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OUR PROCESS

Our product is made from a foamcore, also referred to as Expanded Polystyrene, or EPS. Depending on exterior or interior, the materials differ as seen below.

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 exterior manufacturing process. You can also view it here. 



EXTERIOR COMPOSITION

STAGE 1 - DENSE 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 - SITE APPLIED 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.

 

INTERIOR COMPOSITION

STAGE 1 - DENSE EPS FOAMCORE 
As in our exterior process except we use a higher density foam. Great rigidity yes still very flexible.

STAGE 2 - OPTIONAL FIBER MESH 
Mesh is optional and typically applied for non-residential applications. 

STAGE 3 - WHITE CEMENT
Our exclusive white cement application is the foundation of our interior product line. It's a tough coat, protecting the foam underneath yet smooth enough to accept the next layer.

STAGE 4 - AUTHENTIC PLASTER
After a 24 hour cure period, we can begin to apply our final authentic plaster finish. Our trade secrets make them extremely fine to the eyes and very smooth to touch. 

STAGE 5 - SITE APPLIED FINISH
After installation and joint treatments, apply a painted finish. We recommend either a matte or satin treatment.