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In the process of emptying & cleaning the spa, we ran out of time and left it empty (without water) for two nights. During this time, the temps dipped below freezing both nights. We refilled it, and heated it as usual. When we got in the following weekend, the interior spa surface was gritty, almost like 100-grit sandpaper.
In the daylight, further inspection showed timy micro-cracks in the spa shell. It looks like the foam from underneath is being sucked up into the spa water.
This IS an older spa. I am SURE we need a newer one. Trouble is, spa season is here (what's better than the steaming water on a cold starry night?) and we can't afford to be purchasing a new one this winter. If I can repair this one to limp through one final season, it would be a GREAT early Christmas gift for my husband. He LOVES soaking in the water.
Jeee...I just read this and wondered what you did! Did you solve your problem or just get a new spa? I just had a spa built, but mine is attached to my pool and is the same construction.