Foam Core Construction in the Pool Trade

Foam core construction is a relatively new technique in the world of swimming pool construction, but it is quickly gaining popularity due to its numerous benefits. This construction method involves using foam boards as the core material, which are then covered in a layer of concrete. The resulting pool is lightweight, energy efficient, and cost-effective.

To get a better understanding of how foam core construction is being applied in the pool trade we consulted with Nathan Giffin. Giffin is an expert in the field and has been working with foam core construction for over a decade. He has taught countless professionals and contractors on the technique and has helped bring it to the forefront of the industry.

Giffin has been teaching the technique of foam core construction to pool builders who are looking to add this building technique to their repertoire. He says this technique is particularly enticing for those in the pool trade. “With foam core, you can build outdoor kitchens, jump rocks, fire pits, bridges, and you could have rock work actually emanating up out of the pool onto the decks and over the decks,” said Giffin.

Giffin says the future of foam core lies in its strength and versatility. “For decades, the Department of Transportation and various structural engineers and civil engineers have been using foam core in roads, highways, and things like that to displace a lot of material. It’s really beneficial because it can handle a lot of load,” explained Giffin.

That foam core construction has become dramatically more popular in the pool trade is no surprise to Giffin who indicated that contractors may be looking for alternatives to offset the rising cost of construction materials.

One of the primary reasons he is such a proponent of foam core construction is that it is incredibly durable and long-lasting. Giffin says that foam core provides a strong foundation for elements like rock waterfalls, slides, and grottos, and that concrete stone facing adds an extra layer of protection. Consequently, he feels this makes foam core construction a wise investment for those looking to add a swimming pool to their property.

“The first mountain I ever built at a pool with my colleagues, we did steel rebar construction, which is your typical method. You’ll have a worker bend up all the steel, and then you’re welding it, and then you’re backing it and shooting it. By the time you’re all said and done, you’ve got six to eight inches thick of concrete,” explained Giffin.

“We had to dig about 18 caissons just to support the weight of 99 yards of concrete. We shot that for a waterfall that surrounded a pool slide. Six years ago, I did a slide of a similar size, and I used 60 billets of foam. For this project, we used less than twelve yards of concrete, and it’s just held up like a champ,” said Giffin.

Giffin says that the technique is bound to become more popular with homeowners as they become more aware that alternatives like foam core exist. The techniques that professionals like Giffin are using allow for a dramatically shorter turnaround time.

“For a medium-sized mountain, we can probably have the foam carved up in about a week. We’ll actually sculpt this stuff in warehouses and then have the client come out and actually walk on it,” explained Giffin.

“They’re completely bedazzled over the entire structure because it’s so large,” said Giffin who explained that once the client has had an opportunity to view the structure, it’s then scheduled for delivery.

“We put it in a truck, bring it out to the job site,” explained Giffin, “within day one, it’s delivered and glued together. Then all of our pipes are run and we’re structure coating it. That all happens on day one. The rest of the week, we’re just spraying the concrete on and finishing it. I’ve finished very large structures inside of a two-and-a-half week time frame.”

That foam core pool construction is a unique and creative way to build large, complex structures with simple tools was the net-net we got from Nathan Giffin. By using hot wires on the foam structure, you can create intricate sculptures that are both beautiful and functional.

Despite its many benefits structural foam is still a relatively new technique, and some pool contractors may not be familiar with it. However, Nathan Giffin has been working hard to promote and teach the technique. Consequently, he’s been teaching pool builders how to build with structural foam.

This method of construction has been used in the past to create everything from bridges to theme park rides, but it’s also great for creating custom pools. With a little bit of knowledge and some practice, pool pros can learn how to use this technique to create custom outdoor features.

It’s clear that foam core construction is a promising technique for swimming pool construction. It is energy efficient, cost-effective, and durable. With experts like Nathan Giffin leading the way, it is likely to become more popular in the future.

Want to learn more about foam core pool construction? Listen to our entire conversation with Nathan Giffin of Vertical Artisans on the Pool Magazine podcast.