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Styrocoat® 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, Ths 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.

Visit the Spoon Group's website at: www.thespoongroup.com

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1 - A Styrocoat® cartridge is loaded into the EZ-Spray Jr. gun.
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2 - The Styrocoat® is sprayed on the carved foam set piece.
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3 - Care is taken to completely cover all angles of the piece.
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4 - The Styrocoat® is left to cure for at least 1 hour.
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5 - After the Styrocoat® cures the surface is sanded smooth.
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6 - The surface is hand sanded to produce a paintable finish.
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7 - After sanding, the first coat of primer is applied.
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8 - A second coat of primer is applied to give the piece a 'marble' look.
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9 - After the primer is thoroughly dry, the detail painting takes place.
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10 - Faux finishing painting techniques are used to give the piece a 'distressed' look.
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11 - The finished piece is left to dry overnight.
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12 - The set piece has the look of carved stone, yet weighs only pounds.

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