April, 2021 Build - IG steel panels corroding already?!?

wgipe

Gold Supporter
Jul 4, 2020
515
Fletcher, OH
Pool Size
20000
Surface
Vinyl
Chlorine
Salt Water Generator
SWG Type
Pentair Intellichlor IC-40
HI everyone,

Our build (link in sig) finished up in May of this year. Yesterday, I noticed that in about a 2x2' area under where the auto cover docks (circled in pic) is feeling almost like there is grit or sand underneath the liner every inch or so. It starts above the water line at the liner track and goes on down 2 feet or so under the water. It is possible that it's been there all along, but I've definitely not felt that before. I'm concerned that it could be the start of corrosion. During construction, I did notice that there was a 1/4" gap between the cover box and the stainless piece that guides the cover up over the edge of the pool (see other pic from construction). That would allow water from the bottom of the cover to get down in behind the back side of the panels on that end, as there is a hollow space between the cover box and pool wall (I noticed when they poured that section of deck that they couldn't get concrete pushed up all the way behind the cover box - I don't know how you would.

A few questions:

1.) Should I be concerned about this?
2.) Should I try to cover that gap with some flex tape or something (wouldn't have to be pretty - it's always hidden by the cover bar that sits there) to prevent water getting down in that crack as much as possible?
3.) There is a well point that was installed to drain water when changing the liner. I have checked a few times and the water level sits around the half-way point of the panels, as it is in a low area and we have heavy clay soil. I've debated putting a sump pump in there permanently to keep water off the panels - wondering if I should do that.
4.) Maybe I'm over-reacting?

Any guidance would sure be appreciated.

Thanks!

WesIMG_1052.jpgIMG_0568.jpg
 
Are you talking about this opening with the arrow pointing to it?
Annotation 2021-08-05 101956.jpg

If so I think it would not hurt anything to close that gap... I wonder what would be the best option...

I would think you need to fill the area behind it with something.. maybe spray foam or foam backer rod Amazon.com: 3/4" Closed Cell Backer Rod - 100 ft Roll: Home Improvement

Then an epoxy or similar coating over it.. You would need something that the cover would slide over and not stick to it.. It would have to be durable and waterproof...

Sikaflex 1A seems like it would work perfect :)
 
Are you talking about this opening with the arrow pointing to it?
View attachment 361770

If so I think it would not hurt anything to close that gap... I wonder what would be the best option...

I would think you need to fill the area behind it with something.. maybe spray foam or foam backer rod Amazon.com: 3/4" Closed Cell Backer Rod - 100 ft Roll: Home Improvement

Then an epoxy or similar coating over it.. You would need something that the cover would slide over and not stick to it.. It would have to be durable and waterproof...

Sikaflex 1A seems like it would work perfect :)
Yep - that’s the gap I’m referencing. I do like the thought of backer rod and sikaflex.
Is it possible that water from the back side of the panel would cause corrosion on the liner side in just a few months? Seems pretty extreme to me, but I have no other explanation. I’ve tested the bond to that panel and there is zero differential, so I don’t believe that’s a factor.
 
If it is metal it will rust.. no way around it... How fast is the question.. I doubt it did it that fast but the only way to know is to take it apart.. I do not think you want to do that :)
 
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