We were featured on the hit TV series, How It's Made airing on The Discovery Channel where you can get a sneak peak into our manufacturing process. You can also view it here.
Our product is made from a foamcore, also referred to as Expanded Polystyrene, or EPS. It is then wrapped in a fibreglass mesh and coated with two layers of cement providing the ultimate in smoothness.
STAGE 1 - FOAMCORE
Taken from a drawing originated from AutoCAD, we can cut virtually any shape with our hot-wire machine. We have cut profiles as small as 1" to mouldings as large as 4' since we opened our doors in 2001. This process is completely computer controlled leaving no room for error.
STAGE 2 - MESH
Once we have our foam moulding cut, we apply an adhesive techincal mesh by manually pressing it into the shape. This is done for a couple of reasons. The first and most important is that it provides a bond for the cement coating (next stage). The second, while still important, will give the final piece flexibility.
STAGE 3 - FIRST COAT
Now that our piece is cut and meshed, we apply the first coat of cement over top of the moulding. It's an extrusion process that is controlled by highly skilled operators on our coating line. First coat is generally 3/16" - 1/4" thick, completely engulfing everything except the back of the shape.
STAGE 4 - SECOND COAT
After a 24 hour cure period, we can begin to apply a second coat to our mouldings. First coat generally comes off the line with some abnormalities that we correct. The final coat is strictly skimmed on so they have to be perfect in shape and texture beforehand. The final product is a smooth and even look and feel that is now ready to be finished.
STAGE 5 - FINISH
The finish coat completes the process. Our mouldings can be finished in a variety of textures and colour to match each individual's taste. For a wood-like appearance, use a texture-less topcoat. The more popular way is a stucco based finish that provides textures of various grades. It is applied once the moulding has been installed on the wall by the end-user or contractor.
If you have any questions regarding how our product can fit into your exterior curb appeal design, please get in touch with us at 1(888)668-5339 today.