FS 20) Styrofoam. The thermal insulation course should be protected, especially when made of EPS 100 – 038 Styrofoam, from mechanical damage with a coat of 0.15 mm PE membrane.

Application of the pressure course

The pressure course on the thermal insulation course can be applied using ALPOL AP 400 underlay mortar. The pressure course should be at least 4 cm thick. When using additional steel mesh reinforcement, position the mesh on spacers beforehand. Mixed mortar should have the consistency of “moist earth” and be spread within max. 60 minutes from mixing. Intervals between applying the following underlay courses may not be longer than 30 minutes. Otherwise, the strength of bonding with previous layers will be compromised.

Application of the underslab insulation

An underlay for that layer is applied in a similar manner as for the external waterproofing. However, attention should be paid to surface cleanliness and smoothness, especially when thin-coat adhesives are to be used. Remove any loose material and anti-adhesion coats, paint coats, cement stains and grease from the surfaces before starting to work. Smooth surfaces, after boarding is removed, and contaminated with boarding protection agents may require additional treatment, such as shot or sandblasting or milling. Avoid sanding the surfaces as the sanding dust is extremely hard to remove and its particles would impair adhesion of the waterproofing courses. Irregularities, holes after boarding or air bubbles must be patched with system levelling mortars intended for concrete re-profiling.

Application of the underslab insulation

Apply ALPOL AG 707 silica-polymer primer onto the surfaces prepared that way, at least 3 hours before applying the undertile insulation courses using ALPOL AH 753 waterproof mortar. Work with a broad paintbrush.

Critical points requiring additional insulation

Start from fixing additional insulation accessories (tapes, corners and ALPOL sealing sleeves) in critical points of the pool, such as: expansion joints, wall-to-wall and wall-to-bottom joints, penetrations through walls and bottom, fixing of ladders, handrails, inlets, lights, overflows and pool-strand interface.

Fixing ALPOL T1 sealing tape to the expansion joint

Apply ALPOL AH 753 sealing mortar of sludgy consistency on the surface in belts of the same width as that of the sealing mesh tape ALPOL T1 with some slight allowance. Then, embed the tape so it can be pressed into the expansion joint gap to the depth of twice the gap width. The cavity of the tape formed that way allows its free movement and the expansion joint rope to be placed afterwards. Apply the compound again as described above.

Fixing ALPOL T1 sealing tape in the interface edges between the pool bottom and walls

Round the corner edge with ALPOL AZ 130 quick-setting mortar if necessary, before starting to embed ALPOL corner or tape. Apply the mortar of sludgy consistency on the surface and wall in belts of the same width as that of the sealing mesh tape or ALPOL N1 corner with some slight allowance. Fix the tape in such a manner to leave some room for its free movement and the expansion joint rope to be placed afterwards. Apply the compound again as described above.

Sealing the interface between the pool and strand

Proceed with the sealing as for the structural joint. First, protect the existing gap from contamination. Reshape its edges if possible. Apply the mortar of sludgy consistency on the surface in belts of the same width as that of the sealing mesh tape ALPOL T1 with some slight allowance. Then, embed the tape in a way it can be pressed into the expansion joint gap to the depth of twice the gap width. The cavity of the tape formed that way allows its free movement and the expansion joint rope to be placed afterwards. Apply the compound again as described above.

Sealing the overflow (Wiesbaden overflow as an example)

While fixing the overflow fittings, particular attention should be paid to fix and, at the same time, fill the space between the fitting and the surface with waterproofing applied. It is recommended to use ALPOL AH 760 epoxy mortar which provides additional waterproofing action. Instead, ALPOL AK 517 liquefied flexible adhesive for medium thick layers can be used. Before applying the regular waterproofing, fix ALPOL T1 sealing tape to the internal and external edges of the concrete overflow surface; proceed in a similar manner as for the contact points between the walls and pool bottom. Apply the mortar of sludgy consistency on the surface edges in belts of the same width as that of ALPOL T1 sealing mesh tape or ALPOL N1 corner with some slight allowance. Then, fix the tape leaving some clearance for free movement of the tape. Apply the compound again as described above.

Sealing the plumbing inlet

The way the plumbing inlet is sealed depends on its type and installation method. Most inlet types require additional sealing with special flexible sleeves. Depending on the type of component being fixed the following sleeves are available: ALPOL M1 for wall-mounting or ALPOL M2 for floor mounting. Use ALPOL AH 753 mortar of sludgy consistency for fixing, applying it on the surface and inlet edge. The mortar is applied in belts of the arrangement and width matching the perforated edge of ALPOL sleeve. The width of the belts applied should be increased for more precise fixing of the edges. Fix the sleeve avoiding tension that might obstruct free movement of the tape. Apply the mortar again on the contact surface. The inlets can also be fixed with bolts and pins directly to the surface covered with a coat of ALPOL AH 753 mortar, to provide proper sealing. In case of the swimming pool strand, the bolting depth may not exceed the pressure course thickness, in order not to damage the layers underneath. Sometimes the inlet may require additional sealing to be fixed, especially while changing its position (e.g. after chiselling a component that had been embedded in concrete). Proceed in a similar way while sealing water inlets and other components, e.g. handrails, ladders.

Application of the underslab insulation

Insulation in critical point can be applied in 6 hours after fixing reinforcing components. Three coats of ALPOL AH 753 waterproof mortar are necessary. First sludgy coat (with 3% water addition) is applied on the entire surface with a hard paintbrush, rubbing it hard into the surface. Apply the mortar also to the edges of critical points. Apply the sludge profusely trying to keep uniform thickness. Use a putty-consistency mortar to apply the following coats.

Application of the underslab insulation

The second and third coats should be applied crosswise by towelling. This consists in applying a thin coat of the mortar onto the surface using a stainless trowel and float. Remember to apply the following coats after the previous one is set, i.e. after around 6 hours, at 20°C. To avoid shrinkage cracks, do not apply more compound than 2 kg/m². Due to rapid increase of the coat mechanical strength, ceramic tiles can be fixed in 24 hours after finishing the work. The coat will be resistant to rainwater after around 12 hours from application. The ready-mixed mortar should be used within 1.5 hour.

Fixing the cladding

The cladding is made of special ceramic drawn or pressed tiles, intended for swimming pools. Drawn tiles should not be trimmed, hence they must be sized in a way to fit to the pool dimensions and to pipe penetrations and other components affecting the continuity of ceramic cladding. In most cases, thick-coat adhesives are used for fixing such tiles, applied in up to 3 cm thick coat. There are no restrictions as regards trimming pressed tiles to size. Thin or medium-thick-coat C2 class adhesives are used for fixing them. The adhesives may be either of regular consistency or liquefied. Non-liquefied adhesives require combined application method to avoid formation of air cavities under the tiles (applying the adhesive both, on the substrate and tile fixing side). Liquefied adhesives do not require using the above method, as it is enough to apply the mortar on the substrate only. Flexible ALPOL AK 513, quick-setting ALPOL AK 512, thin-coat liquefied ALPOL AK 516 or medium-coat liquefied ALPOL AK 517 adhesives are recommended for fixing tiles.

Fixing the ceramic cladding

Apply the adhesive onto the substrate with a trowel or a float and spread it uniformly with a trowel having semi-circular notches spaced 13 to 15 mm (for liquefied adhesives) or square-notched trowel up to 10 mm (for regular adhesives). Apply tiles and press them lightly against the surface. Position adjustment can be made within 10 minutes from fixing. Fix the tiles within max. 30 minutes from spreading adhesive on the surface. ALPOL AK 516 and ALPOL AK 517 should be used within 1 hour after mixing with water, ALPOL AK 513 within 2 hours and ALPOL AK 512 within 15 minutes. If the adhesive thickens in that period of time, stir it again without adding water. Unused hardening mix cannot be mixed with water again. Throw it away.

Making the expansion joint in the cladding

Two types of expansion joint gaps can be present in the cladding: - structural – continuing the substrate structural joints, - anti-contraction joints, used additionally to compensate the expansion differences between hard concrete base and cladding layers (adhesive, tiles). The joints must be filled with constantly flexible sealing compound. Joint edges before filling should be treated with special primer matched to the sealing compound. Once the primer has dried press expansion joint rope into the gap.

Sealing the overflow in the cladding (Wiesbaden overflow as an example)

The overflow is sealed with two system products: special primer and constantly flexible sealing compound. First, treat the contact edges between the overflow and tiles with appropriate primer, and then apply the special sealing compound. Depending on the gap size, it may become necessary to apply expansion joint rope of sufficient diameter. Use ALPOL AH 760 epoxy mortar to fix the tiles along the overflow. This will provide additional sealing and protection from capillary moisture penetration.

Sealing the plumbing inlet in the cladding

Edges of the inlet and of tiles around should be first suitably primed for the sealing compound. Then, press expansion-joint rope of sufficient diameter into the gap between the inlet and tiles. The next step is to fill the gap formed that way with the constantly flexible sealing compound.

Sealing the interface between the pool bottom and walls in the cladding layer

Edges of tiles in the joint between the bottom and walls should first be suitably primed for sealing with the flexible compound. In addition, before filling the gap, press in water-resistant rope of diameter matched to the width. Proceed in a similar way to seal the joints between walls.

Sealing the interface between the pool and strand in the cladding layer

Seal that joint in a similar manner as in case of the expansion joint. Fill the gap with flexible sealing compound after having primed the tile edges appropriately. Then, press expansion-joint rope of sufficient diameter into the gap between the tiles. The next step is to fill the gap formed that way with the flexible sealing compound.

Pointing the pool tiles

Flexible waterproof grouts are recommended for pointing. Those may be cement and polymer or epoxy products. Due to the great resistance to external factors during the use, especially washing and abrasion, grey epoxy ALPOL AH 760 grout fits best for the application in question. Remove residue of adhesive from joints, clean them and dedust before grouting. Tile edges should be dry. Apply the grout with appropriate tools, so that the entire space between the tiles and surface is filled. Remove the excess of grout diagonally and clean the surface with a moist sponge or cloth. Moisten and clean the joints again after drying.

Pointing the pool tiles

To prepare ALPOL AH 760 for application, carefully stir the whole package with a low-speed electric drill (600 rpm) with a basket mixer until homogeneous mix is obtained (mixing time from 3 to 4 minutes). Then, pour the grout to a clean container to avoid contamination with residues of components that could have been left on the container walls. Work with special tools for epoxy products only. Clean the tile surface immediately after filling the joint. Use warm water to do so.