Beyond Design, Inc. - Architecture

There were two parts to this job. One - the arch covers which provided detail and covered the structural steel. These arch covers were built as wood models, silicone molds made, and then they were sprayed in FRP (fiberglass). The second part was to provide the elaborate scroll work that was attached. These scrolls were cast in high density urethane foam with steel reinforcing for internal structure and attachment.

ARCHES

For the arch covers, we built an exact structural replica of each different arch from templates taken from the existing steel. Once these were built, we made the detailed covers in wood. These models were then covered in silicone and FRP to create the molds. The covers were sprayed into the molds in FRP. Once they were cured, the exterior was sprayed with Polar Roof AC.

SCROLLS

Each part was sculpted in halves so we could create a seam line and the originals were mounted on plywood boards cut to create the clamping surface and provide the form for the FRP mother molds. Because these were to be pressure cast in high density urethane foam, the mold system was designed to withstand the high pressure of the process. (10 to 20 PSI). The molds were brushed up in Mold Max 30 with Thivex thickening agent, to a thickness of ¼” to 3/8”.Then a spray-applied FRP (fiberglass) mother mold was applied. Each part was cast after the steel internal structure was placed in the mold.

FINISHED

Once each part was de-molded and cured, we sprayed a 30 mil layer of Andek, Polarroof AC acrylic elastomer on the part. The color was selected by the scenic painter (Sue Daily / Master Murals) to provide the base color for her faux copper paint to be applied after assembly.