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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….. 

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