Plaster Issues and Meeting with PB This Week - Advice?

MeowMeow724

Well-known member
Jun 2, 2019
337
FL
Pool Size
16200
Surface
Plaster
Chlorine
Salt Water Generator
SWG Type
Hayward Aqua Rite (T-15)
Hello!
We've been noticing some plaster Issues and over time, they've gotten worse.
Our pool was built and plastered just over a year ago by a reputable builder that's been around a long time. We had issues during the build also, and they admitted back in February that they messed up because they were busy and understaffed.

The plaster is DiamondBrite "Marina".. but is the PB version "SmartBrite".

Things we've experienced/noticed:
1. Our pH will not stabilize. So far at 90 alkalinity it's not required muriatic acid for the last couple of days so that's a plus. I've been having to add acid nearly daily, more often if I have to bump the SWG to keep up the chlorine level.

2. In July, our calcium started to climb for some unknown reason. Our water was in-balance. I drained 2/3 of the pool and since then it's been stable.

3. There are many divots, dents, etc throughout the pool that have become more noticeable, or my honest opinion is many are new so I think somehow our plaster is soft. Originally there were just heel prints and some poor smoothing in the corners, but now there are new footprints, dents, even an area that looks "rippled" probably from brushing. I've generally felt like when we used the pool this season, that us stepping in it and using it created new dents somehow. Which I don't understand how that's possible, and makes me not want to step anywhere when I'm using it.

4. There is now A LOT of white spotting and small lines throughout the sun ledge, benches, steps and entire floor. But, the sun ledge, benches have a noticeable "texture" of spotting throughout, really. It's hard to explain what I am seeing. If zooming in pics you can kinda see it better.

5. On the deep end bench, the corners and areas where tile is laid are rough. On one corner there is even a small missing piece of plaster (been like that since the beginning). Also, some areas where tile is, is indented and therefore not level or smooth with the rest.

6. There is one spot I noticed this season, on the shallow end floor, that became a white spot and feels raised... Almost seems like it's gotten more raised over time.

7. There is a spot on the walls of the deep end. Circle shaped, feel to be similar texture as the plaster.

8. When I drained 2/3 for calcium issues, I noticed on the sun ledge that there is little cracks or "crazing" on the sun ledge.

9. Also when drained I noticed what looked like could be swirl marks in the plaster on at least one area. I don't notice them when water is in it though.

10. Along the sun ledge mini-step and where the regular steps meet the floors, there is a noticeable line along the radius.

11. Pool was plastered late October 2019. In February 2020, the PB came to look at it because I complained of the spotting and discolorations. When they were there, I heard the warranty manager and construction supervisor say "this is soft" when feeling the small step on the sun ledge. I didn't know what they meant at the time. The result of this meeting was to acid wash the pool. It looked better for a little while but is way worse now.
Also, after the acid wash it was a torrential downpour for hours before and after, so we had orange staining running down our freshly acid washed pool walls. The PB sent someone here to scrub the walls down with muriatic acid to clean up the orange stains. Since then, there's a "river effect" running down the walls and running just after where the floor "bowl" starts all along the perimeter. Not to mention this cause our pH to tank into the 4s or 5s because they used so much acid on the walls.

There are even other issues such as discolorations running down the wall under the return jets, which were there from the getgo as well. Some dark spots on the floor. Etc.

It's a mess. I know plaster is a hand applied product and imperfections are inevitable. I'm just not sure what's acceptable imperfections or flaws from possible installation errors.

The PB called to meet with us, and a representative from the plaster company. That will happen this Friday, November 6th, 2020.

I'm looking for advice and tips on how to properly explain these issues and essentially, I truly believe this was a bad plaster job. I told the PB this, but he wants to have the plaster rep there so there's no ambiguity. I'm sure they think it's my water chemistry.. I told them I figure that'll be the go-to but I have plenty of records to show this isn't the case... At least to what my understanding of what "aggressive water" means.

It's hard to show the things I mean in pics and I don't have any of the cracking/crazing as that's hard to photograph and you don't really see it when it's full.

Any advice for my meeting is appreciated.

P.S. after reading this, and some other posts I wonder if I have more of an issue than I realize. The floor of the pool looks "dirty" throughout.. could be this issue described here....?
 

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More pics.
 

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I'm surprised no-one has given you the standard brush-off yet - "Clearly the startup wasn't done properly and that's the problem", or "Clearly the pool chemistry hasn't been maintained in balance and that's the problem". Best case scenario, the plaster manufacturer will provide replacement plaster materials, but the $64,000 question is, will the pool builder provide the labor (chip out and replaster)?
 
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I'm surprised no-one has given you the standard brush-off yet - "Clearly the startup wasn't done properly and that's the problem", or "Clearly the pool chemistry hasn't been maintained in balance and that's the problem". Best case scenario, the plaster manufacturer will provide replacement plaster materials, but the $64,000 question is, will the pool builder provide the labor (chip out and replaster)?

Thank you for the reply!
Do you mean you're surprised the PB hadn't given me the brush off of those statements yet?
They did kind of nonchalantly mention the water chemistry when they visited in January and decided to do the acid wash (which occured in February).

Startup was done by them, about a week after plaster and fill.
They did the plaster and instantly put the hose in, and left. The startup guy came about a week or so later and added salt (yep.. right away), and a couple gallons of muriatic acid, shows us how to use everything and left. I guess that's the way they do their startup.
After that I got everything in balance to include TA, pH (ongoing), cH, CYA and chlorine until it was on-trend producing proper levels with the SWG.
 
Your written descriptions of the plaster finish sound really bad, but the photos don't look that bad. But I know that discolorations don't always show up in photos. Minor craze cracking that shows up when the pool is drained is not a problem or defect. So no worry there.

Typical pool plaster is white, and color quartz aggregate can be added to white cement, or sometimes quartz aggregate is added along with a color pigment or dye. Which is your plaster? Was a color pigment added?
Please provide your tap water readings for pH, TA, and CH. And your current pool water readings, including CYA.
What was the temperature the day of plastering? How many hours did it take to plaster the pool?
 
Typical pool plaster is white, and color quartz aggregate can be added to white cement, or sometimes quartz aggregate is added along with a color pigment or dye. Which is your plaster? Was a color pigment added?

Thank you for your reply!

To my understanding, it is white with the quartz aggregate, an aqua green color, "marina".

Please provide your tap water readings for pH, TA, and CH. And your current pool water readings, including CYA.

Fill water pH: 7.8-8.0 (I recall testing it before and I thought it was 7.8 but just tested and it was 8.0)

Fill Water TA: 170

Fill Water CH: 20

What was the temperature the day of plastering? How many hours did it take to plaster the pool?

Temperature... October 24, 2019: low to mid 70s.

They took about 3 - 4 hours or so to plaster the pool. I questioned this with our PM because he said a pool as "big" as ours would take nearly a whole day and they even wanted to prep it the day before. The pool is freeform shape, 18' x 35' at the widest points. 3.5'- 6' deep. Estimated about 16,200 gallons. Not sure that info matters but just in case 😊
 
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If your photos don't show the amount of problems that you listed, and the plaster is as bad as you described, then use the article/post (blotchy plaster) that you linked to above as a basis for why there might be plaster problems. Also, raise the negative results that occurred during the acid wash treatment last February. That should place some responsibility on the contractors involved. If you get push back, then you might consider suggesting that you want the plaster to be analyzed for its' "calcium chloride content." It is likely that more than the allowable 2% to the weight of the cement portion was added.
 
Ok thank you!!

I also have an article I had read before I found stuff on here that seemed clear to me we had issues similar.
Edit 11/4/20= Just realized the PoolHelp article I note below is from OnBalance.. coincidence!) :)

I also found pics of the plaster bags if anyone needs to know what was used. I took pics because I saw empty bags of "bluestone" when we were supposed to have "marina". I asked the PM and they said after he talked with the plaster crew to clarify, they sometimes use bluestone in prep areas like steps, for tile accents, etc. No idea why as that's not what we chose for our pool and I think it's not right for them to do that. But that's just my opinion, and it still burns me.

 

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I just looked up the person who will be meeting with us and the PB. He is the Regional Sales Manager for many manufacturers, working for a manufacturer representatives company for builders, retailers, etc. 🤔

I'm not familiar with this process... Does that sound like the appropriate person to be the plaster "expert" that they called for being involved so there was no ambiguity?
 

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I just took more pics of something I noticed.
There are raised bumps on the plaster.
The area that has the most (that I noticed), is the sun ledge in the area that also has the crazing/cracking. But also some on the floor, the step, etc.

Again, hard to photograph, but here we are. @onBalance could you or another kind soul help me determine what these are and how to speak intelligently with the PB and "expert" on Friday? Thank you 🙌
 

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If those bumps are raised, white, and rough to the touch and there is visible craze cracking in those same areas, then it is very likely that those bumps are "calcium nodules." If so, that would be the best evidence that the plaster workmanship was poor and caused defective plaster. It adds to the likelihood that an excessive amount of calcium chloride (a hardening accelerator) was added to the plaster mix which aids in shrinkage cracking, calcium nodules forming, and discoloration. I suggest that you use this new aspect as your position that the plaster is substandard.

If anyone says that calcium nodules are formed because of aggressive water, tell them that calcium (carbonate) nodules do not form or grow in aggressive water. That is a completely bogus claim. Easy to prove that it is false.

Read up on this issue here: Calcium Nodules in pools
 
Thank you!!
They are indeed all of the above...
Raised, white, rough to the touch and that is definitely the area I saw the craze cracking in.

There is also a spot on the shallow end floor, relatively near the raised bump I noticed originally (that I mistakenly reported originally as white.. that one is just raised).
I think I may see one in the deep end too. Might be a nodule or might be a raised bump (not nodule) as well.
 
Our meeting is in about an hour.
I shot a video last night to show them the issues I see.. of course they are easier to see at night with the light on.
I know plaster isn't ever perfect, and the light brings out flaws, but my oh my, I think it's very excessive. I will find a way to get the video on here later.

I was able to get decent shots of the "humps" I discovered as well. I think there are others, but these two are most visible. These pics also aren't as clear as seen in-person. The one towards the bottom of the picture also has a line going through it, which you can see in the video. Possibly a crack? Not sure.

2020-11-06_ShallowEnd_Humps_PoolPicture.PNG
 
They had to reschedule because the plaster rep wasn't available after all. I waited until about 30 mins after our appointment and called. 🤷‍♀️
The WM said there were emails but I must not have been copied on them because I can't find them. Oh well. They have to coordinate other warranty appointments since they're coming to the area from a different state so I understand logistics can be difficult.

I'm going to work on getting a video and/or new, better pics up if I can get them.
 
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Met with the plaster rep after all.

Very nice guy. Informative, helpful. Said he was there to evaluate the plaster, and wasn't there when crew did it so he can't speak for what they did.. of course.

Essentially says most of the issues are inherent to plaster and curing over time. We will see more changes as time goes on. Any imperfections in the gunite shell could eventually show up through plaster.

Have to get in pool to see if the humps flex. If they do, they are delamination. If not, they're part of the shell.

Said nodules are an application issue but aren't a huge issue, essentially.

When I said something about possibly excessive use of accelerant he didn't seem to think that's the case and actually said "you can't use too much of it". I told him that wasn't what I'm aware of and by plastering standards it shouldn't be over 2%.

He said my water chemistry and maintenance is fabulous and he will note that in the report.


Recommended a zinc anode, because of our pool being salt. Also recommended using ascorbic acid or vitamin C to get up some of the discolorations we are seeing. He also said that the mottling was normal and would fade over time along with other discolorations such as the river effect from the in the pool acid wash. I don't agree that the discolorations will just fade, especially the "river effect" from the acid wash.

He's not a fan of acid washing.... But I said I felt I had to do what the PB said as they were providing warrant for the pool.

He also said that some of the divots or or imperfections in the plaster such as the "ripples" I see, could be from water channeling in certain areas or how the water flows and things like that.
Not much we can do about the divots , dents, trowel indentations, and unevenness aside from replaster, and will the new job be any better? If they were to do replaster that is.

I need to meet with the warranty manager as well. I wish he had been here.

There's more to it but this is the gist. It was a 3 hour meeting.
 
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