Pool Plaster By Alan Smith
The pool plaster industry has a rich history, deeply rooted in craftsmanship and innovation. From its inception in the 1950s, it has grown from simple beginnings into a sophisticated field requiring precise techniques, high-quality materials, and advanced solutions to address persistent challenges.
Early finishes, made with white cement and quartz or marble aggregates, were designed to provide a serviceable, smooth, and watertight surface. Over decades, these finishes evolved from smooth, troweled white quartz and marble to colored finishes, exposed pebble and quartz finishes, and polished aggregate surfaces. Each innovation aimed to enhance aesthetics, durability, and functionality for consumers.
In the mid-20th century, residential pools became symbols of leisure and luxury, driving demand for durable and attractive pool finishes. White plaster was the gold standard, favored for its simplicity and affordability. However, prolonged exposure to water, chemicals, and weather caused degradation, leading to issues like etching, discoloration, spalling, and craze cracking. As pools transitioned from simple rectangular designs to intricate, customized installations, the demands on finishes increased.
Despite advancements, pool plaster has long struggled with chemical interactions inherent in swimming pools. Factors like acids, salts, low calcium hardness fill water, and stabilizers such as cyanuric acid contribute to the deterioration of cement, particularly its soluble component, calcium hydroxide. This compound, which makes up about 25 percent of cement paste, is highly vulnerable to dissolution, resulting in etching, spalling, calcium nodules, discoloration, and aggregate loss. Even enhanced materials introduced in the 1980s and 1990s, such as quartz and pebble aggregates, were not immune to problems like uneven color distribution, plaster dust, and chemical etching.
A key historical challenge emerged with the introduction of cyanuric acid in the 1960s. While it stabilized chlorine, it also complicated water chemistry management. Improperly balanced water chemistry exacerbated calcium hydroxide dissolution, leading to widespread issues like spalling, nodules, and discoloration. These challenges spurred extensive research into improving the resilience of pool finishes.
Innovation and the Role of Best Practices
Throughout my career in the pool plaster industry, I’ve witnessed how refined practices and innovations can address persistent challenges. Curing, for instance, is essential for ensuring the longevity of plaster finishes. Proper curing involves maintaining adequate moisture and temperature conditions during and after application, allowing the hydration process to fully occur. This process forms calcium silicate hydrate (C-S-H), which gives cement its strength and durability while reducing the presence of weaker, soluble calcium hydroxide. Without proper curing, finishes are more prone to etching, discoloration, and craze cracking.
The recognition of curing’s importance has driven advancements in both application methods and materials. Standardized curing techniques and consistent hydration processes have proven to significantly reduce common issues and ensure that plaster layers reach their full potential in strength and resilience.
Game-Changing Technologies: SetNCure and MicroGlass
Research efforts, including studies by the National Plasterers Council and Cal Poly San Luis Obispo in the early 2000s, identified the need to find solutions to mitigate calcium hydroxide loss. Two standout innovations — SetNCure and MicroGlass — have transformed the industry. SetNCure, a mix-in liquid for new plaster applications, enhances cement durability by converting calcium hydroxide into calcium silicate hydrate, significantly improving long-term performance.
Similarly, MicroGlass, a spray-on product, converts calcium hydroxide into a durable calcium silicate Pro
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hydrate, protecting both new and existing finishes.
SetNCure improves the application process by enhancing pumpability and ensuring uniform pigment distribution, reducing discoloration and streaking.
For smooth troweled finishes, SetNCure has been revolutionary, enabling contractors to achieve consistent, high-quality results with less risk of imperfections. Additionally, SetNCure optimizes curing conditions, ensuring strong, durable finishes that resist chemical exposure.
MicroGlass penetrates deep into the plaster’s microstructure, reinforcing its weakest elements. This transformation creates a chemically resistant, ceramic-like material that withstands acids, salts, and low calcium fill water better than untreated finishes.
Unlike traditional sealers, which sit on the surface, MicroGlass strengthens from within, preserving both appearance and durability. Its benefits extend to existing pools as well, making it an ideal solution for restoration projects and after acid washes.
Refining Practices for Long-Term Success
Over time, the industry has refined its practices to support these technologies. Proper startup procedures and balanced water chemistry (e.g. NPC Startup guide and Orenda Technologies LSI Balanced Startup) are now recognized as essential for maintaining pool finishes.
These best practices include neutralizing agents like sodium bicarbonate during acid washing and ensuring adequate hydration during curing.
Combined with technologies like SetNCure and MicroGlass, these approaches deliver transformative results: extended lifespan, enhanced aesthetics, and reduced maintenance requirements.
Advances in education and training (e.g. Watershapes University and Genesis) have also equipped contractors with the skills needed to apply these solutions effectively, reducing errors and improving outcomes.
Education and Innovation Driving Progress
The pool plaster industry’s evolution has been fueled by a commitment to education and innovation. Staying ahead of the curve by understanding the science behind materials and embracing new technologies ensures that pool professionals can deliver the best possible results for their clients. Collaboration among researchers, manufacturers, and industry leaders has played a pivotal role in driving these advancements forward.
A Legacy of Craftsmanship and Innovation
The history of pool plaster is one of continuous innovation, driven by the need to overcome chemical challenges and enhance durability. From its humble beginnings to the sophisticated materials and techniques available today, the industry’s evolution reflects its commitment to quality and craftsmanship. With cutting-edge technologies and improved methods, the pool plaster industry is now better equipped than ever to deliver lasting value to pool owners, ensuring both beauty and resilience in every finish.
Alan Smith, started working as a pool plasterer in 1974 at age 19 and quickly rose up the ranks to become a foreman within a year. In 1981, Alan Smith Pools Plastering was founded, and over the next 44 years, Alan has learned the in and out’s of every aspect of pool plastering, pool tiling, coping installation and overall pool remodeling. Alan is a pioneer with several innovative product ideas and developments. Alan is one the first contractors to pebble pools in California.
Alan Smith is known as an expert in the pool plastering industry, and is highly regarded by pool industry professionals nationwide.
