A custom build only lasts if the core substrate and protective coating match the real environment. Here is what we mill, pour, and spray in our Barrie workshop.
Foam Props & Sculptural Cores
Virgin High-Density EPS Foam: Available in multiple densities (1 lb to 3 lb+ per cubic foot) depending on structural load and detail crispness.
Sprayed Polyurea Elastomer Shell: Fast-curing structural hard coat that encapsulates raw foam in an impact-resistant, waterproof armor.
Internal Armatures: Welded steel baseplates, square tubing spines, plywood bulkheads, and rated rigging points for freestanding or suspended pieces.
Cementitious & Stone Coatings: Fiber-reinforced architectural hard coats engineered to replicate cast limestone, precast concrete, or stucco.
Multi-Section Indexing: Large columns, capitals, dormers, and pediments milled in interlocking segments for seamless field installation.
Column Configurations: Supplied as full structural-wrap split columns (to wrap steel or wood posts) or solid freestanding decorative columns.
Weather & UV Resistance: Exterior elastomeric primers and masonry topcoats built for Canadian freeze-thaw cycles.
Epoxy Signs & Fine Woodwork
Kiln-Dried Select Hardwoods: Quarter-Sawn White Oak, American Black Walnut, Hard Maple, and Western Red Cedar.
Pigment & Metallic Resins: Deep-pour and surface-inlay epoxies in jet black, slate, solid brand-matched colors, and copper/bronze/gold metallics.
Precision CNC Surfacing: Every resin pour is CNC-planed flush with the surrounding timber before multi-stage orbital sanding.
Protective Topcoats: Commercial satin catalyzed conversion varnish for interiors; marine UV-inhibited spar/polyurethane systems for exterior plaques.
Finishing Comparison in the Shop
Below, three full-height CNC-fabricated columns illustrate how the same core geometry can be finished for completely different architectural or scenic requirements:
