Ever wondered what goes into making your fibreglass pool shell? You're about to find out...
Just off the Pacific Highway in Brisbane lies the manufacturing plant of our partner, Barrier Reef Pools (BRP). Perhaps you've driven past and seen the blue shells out in the open for the world to see and lust over! So what happens here?

» Pool Design & Development
» Constructing a Plug
» Manufacturing a Mould (from the plug)
» Mould preparation & Maintenance
» Manufacturing a Pool Shell
» Production Controls
» Quality Assurance
» Pool Shell Trimming, Final Inspection & Detailing
» Storage, Loading & Transport to Client
Pool Design & Development
The guys at BRP are very talented in their field right from the get go. During this stage, a technical drawing is sketched out in order to get the next phases underway. There's a lot of maths involved with angles/areas/volumes so it's lucky these guys are little Einsteins!

Constructing a Plug
By plug, we mean a similar sort of thing to a die used in injection moulding, not the thing in the middle of your sink! As you can see from the pictures below, this stage requires absolute precision otherwise you'll end up with a very oddly shaped pool! You'd be mistaken in thinking this is just a one-step process. A lot of reinforcement of the shell goes on during this phase with the gelcoat, vinyl ester, glass rovings and fibreglassing all happening one after the other.

Manufacturing a Mould (from the plug)
So the mould is sitting in the plug...now what? This is where the toys come out to play. Steel framework goes inside the shell to make sure it holds its shape and a large crane lifts the mould from the plug. It is then placed facedown on the ground ready for detailing.

Mould preparation & Maintenance
A nice polish makes the shell shiny but also makes way for a crucial inspection for flaws and imperfections. The mould hasn't been given the all clear until it has been washed, cleaned and inspected (again!) so BRP can guarantee that you have the perfect pool. Once the shell passes the test, it is sprayed with not just one coat of mould release but SEVEN! It's worth it though, check out how shiny it looks just before the gelcoat!


Manufacturing a Pool Shell
This is where the magic happens, folks! The gelcoat application makes your pool shell look how you know a pool shell to look. In a range of colours depending on your colour choice, the gelcoat adds even more strength thanks to a mix of glass fibres, resin and a catalyst to speed up the process.
The diagram below illustrates all the stages that go into making the final product but we want you to understand the whole process so below are the steps from manufacture to the client: you!

For an easy-to-read summary on how the pool is made, click here!
Production Controls & Quality Assurance
How does BRP ensure your pool is perfect? The answer lies right here with their QC procedure. As you can see, they are thorough and will not release a pool without it first passing a scrutinous test.


Pool Shell Trimming, Final Inspection & Detailing
The last hurdle for these pool shells and then their off to their forever home!

Storage, Loading & Transport to Client
And this, dear pool enthusiasts, is how we get the pool from Brisbane to wherever you live in Australia. Watch out for the BRP trucks along the Australian roads...give them a toot and a wave!

So when you're ready to buy a fibreglass pool, make sure you stop at nothing to get the best quality from the No 1 choice of fibreglass swimming pools manufacturer in Australia.