Brownish Spots Forming All Over Plaster

ETXdbw

0
Jul 22, 2017
7
Bullard, TExas
Pool Size
35000
Surface
Plaster
Warning - this is a long post. I've included a lot of history and detail because at this point I'm not sure what might be relevant to the issues that we are having. There are several pictures of the issues discussed at the bottom of the post.

This is my first post (EDIT: it turns out I posted in 2015 about our old above ground pool so this is my second post) but I've been reading the forum for a long time and I am thankful for the wisdom shared here. Hopefully someone can provide more insight into our problems.

First let me tell you about the pool - 35,000 gallon gunite in ground pool in East Texas. 20'x40 main pool area with a 10'x12' sundeck and 10'x10' hot tub with a waterfall into the pool.

Current water chemistry info below:

PH - 7.3
TA - 100
CH - 350
CYA - 50
FC - 6.0
Water Temp - 82 F

We just built this pool last year. It was completed in September. Within a week, the pool settled and a crack formed across the entire pool. The crack was confirmed as being all the way through the gunite with dye as the pool was losing water. A second partial crack was identified down a wall and a couple of feet across the bottom during the repair work.

Pool builder came back and did a full repair. They took a jack hammer to the gunite along all of the cracks then reshot those areas. They also did a full chip out and replaster of the entire pool, not just the cracked areas.
The replaster was completed on the afternoon of December 8th and we immediately began refilling the pool. The pool was full by the end of the day on December 9th.

Before Christmas, the pool plaster started showing these brownish stains that are an ongoing problem. The pool builder identified them as scaling but I'm not sure I agree due to the color and everything that has happened since. The stains were more of a brownish color as opposed to typical gray colored scaling.

These spots appeared on the plaster over the cracks that were repaired - in one section the stains literally had a straight line edge that followed the gunite that was removed and reshot. They also appeared all over the deep end where dirty water from loose gunite sat during the repair process. There were a few other spots on the wall around side intakes (for our second water feature pump) and one spot on the sundeck which I cannot tie to any repairs to the gunite.

The builder came back on April 11th, after the weather warmed up, and did a hot start on the pool. The stains disappeared within a day though we brushed it with a metal brush for 2 days before returning the pool TA and PH to normal levels.

By April 24th, the stains started to reappear in a few spots. By May 10th they were back in full force in the same areas of the gunite repair and all over the deep end of the pool as well as that same one spot on the sundeck.

Last week, on May 17th, the builder and plaster guy came in to attempt to buff out the stains thinking the scaling just was not removed with the hot start. They stopped after a few hours because it was too difficult to hit all the spots. The buffing did remove the stains. The plaster guy has ruled out hydration issues because there is no coloring under the stains after they buffed them out.

By May 20th, several of the spots that they did buff out started to reappear in the pool.

The current plan is to test for metal in the water. If that is negative, then they intend to drain and acid wash the plaster.

I've never had an in ground pool but this seems to be a little over the top. I am being told that I have to keep my water PH levels in a very narrow range - between 7.2 to 7.4 at all times or it will cause scaling within 48 hours. I'm sending photos to the builder every day to verify those levels. I've never heard of a pool that finicky. How would we ever go out of town for more than a day?

I'm also being told that we have to keep our CSI between -.1 and +.1 or scaling will form within 48 hours. That seems like an extremely narrow window. Everything I find online suggests CSI below +.5 will avoid scaling issues and even if it gets over +.5 scaling is not instantaneous.

I'm skeptical because new spots are appearing even if we keep the PH between 7.2 and 7.4. We are adding 1/2 gallon of acid every day to keep the pool in this range. We have 3 deck jets and 2 fountains but we do not run them at all to avoid adding to the PH. I've slowed the pool pump down as much as I feel comfortable (45GPM) to slow down the water fall so it just dribbles into the pool. We are running the pump 15 hours per day. The current 1/2 gallon per day acid usage is after these adjustments.

I'm using 2 different test kits to verify the chemistry measurements. We are also regularly adding baking soda to keep the TA up due to the high acid usage. Our TA was down in the 40-50 range when we ran a higher PH level (7.6-7.8) but I raised it to offset the lower PH our builder wants us to keep it at. The stains formed with the TA at 50 and PH at 7.8 just the same as the PH at 7.4 and TA at 100.

I brush and vacuum the pool every Sunday in addition to running the automated vaccuum for 3 hours each day.

We are on a large public water system. It has high PH out of the tap (8.0+) and high TA out of the tap (300+). That being said, we know several other people with gunite/plaster pools on this water system and none of them have these problems or come close to the acid usage that we have.

Another thing that I've noticed is that our CH levels have risen from 300 to 350 over the last 3 weeks. The 300 measurement was consistent for 2 weeks after the stains reappeared after the hot start. They rose to 330 for 2 weeks then 350 as of yesterday. I have done nothing to intentionally raise those levels.

I am using tablets for chlorine. I started with bleach but our acid usage made the costs of doing bleach and acid untenable.

One other potentially relevant note - the hot tub plaster was not redone when the repairs were done on the main pool as it was not damaged. We have not had a single stain appear in the hot tub. The same company did the first plaster job and the replaster.

I'm attaching a few photos of the repair work as well as the stains.

I would appreciate any input or suggestions on what the problem is, and even better, how to solve it. We are trying to be patient and let the builder trouble shoot the issue but I'm not sure we are making any progress at this point. Any thoughts or suggestions are appreciated.

Thank you.
1.jpg2.jpg3.jpg4.jpg
 
Last edited:
UPDATE: Vitamin C in a sock for 5 minutes left a clean area in the middle of one of the spots.

Then they are iron stains.

I see the rebar in these cuts. It may be the rebar rusting under the plaster.

How were these cuts filled?

The shell should have 8"-9" of thickness and it does not look like that much in these pics. The rebar would be in the middle so there should be about 4" of gunite/cement above the rebar and then plaster above it.

The rebar should also have been sprayed with a rust neutralizer like rust-oleum paint prior to patching.

Rebar close to the surface can rust and the stains can get out to the plaster. Rebar under 4" or more of concrete typically don't stain the plaster.

1-jpg.495106
 
This is where I get confused. Pool builder came back out with test kits for iron and copper. Iron came back negative.

I took the water to get tested and it showed .1 copper. Any chance the heater is leaking copper into the water?
 
Then they are iron stains.

I see the rebar in these cuts. It may be the rebar rusting under the plaster.

How were these cuts filled?

The shell should have 8"-9" of thickness and it does not look like that much in these pics. The rebar would be in the middle so there should be about 4" of gunite/cement above the rebar and then plaster above it.

The rebar should also have been sprayed with a rust neutralizer like rust-oleum paint prior to patching.

Rebar close to the surface can rust and the stains can get out to the plaster. Rebar under 4" or more of concrete typically don't stain the plaster.

1-jpg.495106
The cuts were filled with gunite then replastered on top of that. You can see the gunite fill in the second photo in my original post. Now that I look at it though, the gunite that was filled was maybe a 1/2" short of the original gunite.
 
This is where I get confused. Pool builder came back out with test kits for iron and copper. Iron came back negative.

I took the water to get tested and it showed .1 copper. Any chance the heater is leaking copper into the water?

The pool builder test will not find iron in the pool water. The rusting rebar deposits iron on the surface of the pool as the stain.

You do not have iron in suspension in the water to show on the test.

Iron on surfaces as stains and iron in suspension in pool water that a metals test can find are two different things.
 
The pool builder test will not find iron in the pool water. The rusting rebar deposits iron on the surface of the pool as the stain.

You do not have iron in suspension in the water to show on the test.

Iron on surfaces as stains and iron in suspension in pool water that a metals test can find are two different things.
So what is the solution long term? Here is a closer up photo of the repair.
 

Attachments

  • 1.jpg
    1.jpg
    551.4 KB · Views: 13
Last edited:
So what is the solution long term? Here is a closer up photo of the repair.
I have never seen that type of repair that exposed that much rebar.

In hindsight the builder should have anticipated rebar rusting and coated the rebar with rust neutralizer before encapsulating it. Rusting is a chemical reaction and once it begins it continues.

I don’t know of anyway to fix it other than open those areas up again and treat the root cause of the rusting. I am sure the builder will be very reluctant to do that.
 
I have never seen that type of repair that exposed that much rebar.

In hindsight the builder should have anticipated rebar rusting and coated the rebar with rust neutralizer before encapsulating it. Rusting is a chemical reaction and once it begins it continues.

I don’t know of anyway to fix it other than open those areas up again and treat the root cause of the rusting. I am sure the builder will be very reluctant to do that.
The spots are appearing all over the pool - including areas that were not repaired, such as the hot tub and sundeck. Does that indicate there is another source of the problem? Would the rust really leach out in completely separate areas?
 

Enjoying this content?

Support TFP with a donation.

Give Support
The spots are appearing all over the pool - including areas that were not repaired, such as the hot tub and sundeck. Does that indicate there is another source of the problem? Would the rust really leach out in completely separate areas?
Once the rust/iron gets to the pool surface it can travel in the water to other areas of the pool. The iron does not need to come from beneath the area that has the spots.

The Vitamin C treatment confirms you have iron staining. The source of the iron is unknown but given the staining is mostly over the repaired areas that is the best clue you have.
 
Thread Status
Hello , This thread has been inactive for over 60 days. New postings here are unlikely to be seen or responded to by other members. For better visibility, consider Starting A New Thread.