Transforming carved foam into durable sculpture.
From theatrical scenery for Broadway shows and Coachella performances, to cruise ship sets, indoor and outdoor sculptures, larger-than-life replicas, trade show displays and more, there isn’t anything we can’t Hard-Coat.
⌄
ABOUT THE PROCESS
What is Hard-Coat?
The generic term “hard-coat” generally refers to the sprayed application of fast set urethane or poly-urea elastomer on a carved foam surface. These products can work as well on wood or other materials for a variety of applications. Many formulations have fire resistant capabilities and have UL tested fire ratings.
Because of these qualities it allows for styrofoam and urethane foam carved sculptures to be used on stage sets. Because these materials are 100% solid and contain no solvents they are “0” VOC (volatile organic compounds) and are generally vapor barriers.
There are many formulations with various physical properties that vary from soft and rubbery to very hard and rigid. They can be tinted to a base color but are generally not UV stable unless they are an Aliphatic formulation. This means they generally need to be painted. Primers are necessary for good adhesion and in extreme conditions, surface preparation is recommended with sanding of media blasting. We are happy to consult, to be sure the best result comes from the application.
MY WORK WITH HARD-COAT
50 Years of Experience
The capability to spray-apply urethane was developed in the late 50’s / early 60’s and generally perfected by the Gusmer Corporation. I first became aware of urethane foam in 1970 and it changed the course of my life. I bought my first Gusmer FF machine in 1971 and engaged in the application of urethane foam for industrial insulation. Back in those days it was a specialty business. Work was mostly done in hard-to-insulate applications in high humidity environments such as cold storage, heated tanks, and pipes. It was also used for roofing application in conjunction with elastomeric coatings.
In the early 90’s Gerhardt Regenauer from the Urethane Technology Company developed a product called Rimspray. As far as I know, this was the first “hard coat” developed. Specific formulations can be used for water feature liners or for mold surfaces for cement and plaster casting. Surface textures are variable from very smooth and slick to pebbly and rough to create a rock-like texture. Flexible formulas can be sprayed in molds to create tree-bark and other surfaces.
The foam business has taken me all over the world, from the World Trade Center in Moscow, USSR to anhydrous ammonia tanks in Taiwan, to roofing in Holland, to numerous projects in the United States. I have insulated everything from a homeowner’s water tank to whole military housing complexes.
My first theater application was for a Kenny Rogers’ Christmas show, on a project done by Centerline Studios (in 1995). Since that time we have coated hundreds of pieces, for everything from Broadway shows, to cruise ship sets and games, to indoor and outdoor sculptures, and all kinds of objects for displays and trade show events. Below is a sampling of my work.
HARD-COAT PROJECTS
CLICK ON THE IMAGES BELOW TO READ MORE ABOUT EACH HARDCOAT PROJECT
MOLD-MAKING PROJECTS
CLICK ON THE IMAGES BELOW TO READ MORE ABOUT EACH MOLD-MAKING PROJECT
We have associations with various companies who do carving and computer controlled routing to create almost any shape and can assist in the creation of all sort of applications. My fifty years of application experience can help a designer or a shop solve many application challenges. We also have sprayed, large scale silicone mold making capability as well as composite fabrication with fiberglass or epoxy.
As the world recovers from the pandemic, the doors of theater and public gatherings are opening, and events resuming. The need to cover styrofoam and urethane foam with this hard, fire-retardant covering is growing. Many new companies are opening and opportunities are expanding so we have created this website to show some history and capability of these materials. Contact us if you have interest or need technical information or support.
Let’s Connect
Use the form below to contact me. You may also email me directly at klopping13@yahoo.com.