How Quality Fiberglass Swimming Pools & Spas are Manufactured
The unique look and unmatched durability of your Trilogy Pool is a direct result of our manufacturing processes. This includes taking over 60 measurements during pool construction and capturing a comprehensive quality report that includes a retained sample from every pool we manufacture. This enables the highest quality that can only be assured through meticulous processes, recording results, and maintaining the integrity of our manufacturing day in and day out. When manufacturing is complete, you've got a pool that is as durable as it is beautiful.
The Best in materials and manufacturing
Trilogy Pools partners with the best resin suppliers in the United States, and selects only the very best raw materials available.
The Best in quality control
Our quality control system ensures that your pool will be durable and beautiful. We can tell you the day your pool was built, the shop conditions, the composites technicians that built your pool, and the lot and batch numbers of the resin used. We even retain a piece of your pool in our files—FOREVER!
Let's take a look at the actual manufacturing process and you will see why a Trilogy Pool equals Peace of Mind!
Layers of excellence
The Trilogy manufacuring process uses the highest quality composite resins and gelcoats in the industry
- Coping Options Brick, Concrete, or Stone Coping provides an elegant and durable finished edge around your Trilogy Pool.
- Interlocking Bond Beam The Bond Beam is formed when concrete from the deck is poured around and up next to the flange of the pool. This step structurally ties your deck to the outside of the fiberglass pool shell.
- HydroStone / Gelcoat Whether you choose one of our 6 beautiful HydroStone finishes or white gelcoat, you are assured of maintenance-free durability for years to come. To find out more about our exclusive HydroStone finish click here.
- Vinyl Ester Barrier Coat This layer gives your pool extreme resistance to even the most corrosive chemicals.
- General Purpose (GP) Resin This structural layer of general purpose resin and fiberglass provides the rigidity needed for transportation and installation of the swimming pool.
- Woven Roving + GP Resin This 24 oz. woven glass cloth is the final laminate for a Trilogy Pool. The glass cloth encases the entire pool in a network of fiberglass. The end result is a swimming pool with outstanding structural integrity.
Your Trilogy Pool is Custom Crafted for You
Trilogy Pools has a very unique process of manufacturing your pool – one that focuses on the ultimate in quality control and peace of mind. Let's take a walk through the manufacturing process step by step!
STEP 1: Your Swimming Pool Shape enters into Bay 1
Your pool shape starts its manufacturing journey by entering into the first bay of the 60,000 square foot state of the art Trilogy manufacturing facility.
Once your pool enters the building, bay doors on either side of the pool are shut.
Why is the Pool Mold Orange?
The Trilogy pool mold is always in bright colors such as orange or lime green. This provides and excellent visual medium and stark contrast to the actual pool finish material. (We've never had anyone order a bright orange or lime green pool… so we feel pretty safe about these color choices!) This is just another way of ensuring excellent quality control. There are other technical reasons behind our tooling color choices too (such as long-term durability of the tooling finish). All of them oriented toward manufacturing only the highest quality swimming pool shells!
STEP 2: The Fiberglass Pool Mold is Inspected and Polished
Before we begin the process of manufacturing your swimming pool, we want to make sure that the pool mold surface is spotlessly clean and polished. We take A LOT of time to review the surface. Why? Because your pool can only be as good as the mold it's built on!
Building Your Pool from the Inside Out! You've probably noticed that the pool mold is upside-down on a trailer. All fiberglass pools are built from the inside out. Think of a Jello Mold or some Fancy Chocolate candy mold. The shiny, beautiful part is applied first and then all of the bulk follows suit.
STEP 3: HydroStone Finish Application (or White Gelcoat Finish Application)
Now that the mold is prepped, ready and blemish free we can begin with the beauty coat.
This is the part where we apply one of the 6 Trilogy HydroStone finishes, or the Trilogy White Gelcoat Finish.
The technicians work from a scaffold system and spray the material onto the mold.
Because the technicians don't stand on top of or touch your pool while the finish coat is being applied, you are guaranteed a high quality, untarnished finish.
STEP 4: Quality Control Checks
During and after the finish coat is applied, the technician will gauge specific points on the pool – taking both a visual and written account of the findings.
By gauging the material all over the pool, we don't have to guess as to whether enough material was used.
Assembly-Line Manufacturing - Trilogy Pools are built in a unique assembly line setting. Each building stage is performed in its own bay. How is this good for you and your pool? By having separate areas for each stage, there is no chance of cross-contamination of materials and is extra quality control protection. Your pool technicians are specifically trained for Finish Coat Application, 100% Vinyl Ester Resin Application, General Purpose Resin Application, and Detailing. Trilogy leaves nothing to chance!
STEP 5: Application of the 100% Vinyl Ester Layer
The HydroStone finish is then followed up by a layer of vinyl ester. This solid colored 100% vinyl ester layer does 2 things: It deepens and unifies the first layer. And, gives your pool extreme resistance to even the most corrosive chemicals.
What is 100% Vinyl-Ester Resin and Why is it so Important?
Ever heard of Osmotic Blisters? These little blisters plagued the boating and fiberglass pool industries for years. It was found that, although the beauty coat of a boat or pool looked shiny and non-porous… it actually allows molecules of water to permeate the surface. Is this a problem? Not in and of itself. But if once the water gets in, if it has something to react with, it will. The result is osmotic blisters. Enter 100% vinyl ester resin. Applying this material behind the beauty coat protects the surface because Vinyl Ester resins cure to the point that they are no longer reactive with water or chemicals. No reactions = No blisters! Any good quality fiberglass pool manufacturer uses 100% Vinyl-Ester Resin in their manufacturing process. Trilogy offers a Limited Lifetime Warranty against Osmotic Blistering. To read more about our Limited Lifetime Warranty, just click here.
STEP 6: More Quality Control Checks
During and after the 100% vinyl ester layer is applied, the technician will gauge specific points on the pool – taking both a visual and written account of the findings.
By making use of the TFM system, and gauging the material all over the pool, we don't have to guess as to whether enough material was used.
The TFM System – Maximizing Quality Control
This CRAZY Octopus looking machine is actually more like the ultimate insurance policy. The TFM System gives our technicians an extra "brain." It provides our composites technicians real-time information as they are spraying material—giving them accurate readings on the quantities and ratios of the material being sprayed. Should the numbers change, the technician is immediately alerted and can make adjustments. The TFM System also collects all of the data about your swimming pool:
All of this data is then transferred to your Warranty Packet and kept on file FOREVER! Trilogy does not leave the quality of your pool to chance!
STEP 7: General Purpose Application – Building in Stability and Bulk
The General Purpose layer is also known as the structural layer.
This bulk layering of materials provides the rigidity needed for transportation and installation of the swimming pool.
This is where we also incorporate Sandwich Core Construction if needed.
STEP 8: Wetting Out the Material
Just like the 100% Vinyl Ester Resin Application, we want to make sure there is consistency in the General Purpose materials.
Once the material is sprayed on we want to make sure there is consistency in the materials and that all of the air is removed between the layers.
Air = Weakness, and we resolve this by using rollers to "Wet Out" the material and "Roll Out" the air.
STEP 9: More Quality Control Checks
During and After the General Purpose Resin is applied, the technician will gauge specific points on the pool – taking both a visual and written account of the findings.
By making use of the TFM System, and gauging the material all over the pool, we don't have to guess as to whether enough material was used.
You mentioned Sandwich Core – What is That?
No Worries! It's not something you eat! Sandwich Core Construction is technology that is borrowed from the aeronautical industry. It's used quite a bit in airplanes, as a means of building extreme strength without additional weight. Since after your pool is installed it won't be required to go very fast (like a boat or an airplane), we don't have to be too worried about overall weight. We do want your pool to enjoy a lifetime of strength though.
Enter Sandwich Core.
By adding a layer of lightweight core material in between two layers of fiberglass and resin, we can increase the stiffness of the pool shell by 8 times! Your builder has a great sample piece that shows you how Sandwich Core works – make sure you check it out!
After the General Purpose Resin is applied and the pool is gauged, the measurement information is recorded for our permanent files. The pool is then moved to Bay 4-the Mold Release Bay.
STEP 10: Releasing Your Trilogy Pool from the Mold
Your Trilogy Pool has now been transported outside. Because the Trilogy team took time to prepare the mold initially, the pool is easily lifted off – looking nice & shiny!
STEP 11: Final Detail
Because we want your pool to look as clean and beautiful on the outside as it is on the inside, we take a little extra time to detail your pool.
After the pool is relieved from the mold, it is lowered for detailing.
We clean up the coping and polish out anything that doesn't quite meet our expectations.
What happens if you need to repair the surface of my pool?
The beauty of the materials we use is that they are so easy to repair in the rare case it's needed! With our HydroStone Pool and Spa finishes, just think: Beautiful, Long-Lasting Durability – Repairable with Renewable Qualities.
STEP 12: Time to Build Your Neighbor's Pool!
The pool mold makes its way around the building to begin the process again.
Enjoy Your New Trilogy Pool!!!