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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.
 A StyrocoatŪ cartridge is loaded into the EZ-Spray Jr. gun.

1 - A StyrocoatŪ cartridge is loaded into the EZ-Spray Jr. gun.
 The StyrocoatŪ is sprayed on the carved foam set piece.

2 - The StyrocoatŪ is sprayed on the carved foam set piece.
 Care is taken to completely cover all angles of the piece.

3 - Care is taken to completely cover all angles of the piece.
 The StyrocoatŪ is left to cure for at least 1 hour.

4 - The StyrocoatŪ is left to cure for at least 1 hour.
 After the StyrocoatŪ cures the surface is sanded smooth.

5 - After the StyrocoatŪ cures the surface is sanded smooth.
 The surface is hand sanded to produce a paintable finish.

6 - The surface is hand sanded to produce a paintable finish.
 After sanding, the first coat of primer is applied.

7 - After sanding, the first coat of primer is applied.
 A second coat of primer is applied to give the piece a 'marble' look.

8 - A second coat of primer is applied to give the piece a 'marble' look.
 After the primer is thoroughly dry, the detail painting takes place.

9 - After the primer is thoroughly dry, the detail painting takes place.
 Faux finishing painting techniques are used to give the piece a 'distressed' look.

10 - Faux finishing painting techniques are used to give the piece a 'distressed' look.
 The finished piece is left to dry overnight.

11 - The finished piece is left to dry overnight.
 The set piece has the look of carved stone, yet weighs only pounds.

12 - The set piece has the look of carved stone, yet weighs only pounds.