Footwell housings

All of the blocks are now placed in the first row. The next step is to measure, cut and install all of the pvc spa jet housings and return-suction lines that go through this first row before I fill all of the block cells with mortar, which is called hard grouting.
I had to plan where all of the lines would be placed for the finished spa in order to figure out how far out of the outside blocks to bring these housings in order for all of the lines to fit. The jet lines will be the farthest out in order to access them and provide the biggest radius around the corners.
I'm constantly trying to think ahead, like how best to tile the spa. One of the considerations I had was tiling tight spaces, like the one I have around the 2 main suction lines in the corners. They have large anti entrapment covers that will be impossible to properly tile around unless I plan ahead to create a threaded connection where I could install the cover after the tile is done. The only problem was trying to get a good silicon bond on the inside of the block cavity using my tiny little hands. I guess I don't really need the skin on those knuckles anyway.
All of the housings got silicon around them on the inside of the waterside and outside blocks. The outside of these blocks gets filled with a different product as another step in the waterproofing process.
It is important to make sure these lines don't slip during the rest of construction, even though the blocks they are in will be filled with mortar. A little bump could dislodge them, and that would not be good. The answer is to glue rings of pvc in the inside of the blocks that keep the housings from ever moving once the cells are filled with mortar. You can see them in the pictures.
All of these housings need to protrude 3/8" into the waterside of the spa to account for the tile. The silicon will hold them in place until the cells are filled with mortar.

Building the walls

I went to Home Depot to get enough concrete blocks and mortar to get started. I found that you can get about 24 blocks and 4, 90 lb bags of mortar on one of those flat carts before it can no longer be moved! I lifted each 35 lb block onto the cart, into the truck and out of the truck. The bags of mortar are the most fun!
I made a couple of trips there before I decided that it would be better to have the rest of the blocks and mortar delivered. I thought it would be better to go and get the materials as I needed them instead of having to find a place to put them if it was delivered all at once. I was wrong. Its a killer to make those trips with all of the loading and unloading.
The first picture is of the material for the outside first row ONLY! There will be 5 rows plus seating.
The first row is important for a couple of reasons. It needs to be laid out as square as possible, and it needs to be level. I laid out all of the blocks to be sure they would be square. I drew lines for the inside of this row and marked approximately where the mortar joints would be so I wouldn't come to the end and not have enough room for the last 1/2" mortar joint.
The book says to place the 2 blocks in each corner first. In order to level the blocks in each corner with the blocks of the other corners, I used a 12' metal stud to span the diagonal corners. It was straight and light enough to not move the blocks.
With the corners placed, I could use a mason's string to guide me to cement the blocks between the corners.
When the perimeter was done, I began to place the first row of blocks for the seating. I will place rebar across the top of the outside of this row, even though it doesn't call for it in the plans. when this row is done and I have place the spa jet housings I will fill all of the cells with mortar
I'm a little discouraged that I cannot seem to place these blocks any better and faster. I'm hoping that I will get better with experience, especially since I have about 200 blocks to place!

Pouring mud

For the slab, I had originally planned on buying bags of concrete and renting a mixer to mix the concrete required for a 6" slab that is 8' X 10'. But when the calculations came in requiring a 9" slab and I figured I would need 130 bags of concrete it was clear that I needed a concrete truck!
2 1/2 yards of concrete later we were finishing up the slab.
I got enough blocks at Home Depot for the first of 5 rows required for the spa. I also got the blocks for the steps which are a different size.
I was curious about how much the 8" X 8" X 16" weighed. Do you want to guess? 35 pounds! Thank goodness I'm only going to need around 180 of them. Wait a minute, that's 6,300 pounds in concrete blocks alone! Maybe I shouldn't keep wearing flip flops in case I drop one!
While the concrete cured I began cutting the 3" holes in the concrete blocks for the spa jet housings and return lines. The hole cutter is pretty serious and requires a little patience or you run the risk of the cutter catching and twisting the drill out of your hand. I've cut about half the number of blocks that I need.

Putting in rebar

The County required me to have 1/2" rebar placed through the slab and up the walls every 16". I had not planned on putting in rebar when I started, which is probably a good thing, since I've never placed rebar before and I may have bagged the whole thing had I known!
I knew my brother Fred had worked with steel and that he had the tools to work it, including 3' bolt cutters, so I had a dozen, 20' lengths of #4s delivered.
I got to know Dave Rose when I first came to High Point and he and his company were constructing the concrete stadium seats overlooking the field, and later when he built the music building. He explained to me how to place the rebar and lent me his rebar cutter/bender to do the work. The right equipment makes alot of difference!
I cut, bent and placed the rebar after I leveled the hole and built the forms.
I passed inspection and I was ready to pour mud!

Digging continued with the help of Tommy (actually he is a big help, but I thought this picture was funny). Half way there I remembered the footings I had set for the play structure that I built for Tommy and Katie when they were little. I remembered them because they happen to be right where I was digging for the spa! Now I had to figure out how to get rid of these footings as well as a bunch of other concrete and bricks that were piling up quickly. I obviously couldn't throw them in the trash. Weeks went by and wouldn't you know, my neighbor needed a low dumpster just for concrete that he let me put the heavy stuff in when he was done!
By now I was getting an education in the permit process through L.A.County. The good news was that I got my plans back in 2 days when they said it would be weeks. The bad news was that they came with a list of corrections and requirements that included getting an architect and structural engineer to review my plans and do calculations to justify my plans.
I knew we used an architect at High Point for the kindergarten play yard and we were going to use him again for another project soon. He turned out to be an SC guy and generously agreed to sign my plans and recommend an engineer. The result was a successful effort that eventually resulted in approved plans and a permit to build the spa.
Back to the hole to finish it up, build the forms, set the rebar and prepare for pouring the slab.

From the beginning

Sometime in April I had completed enough research into the zoning and setback requirements to make some drawings and layout the proposed placement of the spa.
I submitted plans to L.A. County in the first of 3 steps to get a permit to build the spa.
I had to dig out the St. Augustine grass before I could even start digging the hole. I cut it with a flat-nosed shovel, pulled each piece out and turned it over so it would dry out so I could knock the dirt off and throw away the grass.
April 17th I started digging and found out just how nasty it can get throwing dirt around. I started wearing a mask and quickly went to a handkerchief over my nose and mouth. I remember thinking that the hole did not seem to be getting any bigger! I used what I thought was a lot of dirt for the tortoise planter, and then I started to realize that there was much more dirt to come out. Where was I going to put it?

First entry

Hello! This is my first entry as I chronicle my journey to dream, research, design, draw, permit, build, use and enjoy a 6' x 8' in-ground spa!
I'm planning on doing most of the work myself. I bought a book 2 years ago and I have been thinking about it since. This summer I'm finally going to do it. I'm going to build the spa!
It will be made of concrete blocks built on a concrete slab. The plumbing is large (2 1/2" and 2") pvc. I plan on tiling the entire inside.
It will be inground with about a foot out of the ground. I'm planning on a waterfall at one end.
The next entries will feature pictures, drawings and descriptions for you to keep up with my progress as I boldly go where no man has gone before. Not really, but I had to get that in here somewhere.
Spatrek Man