How A Thursday Pools Fiberglass Pool Is Made

INQUIRING MINDS WANT TO KNOW

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What do all of these things have in common?

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If you guessed fiberglass, you’re the smartest person in the room.*Disclaimer: We have no way of knowing how many other smart people are actually in the room with you.

FIBER + GLASS = FIBERGLASS

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Yes. Fiberglass is quite literally fibers of glass. But you won’t cut yourself on it because the fibers are heated until they’re molten. Then that ooey-gooey molten mixture is forced through superfine holes, creating glass filaments that are very thin–so thin that they are measured in microns.

These threads are often woven into larger swatches of material for things like insulation, but when thermoplastic polymer resins (say that five times fast) are added to them, the material becomes stronger than many metals by weight and can be molded into complex shapes, like rocket ships, boats, Tilt-a-Whirls and pools. In fact, the highest quality fiberglass is destined to become a Thursday Pools fiberglass swimming pool.

It’s a match made in heaven because the flexibility of fiberglass allows us to create incredible features in our pools, such as tanning ledges, sun shelves, benches and play areas. It also allows for a great variety in shapes, sizes and finish colors.

“What?!” You ask. “Thursday Pools makes pools from glass?”

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“How do you know if your crazy creative designs will work?”

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It’s as simple as 1-2-3

First, we design something awesome. With an amazing 3D software program, we create the shape, size and features for our fiberglass swimming pools.

We analyze the design. All of our designs must meet all ASTM 5 safety standards for residential pools.

We create a Computer-Assisted Drawing (CAD). CAD drawings define the technical specifications and create the blueprint for the pool’s pattern. And to triple-check ourselves, we conduct a Finite Element Analysis (FEA) to ensure the structural integrity of the design.

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This part is tricky … and impressive. Once the design meets our rigorous

testing standards, our expert craftsmen build a pattern out of

wood on an I-beam steel structure to ensure precision as well as a

solid foundation.

From the pattern, we make the mold, which will be used to make every pool

of that model, ensuring that every pool is uniform and structurally

sound. When we’re done with the mold, we haul out our big crane

to remove it from the pattern.

“How do you make a pool in one piece?”

If the mold is not properly prepped, the

gel coat of the pool will stick to the mold, making it

impossible to demold the pool without damage to both the pool

and the mold itself. Nobody wants that to happen, so we’re awfully careful

when we do this.

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“Did someone say lunch?”

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I think you’re talking about our Composite Sandwich of Awesomeness!I can explain. Once finished, we move the mold to the gel station and begin at the finish. The top gel coat of the pool is hand-applied first. Then, we continue to build “our sandwich” by layering resin, chopped fiberglass, and hand-laid woven roving fiberglass in a series of lightweight structural honeycomb panels sandwiched between layers of laminate to dramatically strengthen the pool shell. Overnight, when all of the fiberglass molecules crosslink, a total of nine carefully crafted layers (our Composite Sandwich), becomes a Thursday Pools fiberglass pool with 360 degrees of durability.

1. Gel coat.

2. Vinyl ester barrier coat.

3. First application of chopped fiberglass.

4. Second application of chopped fiberglass.

5. Hand-laid woven roving fiberglass.

5. Hand-laid woven roving fiberglass.

6. Third application of chopped fiberglass.

7. Honeycomb core.

8. Fourth application of chopped fiberglass.

9. Fifth application of chopped fiberglass.

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“Does the customer get the pool after the Composite Sandwich is made?”

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Not quite. We give it one more thorough inspection.This final inspection includes:

Ultrasonic measurements to check the pool’s thickness and total weight.

A visual inspection.

AND

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“Do you really need all those steps?”

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Our customers depend on us creating better-built, longer-lasting, lower-maintenance, stylish pools.

We won’t skip a single step or layer because our customers’ satisfaction is our top priority. Maybe that’s why we are the only ISO 9001 manufacturer in the fiberglass pool industry. At the same time, we care for the environment, so we are equally proud to be ISO 14001 certified.

ISO 9001 ISO 14001

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“Thanks! I am really going to impress people with this stuff!”

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You’re welcome. The real influence starts when you invite your friends to enjoy a custom pool by Thursday Pools and tell them this story about a happy group of passionate people in Fortville, Indiana, who believe in dedication, craftsmanship and hard work. When you are telling a story about people doing what they love every day, who wouldn’t be impressed?

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With over 35 years’ experience manufacturing fiberglass and composites, Thursday Pools brings new innovations to the fiberglass pool industry. We are dedicated to bringing

cutting-edge innovations to the pool world.

Thursday Pools designs and manufactures fiberglass pool shells that are handcrafted with the highest standards and

craftsmanship. Our one-piece, inground fiberglass swimming pool manufacturing facility is based out of Fortville, Indiana.

At Thursday Pools, we aspire to be the world’s most respected fiberglass pool manufacturer. We believe passion, care and

attention to detail make the difference. We aspire to deliver artfully-crafted, durable fiberglass pools and innovative

products that empower our customers to make a lifetime of remarkable moments with their family and friends.