We all know that fibreglass pools are made of fibreglass — but how are they made exactly? There are many intricate steps involved in producing a fibreglass pool. To give you a basic understanding of how they are manufactured, this guide walks through the full process of making a fibreglass pool shell.
Key takeaways
- Fibreglass pools are manufactured in a controlled factory environment using a pattern, a precision-level mould, and a multi-layer shell build.
- The pool shell is made from the inside out, built in 7 layers that combine gelcoat, resins, glass fibre, and a sandwich core for strength and durability.
- After the shell cures, it’s released from the mould, trimmed, fitted (skimmer/main drain), and put through final quality checks before delivery.
- Quality and levelness at the pattern/mould stages are critical—defects or unevenness can transfer into the finished shell.
There are 3 main components involved when constructing a fibreglass pool
Part 1: The pattern
The very first thing that is required to make a fibreglass pool is the pattern. It is built with filler, primer, timber, and fibreglass. The pattern determines the shape, size and design of the fibreglass pool and is made to look the same as the finished pool once installed.
From the pattern, the mould is created. Once the mould has been built, it is removed and then used to build the fibreglass shell on top of it.
When it comes time to install your fibreglass pool, builders can find it difficult to place the pool correctly if the shell has not been built level. If the shell is not constructed evenly, time can be wasted as the pool is lifted and replaced to attempt to place it correctly. Reputable manufacturers use laser levels to avoid this from happening.
Part 2: The mould
The quality of your fibreglass shell is highly dependent on how good the mould is, as the pool is built directly on it. An inferior mould can compromise the structure and quality of the pool shell drastically. If the mould has defects, the fibreglass shell can inherit those defects.
It is essential that your pool shell is built on a mould that is precisely level, otherwise the finished pool will not be level. All pools manufactured by The Fibreglass Pool Company have a unique 5-digit number to allow shells to be tracked once they have left the manufacturing plant, and each shell goes through a strict quality control process.
Part 3: The pool
Your fibreglass pool is made from the inside out, constructed with various layers. Each layer is hand laid or sprayed onto the mould.
Here are the layers that make up the shell of a Fibreglass Pool Company shell
1st layer: Interior surface finish
The first layer applied onto the mould is an Advanced Pool Colour Technology gelcoat. This makes up the interior surface of the pool and is applied at approximately 0.8mm to 1.0mm thick. This layer is UV and chemical resistant.
Wondering what colours your fibreglass pool can be? Click here to find out!
2nd layer: Anti-corrosion barrier
The second layer is a high-quality Vinyl Ester resin layer. This provides excellent bonding to the Advanced Pool Colour Technology layer and adds resistance to chemical and UV impacts on the pool, helping ensure strong long-term protection.
3rd layer: First structural and additional chemical resistant layer
The third layer is an additional coating of high-quality Vinyl Ester resin combined with JUSHI E6-CR glass fibre. It is applied at approximately 1.5mm to 2.0mm thick. This further increases resistance to corrosion and strengthens the laminate.
4th layer: Second structural layer and lifting hook application
Layer 4 consists of high-quality polyester resin combined with JUSHI E6-CR glass fibre. This layer adds further strengthening properties to the structure of the pool. No filler is added.
Lifting hooks are installed at this stage and are glassed in (and glassed over again) to ensure optimal strength. These hooks are used to lift the shell out of the mould once it is ready.
5th layer: Reinforcement layer
The reinforcement layer is an additional layer of high-quality polyester resin with JUSHI E6-CR glass fibre. It is rolled to eliminate any trapped air and further reinforce the pool shell structure. Again, no fillers are used.
6th layer: Outer core laminate
The sixth layer is a Klegecell/Divinycell sandwich core laminate. This product is commonly used on luxury yachts and high-performance marine applications. Klegecell/Divinycell are widely regarded as leaders in high-performance sandwich core strengthening.
7th layer: Outer sealer coat
The final layer used to construct the fibreglass shell is an outer sealer coat. This is the outer layer of the pool, finished with a glossy coat made using high-quality polyester resin to protect the interior layers of the pool.
Final steps before delivery
Curing and release from mould
Once the pool has been completely built and has had adequate time to cure, the next step is releasing it from the mould. It is removed using the lifting hooks that were glassed into the pool layers.
During manufacturing, brick ties are placed to allow the pool to be tied into the concrete bond beam during installation.
Trimming, final inspection and detailing
The pool shell is supported on drums while it is detailed and trimmed. At this stage, the skimmer box is cut into place and the main drain hole is prepared before it leaves the manufacturing facility.
Detailed production records (including the pool number, size and shape) are filed for future reference if required, and the shell undergoes its final quality control inspection.
Finished pool ready for delivery
The final step involves loading the fibreglass shell onto the truck for delivery. All paperwork is checked to ensure the details are entirely correct before leaving the manufacturing plant.
Where are the fibreglass pool shells made?
The Fibreglass Pool Company shells are constructed onsite at their manufacturing plant in Beaudesert, Queensland. The shells are made in state-of-the-art, temperature-controlled plants with the ability to produce multiple shells per day. The site includes dedicated space for housing the range, equipment, and a warehouse for mould maintenance and research to help ensure consistent quality.
Need help choosing a pool?
We hope this article gave you a clear understanding of the construction process involved with building fibreglass pools. If you’re considering a fibreglass pool or have any questions, give our friendly team at The Fibreglass Pool Company a call — we’re more than happy to help. You can also request a Free Quote.
Frequently Asked Questions
How are fibreglass pools made step by step?
Fibreglass pools are made in a factory by first creating a pattern (a master model of the pool), then building a precision mould from that pattern. The pool shell is then constructed on the mould “from the inside out” in multiple layers (starting with the interior gelcoat finish, then resins and fibreglass reinforcement, then a sandwich core and outer sealer coat). After curing, the shell is released from the mould, trimmed and detailed, the skimmer and main drain openings are prepared, it goes through final quality checks, and is then loaded for delivery.
What is the pattern in fibreglass pool manufacturing?
Why does the mould need to be perfectly level?
What are the 7 layers in a fibreglass pool shell?
A typical multi-layer fibreglass shell is built from the inside out and includes:
– Interior surface gelcoat (pool colour finish)
– Anti-corrosion barrier (vinyl ester resin)
– First structural / chemical resistant layer (vinyl ester + fibreglass)
– Second structural layer (polyester + fibreglass) + lifting hook installation
– Reinforcement layer (polyester + fibreglass)
– Outer core laminate (sandwich core such as Klegecell/Divinycell)
– Outer sealer coat (protective outer resin coat)