Plaster scaling and losing bits of plaster

needsajet

TFP Expert
LifeTime Supporter
Jan 4, 2016
5,392
Sydney, NSW, Australia
Pool Size
44000
Surface
Plaster
Chlorine
Salt Water Generator
Hi, I'm hoping the TFP plaster experts can help keep me on the straight and narrow.

I’m concerned this plaster is failing and wondering the best things to do to make it last and also look good. I took over this 7300 gal pool 5 months ago, just helping out family. First test was:

FC 2.5
CYA 0
SWC running 6 hrs per day at 100%; now 4 hours after adding 40 ppm CYA and keeping FC around 2-4

pH 8+ (2 demand drops to get to 8)
TA 130
CH 200 (added 50)

Here’s a picture of the scale. I collected some and there was instant healthy fizz with MA.

Resize of Plaster with scale.jpg

So my plan was/is run the pool around -0.6 CSI and see if the scale will dissolve. After several months with -0.6 CSI just after acid addition pH 7.4, then back to 0.0 in a few days before the next acid addition at pH 7.9/8.0 (there’s a lot of aeration). Maybe there’s less scale, maybe not. Should have used Kim’s suggestion and taken before/after pics, but bottom line is that it’s still a blemish.

Today’s numbers:
FC 4
CYA 40
pH 7.9 (1 drop acid demand 7.6, 2 drops 7.4, added 300 ml MA for target 7.5)
TA 60
CH 275
Temp 28C (82F) with hot days lately pushing water to 32C (90F)

A few weeks ago, I emptied the skimmer and found some bits of scale that had been vacuumed up, and I thought winner winner chicken dinner.

So I took a plastic scraper and did some duck diving and was making a bit of progress but not quick enough for me. And shock horror, I knocked off this chunk of plaster. Was a bit deflated by that.

Resize of Plaster chunk water side.jpg
Resize of Plaster chunk underside.jpg

On the underside, I hope you can notice the white streak extending from the end of my finger to about halfway along the chunk. I peeled some of that off and it fizzes just like the scale. I also tried some of the pool plaster, and it fizzed but not vigorously. Does this mean that scale has gotten under the plaster? Or filled a fissure or something?

Saved the chunk and I’m wondering if it can be epoxy’d back in.

I was swimming in the pool on the weekend and noticed I could dislodge the odd piece of scale with my toes. Since it is not going away quick enough and I have a couple months left of warm water, my plan was to buy a pumice stone and a weight belt and try to ease it off without scratching the glass beads too much. But now I’m a bit antsy about it.

Two weeks ago, I emptied the skimmer and saw the odd chunk of plaster. Uh oh, I didn’t like that. I emptied the skimmer yesterday and saved the chunks, picture below. You can see some scale and also beads and plaster. The pieces fall apart very easily.

Resize of Plaster and scale bits.jpg

I felt some of the scale with my fingers, and I’d say in many locations, there’s both scale and an erosion of plaster just below the scale, a groove in some places and dimples small and large in other spots, some deep enough that they’re through the glass bead layer and into pure plaster.

So what do the plaster experts think about this? See background below if needed.

Background:

The pool is about 5 years old. I know the plasterer and he told me that the owner, who’s also a friend of his and they socialise, didn’t do everything they were supposed to do (he visited often so he knew) and God knows about the water chemistry. The plasterer was new at doing pools at the time, but ran a business prior to that in cementitious products including paver manufacturing, and he’s a smart guy.

When I took over I talked to the owners about the scale and they said they’ve struggled with that stuff. At one point they said ‘yeh, had to scrape it off with a screwdriver’ That comment made me shiver, but I think the screwdriver was used on the stone under the water blade a few years ago. At another point they asked what to use and I suggested pumice stone but stay away from the waterline and marker tiles cause anything glass will scratch, including the glass beads in the plaster. (more info from TFP, thanks!)

They’re very busy people and needed to go with a service to keep up with kids and careers. I know the brushing didn’t get done after pool fill, but that’s all I know first-hand. I think they did the pool store routine for a year or so, then a series of pool services, the last of which left the pool way over pH 8 and 1.0 CSI. It’s not out of the ordinary for a cheap pool service here to just run the SWC hard, no CYA, cup or two of acid once a weekish, quick skim and run to the next one ($50 a week plus chemicals but including acid); stretches to $50 a month in winter.

Solar heating was added last year, the pool is square and level, pretty, with massive aeration from venturis on the returns, plus a stone feature wall with water blade. It gets a lot of use daily when the sun is shining, anything from 2 to 6 hours.

I have the same finish by the same plasterer in my own pool, and it’s not often I see glass beads and I’ve never seen plaster in the skimmer.

Help :?
 
Hmmmm....very intersting puzzle you have here.

That white streak under the large chunk is very intriguing. Definitely sounds like there was a defect in the plaster, such as a crack and small fissure that extended into the bulk of the plaster. Water would get into that area and then the Ca(OH)2 would leach from the plaster into the water in that space and form calcium carbonate. I bet that ribbon you peeled off was pure calcium carbonate.

Couple of thoughts, and they sadly implicate your plasterer friend -

1. Improper cement/water ratio or plaster allowed to sit too long before troweling. My thinking here is that the plaster was somehow too "thick" and then excessive working and troweling of the plaster led to physical damage of the plaster (cracking or fissures).

2. Too much aggregate. If the aggregate-to-cement ratio is too high, that can lead to weak plaster that might allow this kind of scaling and chipping to occur.

3. Air entrainment - maybe when they were operating the shotcrete equipment, too much air got into the mix...

You did say that the plaster was new to pools when he shot this one. Just because I might know a guy who had 20 years as a union-boy "behind the hose doing the darby and scratching the undercoat" doesn't mean I'm going to let him anywhere near my pool...

But heck, what do I know...I'm just the resident propeller head.... :geek:
 
What a shame since that is a beautiful finish....and only 5 years old :brickwall:

Is that piece that dislodged full thickness or is there still plaster/aggregate below?

I think what you are experiencing is a combination of both poor plaster application and obvious water balance negligence thereafter. Delaminations like that are typically caused from "stratifying" the plaster surface by excessive troweling. Steps, coves and large flat expanses are the common places since so much effort is put into ensuring a smooth surface.

Delaminations also happen when plaster is applied on very warm days since top layer of plaster begins to set up much quicker than the bulk of the plaster below. These areas are then troweled and can create small fissures between the layers where water can enter and is exposed to very high pH levels from the calcium hydroxide "skin" that is forming.

Excess water is often added at mixing to make troweling easier on hot days (or just out of ignorance) which severely weakens the plaster by making it less dense.

That really is a shame...I'm sure they paid a premium for that finish
 
Gee thanks ;) I'll get a toe in there someday, and wait for a decision, lol

So it wasn't the plasterer's first pool, but from what I understand, it was early in the introduction of the glass bead. I think one or more of his relatives might have been in pool plastering, then they teamed up and introduced the glass bead premium finishes. But yep, everyone involved recognizes some inexperience and learning curve, so no sweat on getting to the bottom of it. Won't be any sharks circling or anything. They do around 200 pools a year these days.

I can confirm the scale is mostly on coves (called "the radius" down here). I'll look more closely and see if there's any other consistent pattern.

With Matt's first thoughts, it reminds that when they did my pool, they sprinkled the glass bead into the top layer after the first rough troweling pass. I was surprised that the chunk seems to have glass bead right through it. The chunk that came out left a divot with plaster at the bottom, no gunite visible, but I can't say if that's a mil or an inch.

When they did my pool, they tarped it very well so no sun was hitting the plaster, so I think they're conscientious in that respect, but obviously nothing known about this one. I'll find out what time of year it was done.

The finish is truly beautiful, yeh. They got a good deal on the finish at the time, might have been somewhat introductory. A good bit less than what we paid, cause the close mateship is between the pool owner and the plasterer, and a lesser extent with us.
 
I am in to watch and learn from this one. It will be interesting to see what ends up happening.

As for putting the pieces back in..........I would be VERY mindful of making sure the edges are welled sealed so water could get in there and breed algae.

Kim:kim:
 
Based on the photos, I would say that your plaster is cracking and delaminating (bonding failure).
I do not see typical "out of balance" scaling issues. The existing scale is only emitting from the cracks and from the substrate, and has nothing to do with unbalanced pool water.
As others have stated above, there can be many reasons of improper plastering practices that can cause delaminations and cracking. One cause not mentioned above and is very common is simply due the substrate being too smooth and not rough enough, or too dirty, etc., to achieve a bond.
The photo of the small "chips" concerns me, and indicates poor quality plaster, which can be caused by the conditions mentioned above. Poor workmanship and mixing.
 

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onBalance, thank you very much for your great explanation and answer. I have been wondering why if there was a water balance issue, the failure wouldn't be more widespread and more consistent in nature. I take from your answer that even if the water had been kept properly balanced, the plaster would have delaminated just the same.

So now my TFP friends and lovers of phelanges - helping out the pool owner. Is this about right as to what I need to figure out in order to help them out?

Option A. Monitor for leaks; let it go as long as the appearance is tolerable; eventually plaster
- guesses welcome... 2 or 3 more swim seasons? (6-month season)
- are there any downfalls to continuing to run the pool as the plaster gets worse?
- is there anything I can do to slow down the failure in terms of water chemistry?
- is it a bad idea to scrape off the calcium carbonate?

Option B. Re-plaster as soon as possible and be done with it
- better to do it while they're for sure still in business and doing well
- good timing for lining it up for their dead season
- just finishing a good season so maybe plasterer is feeling generous
- is it true that the pool owner always takes the kick in the guts because water chemistry gets blamed and it's un-provable what happened?

And Kim, good point, that chunk would have to be epoxy'd in with care to fill behind it!
 
Yes, it doesn't matter how the water was maintained whatsoever, and does not cause delamination.
Out of balance water causing scaling is usually evidenced by mostly uniform scaling.
There is a slight chance that the pool could be leaking due to delamination, so check that.
The downside to leaving as is and not re-plastering is that the plaster will probably continue to crack and perhaps large chunks of plaster breaking away, leaving a very rough surface.
You cannot slow down the failure by changing the water chemistry.
It doesn't matter much if you scrape off the calcium scale.
If the pool is 5 years old, I would imaging that the warranty period is over, but you could talk to the contractor and see they may do for you.
It is easy to always blame water chemistry for plaster defects that don't show up immediately or soon after original job.
Btw, delamination can also be caused by leaving the pool empty and dry for a long period of time.
 
onBalance, thank you for those clarifications. I'm think if we approach him right, he'll do a deal or gratis. We'll ask carefully, but ask for the max cause you never know, then be comfortable achieving yes wherever it lands. Then walk or stay :) Sounds on balance.

I noticed a dry pool in another thread and wondered about what happens. Pools stay full here which I suspect makes pool maintenance easier than many have it over there.

I'll put a bucket test on my to-do list for their pool.

TFP is a great place to be :) Many thanks.
 
Hi Needsajet,
Sorry I read your post and I could not find the substrate of the pool? I have had a big day so it may be my inability to read the detail. Prior to replastering are you sure you don't have a leak in the substrate which I assume is concrete. I built a pool many years ago..it was my first and I learnt a lot from it. It was concrete with a pebblecrete finish. I had some hair line cracks in the concrete and this caused some hydrostatic pressure (HP) from which resulted in a similar failure. If you have an auto top up...turn it off...do a bucket test to make sure as it could the HP dislodging the plaster finish as well. Now the plaster has come off can you see any fine cracks from underneath?
 
I broke the news to the owner, geez I hate being the bearer of bad news :( After a discussion, they understand that plaster does have a lifespan, so that softened the blow a bit, but I want to be a bit more sure of myself about plaster lifespan (for a pool that never gets any acidic chlorine pucks). My sense is that high pH and TA are more common out-of-spec issues for pools here.

How long should well-applied plaster last when things are done right? (e.g. careful startup, TFP water) And what's a common length of time for plaster to last? (average startup, average pool service co.). I know this is a difficult sort of question, but even with +/- 5 years sort of range will be helpful.

Thanks again for the help!
 
You would need to actively try to ruin a plaster pool in 5 years and that would not be done with high pH and TA.

I regularly see plain plaster pools in the 15-20 year old range but keep in mind that cosmetics are much different than lifespan. Plaster doesn't just up and fail one day...it is usually replaced because it is no longer aesthetically pleasing or too rough for use.

The pool finish you have in question is a premium grade surface. There really isn't anything much better than glass and polymeric additives in the plaster, well except for those nut jobs that use those flame bazookas and plastic pellets ;)
 
... well except for those nut jobs that use those flame bazookas and plastic pellets ;)

Haha, I'll bet that stuff becomes a revolution! Sure makes a lot of sense.

In a re-plaster job, is it possible or advisable to retain the waterline and marker tile? I'm guessing not, but thought I'd ask.
 

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