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An energetic, experienced approach with an obsessive attention to detail and service, and the capacity to create large, complex castings.

Founded in 1987, Plasterform is one of the largest custom composite manufacturers in the world. We manufacture the most extensive line of architectural products available, including GRG, GFRC, Castone and FRP. Our 130,000 square foot manufacturing facility and 150 talented employees give us the ability to do everything under one roof – from consultation to shipping.

A design and technological innovator, Plasterform is at the forefront of the industry. Plasterform’s senior executives and managers personally oversee every step in the design and manufacturing process, and bring an artisan’s pride with the highest professional standards to every project.

Your imagination is our business. We thrive on challenges and excel at custom work. We enjoy working with designers, and we are inspired by complex and innovative projects. Using CNC (computer numeric control) routers for pattern making allows us to achieve tighter tolerances than traditional pattern making. We do what others say can’t be done. Our promise is to make your vision a reality.

We take a hands-on approach and take great care in choosing the best material and the most cost-effective method for every job.

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Glass Fiber Reinforced Gypsum (GRG) has been used as an architectural building material in North America since 1978. It’s a composite consisting of alpha gypsum cement and water, reinforced with glass fibers – and is an ideal choice as an economical, lightweight and durable replacement for traditional plaster.

GRG is a 3/16" thick laminate that can be additionally reinforced with wood or steel. It is used for interiors and is typically installed by drywall, plastering and millwork contractors.

Eastern Michigan UniversityMark Jefferson Science ComplexYpsilanti MI

Marriott Grande LakesOrlando FL

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US Census Bureau HeadquartersSuitland MD

LIGHTWEIGHTOnly 2 - 3 lbs. per square foot.

SETS FASTCan reduce construction schedules.

EASY TO INSTALLCan be installed using off-the-shelf framing, fasteners andjoint treatment materials.

REDUCES COSTSWhen making repetitive parts, it is much less expensive than traditional building materials such as plaster, wood and stone.

INCREDIBLE STRENGTHAbuse resistant, low maintenance.

FIRE RESISTANTMeets ASTM E84 requirements.

SAFENo odor, no emissions, non-toxic.

EXTREMELY VERSATILECan be coated to achieve any desired colorand texture.

PART CONSOLIDATIONCan be used to create traditional multi-tieredmoldings in one part.

Eastern Michigan UniversityMark Jefferson Science ComplexYpsilanti MI

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The use of GRG is limited only by your imagination. It is especially suitable for interior castings such as:

CoffersColumnsDomesLight covesVaultsMoldingsWall panels

Reebok World HeadquartersCanton MA

Harrah’s CasinoJoliet IL

EMPACTroy NY

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1 Shop DrawingsOnce a project is procured, Plasterform’s first order of business is to prepare a comprehensive set of shop drawings referencing the architectural drawings and any additional information provided by Plasterform’s client. Shop drawings typically include plans, elevations, sections and installation details. The drawings are submitted to our client who in turn forwards them to the architect for approval before manufacturing can begin.

2 Pattern & Mold MakingOnce approved shop drawings and site dimensions are received, a pattern and mold must be made before casting can begin. Plasterform’s CNC programmers produce a computer file of the gypsum part using CAD/CAM programs. These programs are used to rout the model in wood or foam to exact proportions with extremely high tolerances. Once the pattern is assembled and checked for accuracy, a mold or negative can be made from the pattern by laminating resin or pouring rubber over the pattern. The mold is an exact negative of the part. Control flanges are mounted on the mold to manage part thickness and facilitate installation.

4 Packaging & ShippingWe manufacture GRG castings in all shapes and sizes. The finished parts are carefully packaged into custom wood crates to protect them from damage during transportation. The crates are built on pallets to reduce unloading time. The finished parts are now ready for delivery to the project site or a nearby warehouse. The wood crates and pallets can be easily dismantled and repurposed.

3 Fabrication & Quality ControlNow fabrication can begin. Gypsum is mixed with water to precise proportions. The mixture becomes a slurry which is placed into a hopper and is pumped through a spray machine. The sprayer coats the mold with the slurry, and then introduces fiberglass roving into the slurry to reinforce the manufactured part. Once the mold is sprayed, the back of the part is tooled to remove air. The manufacturing process is complete and the part is allowed to dry into a solid while in the mold. Once dry, the part is removed from the mold and visually inspected. The gypsum part is checked for quality and accuracy. Air pockets or other surface imperfections are repaired.

McCormick Place Convention CenterChicago IL

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Paul Barret Jr. Libraryat Rhodes CollegeMemphis TN

If you are looking for an economical and lightweight interior building material that can be made into just about any shape imaginable, GRG is for you. Plasterform’s GRG can be cast into complex curves with extreme accuracy. It is not only used for decorative purposes, it’s used for lighting and acoustic purposes too. GRG is commonly used to conceal lighting or reflect light. In acoustic applications, GRG can be used to reflect or absorb sound. Its standard thickness is 3/16", but can be customized to 1/2" or 3/4" to achieve a desired reverberation. When sound absorption is required, custom sized and shaped perforations can be introduced so sound can pass and be absorbed by other materials.

Gaylord Palms Hotel& Convention CenterOrlando FL

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Being a custom manufacturer, we understand each component is unique. We comprehend the needs of the architect and the installer. Our experienced CAD technicians aim to maintain design intent and provide practical construction details to facilitate installations. These details were developed over 25 years of proven performance. Visit us at plasterform.com for more information.

St. James BuildingJacksonville FL

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GRG is typically smooth and requires field applied coatings to achieve the desired color and texture for optimum effect.

GRG accepts most latex, acrylic and alkyd paints, providing nearly limitless options for those important final touches.

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Plasterform is committed to ensuring that our products meet international green building standards. To that end we support Leadership in Energy and Environmental Design (LEED); an internationally recognized green building rating system and certification program that evaluates a building’s environmental performance.

LEED awards projects with one of four certification levels: certified, silver, gold and platinum. Plasterform’s products can help projects achieve credits under the following categories:

MATERIALS AND RESOURCES

LEED Credit 2 Construction Waste Management

Plasterform engineers products to minimize waste. Most of our projects are designed with prefab corners, and parts are supplied to suit field measurements and conditions that minimize job site cutting and thus, waste. Our products are crated using pallets and 2 x 4’s that can be easily reused or recycled.

LEED Credit 4 Recycled Content

Plasterform uses new raw materials for standard castings. Post-industrial fillers can be introduced into the casting to achieve a custom matrix specific to your needs. Contact Plasterform for assistance in developing your specifications before your project tenders.

LEED Credit 5 Regional Materials

This LEED credit promotes the use of regionally harvested or manufactured products to support the regional economy and reduce the environmental impact of transportation. Plasterform’s manufacturing facility is located in Mississauga, Ontario, Canada. Contact Plasterform to determine if your project qualifies for this credit.

INNOVATION IN DESIGN

LEED Credit 1 Innovation in Design

This LEED credit provides a project with the opportunity to achieve points for exceptional performance above LEED standards by achieving measurable environmental performance not ad-dressed in LEED. Plasterform’s materials are significantly lighter than conven-tional building materials and therefore reduce the amount of structural steel required for construction. Our products also require little or no maintenance. Contact Plasterform to find out how our products can contribute to this LEED credit.

National ArchivesWashington DC

The Cooper UnionNew York NY

Plasterform Inc.1180 Lakeshore Road East Mississauga Ontario Canada L5E 1E9 t 1.800.268.4534 t 905.891.9500 f 905.891.2232 plasterform.com