StyrocoatŪ Makes Lightweight Props Possible For Spoon Group
The Spoon Group (Rahway, NJ) is a
world-renowed prop and set fabrication shop. Besides television and commercial projects,
The Spoon Group has produced props and set pieces for Broadway productions of
Grease!, Legally Blonde, Xanadu, Phantom of the Opera, Les Miserables, Chitty Chitty
Bang Bang, The Color Purple, 42nd Street, Chorus Line, Dracula, and many more.
For the Broadway production of Dracula, many large "marble" set pieces were needed. They
had to look like heavy carved stone but be lightweight enough to be "flown" on stage
rigging between scenes. It was decided that carved foam would be used for the larger
setpieces, but carved foam is notoriously hard to paint and fragile.
Enter Styrocoat® – Styrocoat sprayable styrofoam coating was used to
give the carved foam set piece a rigid, paintable surface as well as increased strength.
The EZ-Spray® Jr. gun used to apply the Styrocoat is a very easy system to load and
use, and the cartridge-based system means that there is virtually no clean up.
1 - A StyrocoatŪ cartridge is loaded into the EZ-Spray Jr. gun.
2 - The StyrocoatŪ is sprayed on the carved foam set piece.
3 - Care is taken to completely cover all angles of the piece.
4 - The StyrocoatŪ is left to cure for at least 1 hour.
5 - After the StyrocoatŪ cures the surface is sanded smooth.
6 - The surface is hand sanded to produce a paintable finish.
7 - After sanding, the first coat of primer is applied.
8 - A second coat of primer is applied to give the piece a 'marble' look.
9 - After the primer is thoroughly dry, the detail painting takes place.
10 - Faux finishing painting techniques are used to give the piece a 'distressed' look.
11 - The finished piece is left to dry overnight.
12 - The set piece has the look of carved stone, yet weighs only pounds.