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Atruim Court, Fashion Island Shopping Center, Newport Beach, California

One of the more common questions we get about FRP is regarding longevity.  We have been producing architectural FRP for over thirty years and have many projects that were produced in FRP and continue to look great.  In fact, one significant project is located in Newport Beach, CA and was installed in 1985.  While the retail space has changed many times in the last 25 years, our cornice material has not been repaired or replaced, only repainted.

The building is part of the Fashion Island Mall called Atrium Court.  It now is primarily a Bloomingdales department store on the upper floor and many specialty shops on the lower floors. We provided the two large upper cornice profiles, the lower bullnose banding and the quatrefoil in FRP.  This project is within sight of the ocean so the corrosive salt air would have attacked either metal or wood if used on the cornice.  FRP is specifically used and formulated to be unaffected by corrosive environments.

So this is just one example of how durable and attractive FRP cornice can be on a building.  We are confident that this material will be performing just as well during the next twenty-five years and beyond.

While we produced this cornice in our standard FRP, we have produced other cornice applications using our GFRCnext material, our Cornicestone FRP material, and our Echo-Stone material. So whether you are using an existing or custom cornice profiles, use an expert with over 30 years experience in making cornices for all types of architecture in the right material for your application.  Let DEC provide the solutions to your architectural vision.

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One of our recent cornice projects is now in the final stages of completion.  Our work has all been installed but the final finishing touches are being completed on the Bavaro Hall at the University of Virginia in Charlottesburg, Virginia.  We supplied the large dentil cornice in our Echo-Stone GFRC material.  This runs at the upper section of the building, the gable ends and in a horizontal watertable band midway up the building.

While we are always pleased to work on a project of this scope, it was especially exciting to be working on a campus so well known for its architectural history.  “Thomas Jefferson’s University” as it is called was founded, originally laid out and designed by our third president and famous architect.  Working for Capital Interiors Contractors of Richmond, Virginia we supplied the Echo-Stone cornices and brackets based upon the design of the famous architectural firm Robert A. M. Stern Architects, LLP of New York

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The Echo-Stone cornice was over 3’-0” high at the upper levels and over 4’-6’ high at the mid-level cornice section.  These included a dentil band that ran the perimeter and over 500 brackets that mounted on the underside.  We supplied over 1,482 linear feet of cornice, 180 linear feet of handrail system for a total of 1,196 separate parts.  All of this material totaled to 11, 661 square feet of custom fabricated Echo-Stone GFRC. 

As with all of our cornice projects, we detailed the exact profiles on our submittals but also identified the location of each of the parts on all levels of the building.  We indicated the location of the joints, the size of the factory assembled corners and the means for attachment to coordinate the installation with Capital.  This attention to detail not only helped identify field issues before they occurred, it also set an expectation level for the architect and the general contractor, Donley’s Inc. of Richmond, Virginia office.  We supplied all the material needed to complete the project without a change order for any additional parts with the exception of few lengths of cornice that was damaged on-site.  This attention to detail in performing our estimate, as well as the exact scheduling on the building, translates to cost predictability to our customer.

While we produced this cornice in our Echo-Stone material, we have produced other cornice applications using our GFRCnext material, our Cornicestone FRP material, and our standard FRP. So whether you are using an existing or custom cornice profiles, use an expert with over 30 years experience in making cornices for all types of architecture in the right material for your application. 

Let DEC provide the solutions to your architectural vision.

http://www.decassociates.com/materials/index.aspx

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While we have always produced our architectural fiberglass (FRP) in a class one fire rated material, this often required us to demonstrate how to review an architectural FRP application with a code official.  The application of the code was often a difficult and time consuming process since FRP was not specifically addressed as a specific material for many of the architectural applications.  Decorative cornice applications, for example, were addressed in the code, but the cornice material was under a different section. FRP was identified as a plastic material used for signage and that section did not really apply to the application we were having reviewed.  Throughout this process of explanation and interpretation, we felt our efforts were sometimes viewed with suspicion when we asked for a compliance review.  This all changed in 2009 after years of effort, the architectural FRP industry proposed and got included our own section of the building code specifically for FRP.

The American Composite Manufacturers Association –Architectural Division http://www.acmanet.org/index.cfm collectively developed, funded and argued for the addition of Section 2612 of the 2009 IBC building code to include architectural fiberglass (FRP) in its own section.  This has been a tremendous step forward for our industry, but also for our customers, our architects and ultimately the building owners.  This now opens up the market to a new set of possible solutions to building ornamentation.  This was so significant to the construction industry that Construction Specifier Magazine did a front page article covering this development http://www.kenilworth.com/publications/cs/de/200908/pageflip.html. 

Our efforts now will be to continue to educate the building industry about the code change, encourage all the manufacturers to comply with the new standards and to show the architectural community the benefits of architectural fiberglass FRP, Cornicestone and Woodgrain FRP.

For over thirty years, providing solutions to your architectural vision….. 

One of the most common questions we get involves the cost and details needed for us to provide a custom item.  In our thirty years of business, we have created thousands of molds to produce products for our customers. During that time we have been asked to create shapes and forms in an endless variety of textures. While we always suggest a mold that we currently have in-house, some items are not really substitutable or we do not have a mold that is close enough in size to be utilized.  This means that we are going to have to “custom fabricate” the product.

In our last blog entry, I went over the initial steps in making a custom part starting with building a “master”.  The next critical step is the fabrication of the mold for production.  Molds are fabricated in a multitude of configurations and materials.  We make both hard molds and soft molds, depending upon the part.  In addition, the molds can be simple or a multi-part breakaway mold that is disassembled to release the part.  All of this is determined in the estimating and engineering process before we start.

Regardless if it is a soft mold or a hard mold, the quality of the finished part is contingent upon the time and quality of the mold.  We, therefore, allow for sufficient time to allow the mold to be reinforced, have proper draft angles built so the part will release and sufficient time for it to cure before it is sealed and prepped for production.  Any of these steps done improperly can cause a huge delay in the mold being ready, or worse, requiring the mold to be made again.

One of the final things to be considered in the mold making process is the total number of parts anticipated to be produced from the mold.  Each type of mold has a “life” or number of parts that can be made from it before it deteriorates to the point where part quality suffers.  Many times we will make multiple molds on a project for a given part because of the life of the mold or when we have a short lead-time for the number of parts.  While molds are expensive, it is sometimes better to have multiple molds to produce the parts at a higher rate to meet a deadline on a project.  This combination of factors is developed by the plant and the engineer to find the most cost effective combination.

While all of this detail may seem overly complex, you must realize that we are creating a three dimensional object from two dimensional drawings in a composite material that will be cast multiple times.  As a result, there are a lot of factors we have to take into account to make a cornice, column or bracket to your exact specifications.

http://www.decassociates.com/custom-fabrication/index.aspx

Custom Fabrication: FRP, GFRC and GRG

One of the most common questions we get involves the cost and details needed for us to provide a custom item.  In our thirty years of business, we have created thousands of molds to produce products for our customers. During that time we have been asked to create shapes and forms in an endless variety of textures. While we always suggest a mold that we currently have in-house, some items are not really substitutable or we do not have a mold that is close enough in size to be utilized.  This means that we are going to have to “custom fabricate” the product.

Nothing strikes fear into mind of the architect and contractors alike than the word “custom”.  Visions of budget busting numbers and fabricators getting rich come to mind immediately.  In reality, custom fabrication is the majority of the work we do and as a result, we have become very efficient at it.  The cost for a custom mold on a project can be a significant single charge, but when amortized over the number of parts for a project, it can be a very reasonable cost.  If you can spread a $3,000 mold charge over 500 parts, this cost will be $6.00 per part, so quantity is a key determining factor.  Also, if the part has some repetitive shape as others on the project, blocking of molds or modifying the molds to accommodate both profiles will allow that cost to be spread over two different profiles.

It all starts with the architect’s or designer’s drawings of what they need.  We have developed skills to reproduce an architect’s exact drawing into three dimensional realities.  We then take the drawing, manipulate it to include draft angles, location of mold seams, attachment points etc.  All of this is detailed in the shop drawing process and reviewed with the customer.

Each “custom item” requires us to make the item once from scratch so that we can make a mold to produce multiples. This first item is called a “master” or “plug”.

We utilize our in-house craftsmen and artists to create “masters” from wood, foam, clay or rubber to make the original part for many of these molds. We also use three dimensional CAD machines to exactingly create other “masters”. We even take old remnants of items and repair them to their original condition to become another type of “master”, thus allowing us to accurately create reproductions of historical restorations. This is the key first step in making a mold to produce the job.  Time spent on a quality master will result in consistent and true parts when produced in mass.

The next step in the process is producing a mold.  This is a different step requiring a new set of skills and will be covered in the next blog.

http://www.decassociates.com/custom-fabrication/index.aspx

DEC Architectural Composites offers an unlimited range of textures that are cast into our custom GRG parts.  In addition to the texture, we can fabricate the part in various finishes depending upon the project requirements.  With our glass fiber-reinforced gypsum product, we offer the product in a range of finishes such as integral stone finishes, woodgrain finish or a standard white finish.  GRG is limited to interior applications, but is non-combustible and can be used seamlessly with drywall in flat areas.  GRG allows you to cast the difficult, labor intensive shapes and have them secure and seam identical to flat drywall board.

Our standard white GRG is a primer ready finish for projects that are going to be field painted when they are installed.  This is our least expensive finish that allows for any field modifications or patching to be concealed with a final paint finish.  It is also the easiest finish to touch-up or re-paint as time goes on.

http://www.decassociates.com/materials/glassreinforcedgypsumgrg.aspx

Our woodgrain finish GRG is really a combination of a cast-in woodgrain and either a wood color or a base for field applied staining.  Since the parts have a texture, a stain or glaze can be applied that lodges into the grain while the rest is wiped off. This gives the part a natural two-tone look of real wood.  Woodgrains, of course, can also be painted in white or other colors, if a painted wood look is desired.

http://www.decassociates.com/materials/woodgraingrgcomposite.aspx

Our integral stone finish GRG known as Magdaleno Stone, is an integrally colored, natural aggregate finish used to match natural or cast stone.  We offer many standard stone finishes or we will custom to match your pre-cast or stone samples.  This is a highly durable finish that can be cast into very detailed, very complex and very large shapes that would be cost prohibitive in anything but a composite material.  .

http://www.decassociates.com/materials/magdalenostonegrg.aspx

No matter what your choice, a standard white for field paint, a woodgrain finish or our integral stone finish GRG, we can fabricate them all in cornices, columns, rafter tails, false beams or any custom shape for all types of architecture for your application.  Please specify either GRG or Magdaleno Stone on your project.  Let DEC provide the solutions to your architectural vision.

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Fiber reinforced plaster, non-combustible, false wood beams and Magdaleno Stone.

Category: Finishes

Tags Composite Cornice Architectural Composites Limestone Cornice Echo Stone Solutions Cornice Stone EIFS Fiberglass Cornice Architectural Vision Architectural Fiberglass GFRC Cornice FRP Cornice Cornicestone GFRC next cast stone

DEC Architectural Composites, offers an unlimited range of textures that are cast into our custom GFRC parts.  In addition to the texture, we can fabricate the part in various finishes depending upon the project requirements.  With our glass fiber-reinforced cement product (GFRCnext), we offer the product in a range of finishes such as integral stone finishes, woodgrain finish or a standard gray finish.  GFRCnext is the next generation of GFRC that combines the physical attributes with a more forgiving reinforced cement product. Each of these products has their advantages and costs involved in fabricating them, but we try to match the finish with the application and the product application.

Our standard gray finish GFRCnext is a primer ready finish for projects that are going to be field painted when they are installed.  This is our least expensive finish that allows for any field modifications or patching to be concealed with a final paint finish.  It is also the easiest finish to touch-up or re-paint as time goes on.

http://www.decassociates.com/projects/ColumbiaAirport/index.aspx

Our woodgrain finish GFRCnext is really a combination of a cast-in woodgrain and either a wood color or a base for field applied staining.  Since the parts have a texture, a stain or glaze can be applied that lodges into the grain while the rest is wiped off. This gives the part a natural two-tone look of real wood.  Woodgrains, of course, can also be painted in white or other colors, if a painted wood look is desired.

http://www.decassociates.com/projects/JWMarriott/index.aspx

Our integral stone finish FRP known as Echo-Stone, is an integrally colored, natural aggregate finish used to match natural or cast stone.  We offer many standard stone finishes or we will custom to match your pre-cast or stone samples.  This is a highly durable finish that can be cast into very detailed, very complex and very large shapes that would be cost prohibitive in anything but a composite material.  This is our most popular finish, although not our least expensive finish.

http://www.decassociates.com/projects/WilliamAndMary/index.aspx

No matter what your choice, a standard gray for field paint, a woodgrain finish or our integral stone finish GFRC, we can fabricate them all in cornices, columns, rafter tails, false beams or any custom shape for all types of architecture for your application.  Please specify either Echo-Stone or GFRCnext on your project. 

Let DEC provide the solutions to your architectural vision.

http://www.decassociates.com/finishes/index.aspx

Stone cornice, GFRC cornice, Cornicestone and Echo-Stone.

DEC Associates offers an unlimited range of textures that are cast into our custom fiberglass parts.  In addition to the texture, we can fabricate the part in various finishes depending upon the project requirements.  With our fiberglass product (FRP), we offer the product in a range of finishes such as integral stone finishes, woodgrain finish, a gelcoat finish or a standard gelcoat finish.  Each of these products has their advantages and costs involved in fabricating them, but we try to match the finish with the application and the product application.

Our standard gelcoat finish FRP is a primer gelcoat finish for projects that are going to be field painted when they are installed.  This is our least expensive finish that allows for any field modifications or patching to be concealed with a final paint finish.  It is also the easiest finish to touch-up or re-paint as time goes on.

A gelcoat finish FRP is a ‘factory finished gelcoat” that allows the material to be put up with the final finish on the part.  We only use the highest quality gelcoat material with the best UV inhibitors for a finish that will last for many years of service.  This is very cost effective finish, but is not recommended if the material is going to require field modification or cannot be handled carefully during installation.  Like any finished material, care must be used in handling it during installation so that the finish is not scuffed and require extensive touch-up after installation.

Our woodgrain finishes FRP are really a combination of a cast-in woodgrain and either a wood color or a base for field applied staining.  Since the parts have a texture, a stain or glaze can be applied that lodges into the grain while the rest is wiped off. This gives the part a natural two-tone look of real wood.  Woodgrains, of course, can also be cast in white or other colors, if a painted wood look is desired.

Our integral stone finish FRP known as Cornicestone, is an integrally colored, natural aggregate finish used to match natural or cast stone.  We offer many standard stone finishes or we will custom to match your pre-cast or stone samples.  This is a highly durable finish that can be cast into very detailed, very complex and very large shapes that would be cost prohibitive in anything but a composite material.  This is our most popular finish, although not our least expensive finish.

One of the disturbing trends we see in the market lately is a classic “bait and switch” pricing scheme.  An architect selects an integral stone finish, for example, and a competing fabricator may submit a proposal with a standard gel coat finish or primer finish or a different interpretation of an integral stone finish that is less expensive to produce.  Often at bid time, the included finish is not clear in each proposal and if the number is low or if it is a hyper competitive project, the GC will use and rely on the low number.  All parties only learn later that they are going to have to “sell” the downgraded finish or they will have to absorb the cost difference. 

This deceptive scenario will do nothing but alienate contractors, owners and architects from using architectural fiberglass products.  All parties need to be abundantly clear about what is specified and the fabricators need to supply a representative sample, not necessarily the exact color, but a representative sample of what they are supplying at bid time to ensure that prices are “apples to apples”.  We can be competitive with all our finishes, but we want to compete and represent to our customers, the same finish so they can make a fair decision.

No matter what your choice, a standard primer gelcoat for field paint, a gelcoat color finish, a woodgrain finish or our integral stone finish FRP, we can fabricate them all in cornices, columns, rafter tails, false beams or any custom shape for all types of architecture for your application.  Let DEC provide the solutions to your architectural vision.

http://www.decassociates.com/finishes/index.aspx

FRP cornice, GFRC cornice, Cornicestone and Echo-Stone.

One of the most common items we fabricate at DEC Associates  are column covers.  We fabricate both custom and standard profiles in our fiberglass (FRP), Cornicestone, Echo-Stone, and GFRCnext.  What all these types of column material have in common is the ease of installation that you get with a lightweight reinforced composite material.  Our column covers are cast to size in half sections with either a lap joint, butt joint or reveal joint based upon the project requirements.  We offer a large variety of styles and sizes including custom fabrication. 

While there are a large number of distributors of column covers, we fabricate ours with the installer in mind.  If we provide a high quality product that can be effectively and easily installed, we will have a very satisfied customer.  Therefore, we do things a little different with this in mind. We fabricate the column covers in two halves to fit around structural members or supportive framing.  The column covers provide no structural load bearing strength for the building and are for decorative applications only.  We cast them with either the cap or base loose (depending upon style) so that they have some height adjustability for installation.  Both steps make it easier and cleaner to install resulting in a better final product.

Now on some projects require different qualities for the column covers and that varies by their use.  We offer our columns in fiberglass (FRP), glass fiber reinforced cement (GFRC), and in glass reinforced gypsum (GRG) depending upon your needs.  We can also offer the same columns in pre-finished Cornicestone and Echo-Stone.  Since the column covers are going to be custom fabricated to order, we can make sure that you get the right material for your application, even if that means we produce columns in all our materials for your project.  We are determined to give you the right product in the right material to make you a life long customer of DEC.

So either existing or custom column covers, we can fabricate them in a multitude of sizes for all types of architecture in the right material for your application.  Let DEC provide the solutions to your architectural vision.

http://www.decassociates.com/products/index.aspx

FRP cornice , GFRC cornice , Cornicestone and Echo-Stone.

Here at DEC Associates, we fabricate a very significant amount of rafter tails each year.  We fabricate both custom and standard profiles in fiberglass (FRP), glass fiber reinforced cement (GFRC), and glass reinforced gypsum (GRG).  Typically, the rafter tails are cast with an integral wood grain texture on all exposed sides. These rafter tails provide the means to install a false rafter tail on most any soffit condition and since they are lightweight, they appear to be large pieces that can be installed on structures with a minimum of support.

On one hotel structure alone, we supplied over 2,400 false rafter tails that replicated a heavy timber beam.  Given the huge number of beams, a wood beam would have been more expensive to purchase and install while a cast product is so consistent that an installation team can preset blocking and install in a fraction of the time.  The contractor had originally anticipated an 8% rejection of the wood product that he received thus requiring over-ordering of material.  With the FRP rafter tails, they knew that each one would be consistent and predictably high quality.  Since it was less cost per unit and was so much faster to install, the decision to switch was very easy.

Using a composite rafter tails, a building gets a no maintenance rafter tail that will not rot, split check or peel over the buildings lifetime.  These lightweight versions of a rafter ends can be installed on new and existing structures with a simple concealed perimeter angle clip over conventional construction.  At 1.5 to 4.0 pounds per square foot, these durable parts can be easily installed by two men.  Unlike foam products, composites are not vulnerable to burrowing insects or nesting birds.

While exposed beams and rafter tails do not occur on all buildings, many of the styles that do use them are located by the ocean or often exposed to harsh weather such as snow.  Fiberglass (FRP) and glass fiber reinforced cement (GFRC) are both formulated to be immune to those difficult environments.  The glass reinforced gypsum (GRG) is so lightweight and non-combustible that we often convert more than just interior beams and rafter tails from wood to glass reinforced gypsum (GRG).

So either standard or custom rafter tail profile, use an expert with over 30 years experience in making wood beams and rafter tails for all types of architecture in the right material for your application.  Let DEC provide the solutions to your architectural vision.

Fiberglass rafter tails, GFRC rafter tails, and GRG rafter tails are all composite, false rafter tail materials. 

Please call us for our recommendation of material for your project.

http://www.decassociates.com/products/raftertails.aspx