The Plasterform Way
An energetic, experienced approach with an obsessive attention to service and detail, and the capacity to create large and complex castings.
ounded in 1987, Plasterform is one of the largest custom casting manufacturers in the world. We manufacture the most extensive line of architectural casting products available, including GRG (Glass Fiber Reinforced Gypsum), GFRC (Glass Fiber Reinforced Concrete), IMS (Interior Molded Stone) and FRP (Fiberglass). 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.
Attention To Service And Detail
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 manufacture process, and bring an artisan's pride and the highest professional standards to every project.
Your Vision Is Our Reality
Your imagination is our business. We thrive on challenges and excel at custom work. We love working with designers, and we are inspired by challenging, 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.
Inspired Solutions
We take a hands-on approach and take great care in choosing the best material and the most cost-effective method for every job.
Commitment To Quality
Plasterform's goal is to achieve the highest standards of quality in our business practices and operations. We continually strive to improve our company performance while offering our clients professional service and products.
Our Facilities Are Key
Plasterform's 130,000 square-foot manufacturing plant, on 11 acres, is an important key to our success. This building allows us to house all of the administrative offices, employees and manufacturing processes needed to complete every project, from inception to shipping, under one roof. Within our manufacturing facility we perform all estimating, drafting, R & D, pattern and mold making, casting, quality control, packaging and crating.
We purchased this facility in 2003 and completely retrofitted it to bring it up to the highest standards of efficiency, including the latest technologies and equipment used in the industry -- such as our innovative use of CNC equipment for pattern making.
The environmental conditions within the plant, including temperature, humidity and air quality, are monitored to maintain quality and to ensure a safe and comfortable work environment for our employees. Both indoor and outdoor storage is available to retain molds until your job is successfully installed.
Our facility includes:
- 40,000 square feet devoted to CNC operations, pattern making and mold making
- 75,000 square feet devoted to GRG, GFRC, IMS and FRP fabrications
- 15,000 square feet devoted to office space
We are conveniently located in Mississauga, Ontario close to two of Toronto's major highways and Pearson International Airport. Our state-of-the-art facilities ensure that we can handle any assignment and ship anywhere in the world.
Careers
Plasterform is committed to exceeding our clients' expectations by providing the best products and client service in the industry. We believe good people build the foundation of our success. As such, our employees are talented, motivated, dedicated, hardworking professionals focused on meeting our clients' needs. If you have these qualities, please feel free to apply.
Design Engineers
AutoCAD 2008, drafting/interior and exterior architectural detailing experience for commercial construction. BIM and LEED knowledge desirable.
Estimators/Technical Sales Support
Architectural background in commercial construction, customer presentations, technical solutions development and estimating.
CNC Machine Programmers and 3D Modellers
CATIA V5 or Mastercam X2/X3 experience, 3-axis and 5-axis machining experience.
Fluidity Into form
Plasterform is one of the largest custom architectural casting manufacturers in the world. We very capably manufacture large and complex projects.
At the start of each new project, we provide consultation to architects, designers and contractors to ensure that the manufacturing process proceeds in a smooth, step-by-step and cost-effective manner; the right materials are chosen; and the finished parts maintain design intent and are easy to install.
During the tender process, Plasterform prepares a detailed quotation including quantities, price, terms and conditions and lead time. Once Plasterform is awarded a contract a comprehensive submittal package is prepared that includes shop drawings, samples, certificates, brochures and specifications.
The submittals are issued to the Purchaser who in turn forwards them to the General Contractor and Architect for their review and approval. Upon approval, samples, shop drawings and field dimensions are returned to Plasterform and pattern making begins.
Plasterform mills MDF, wood and foam patterns on five-axis CNC routers to tolerances that far exceed industry standards. These patterns are also called models or positives. Once a pattern is removed from the CNC machine and checked for accuracy a mold or negative can be manufactured.
Resin or rubber is sprayed or poured over a pattern to create an exact impression. The mold is extracted. Flanges are then applied to the mold to control part thickness and it is cleaned and ready for casting. The molds are moved to casting rooms where gypsum, concrete or fiberglass is cast into the mold.
The casting is removed from the mold once it is dry. The mold is then cleaned and ready for another casting. The casting is trimmed, patched and checked again for accuracy. Once all of the castings have undergone our quality control, the parts are packaged, crated and shipped on air-ride trailers to the jobsite or our customer’s warehouse.
Materials - The Right Stuff
Plasterform manufactures architectural castings in a variety of materials and finishes. We offer numerous standard shapes, but we excel at custom work. Our large capacity, extensive product range and use of the most innovative technology ensures that the right material is available. We assess each project carefully and choose the best materials for every job.
Peace Of Mind
We put the pieces together to ensure our products are accurate, easy to install and economically manufactured.
We use the best quality materials to ensure your peace of mind. All materials used are:
- Lightweight
- Easy to install
- Class A
- Guaranteed against defects
Interior:
GRG and Castone are used for interior applications only.
Interior and Exterior:
GFRC and FRP can be used for interior or exterior work.
We find the best material, the best way and the best solution for every project -- at the best price. Click on the individual materials to learn more and let us help you decide on the right material for your project.
Commitment To Quality
Plasterform's goal is to achieve the highest standards of quality in our business practices and operations. We continually strive to improve our company performance while offering our clients professional service and products.
GRG
f you are looking for an economical and lightweight material that can be made into just about any shape imaginable, GRG is for you.
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 reinforced with wood or steel. It is used for interiors and is typically installed by drywall, plastering and millwork contractors.
Benefits And Uses
The use of GRG is limited only by your imagination. GRG can be very effectively used to create columns, domes, vaults, coffers, light coves, moldings and much, much more. Parts are seamed together and cast in any shape. GRG is versatile and easy to finish and accepts most latex, acrylic modified or alkyd paints.
The primary benefits of using GRG:
LIGHTWEIGHT - Only 2 - 3 lbs. per square foot.
EASY TO INSTALL - Can be installed using off-the-shelf framing, fasteners and joint treatment materials.
REDUCES COSTS - When making repetitive parts, it is much less expensive than traditional building materials such as plaster, wood and stone.
INCREDIBLE STRENGTH - Abuse resistant and requires very low maintenance.
FIRE RESISTANT - Meets ASTM E84 requirements.
SAFE - No odor, no emissions, non-toxic.
SETS FAST - Can reduce construction schedules.
EXTREMELY VERSATILE - Can be coated to achieve any desired color and texture.
Manufacturing Process
GRG is manufactured by mixing the raw materials into a slurry, and spraying or hand-casting the slurry into molds. The laminate is reinforced with glass fibers applied by hand or with the use of a chopper gun. The GRG is allowed to dry in the molds, trimmed and de-molded.
Castone
If you want to recreate the look of natural stone, Castone is ideal.
Castone is an interior molded stone (IMS) composite consisting of alpha gypsum cement, pigment, aggregate, water and polymers. Plasterform began manufacturing Castone in 1987 to cater to the high demand for retail storefronts.
Castone is used for interiors and is typically installed by millwork carpenters.
Benefits And Uses
Castone can recreate the look of natural stone for use in columns, cornice, trim, demising piers, flat panels, pediments, door surrounds, fireplaces and more. It is available in twelve standard colors and we can also match custom colours (though we recommend lighter colors). Before leaving the factory, a clear sealer with a satin finish is applied.
The primary benefits of using Castone:
LIGHTWEIGHT - Only 2 – 5 lbs. per square foot depending on shape and reinforcing.
DURABLE - Incredible durability is unmatched amongst other cast stone composites.
EASY INSTALLATION - Lightweight and easy to transport. Can be installed by millwork carpenters, helping dramatically reduce installation costs.
ABUSE RESITSTANT - Reinforced with glass fibers and sealed with a clear finish.
FLEXIBLE - Offers unlimited design possibilities.
12 STANDARD COLORS AVAILABLE - With custom color matching also available.
Manufacturing process
Castone is hand cast into an open mold. The raw materials are mixed to the consistency of putty. The putty is then hand-cast into the molds and reinforced with glass fibers to add strength and help the casting retain its shape. The casting is then de-molded and allowed to dry. Once dry, the castings receive a sealer for protection.
GFRC
Glass Fiber Reinforced Concrete (GFRC) is a lightweight composite consisting of Portland cement, sand, aggregates, alkali resistant fiber, polymer, additives and water. Glass fibers reinforce the product, resulting in a much stronger material than normal concrete.
GFRC has been used as an architectural building material in North America since the 1970’s, though its use in Eastern Europe extends back to the 1940s. It is typically an exterior product, but can also be used for interior applications.
GFRC is a ½” thick laminate reinforced with steel and usually installed by drywall, EIFS, millwork or masonry contractors.
Benefits and uses
GFRC is lightweight enough to reduce the amount of structural steel required for a building (much less than 40 lbs. per square foot for pre-cast concrete) and strong enough to be used in hurricane and earthquake zones. GFRC can be used for columns, cornice, frieze, wall panels, domes, finials, pediments, balustrade, and more.
GFRC can be supplied in a smooth paint grade finish that requires a field applied coating or can be supplied integrally pigmented and sandblasted to achieve a look of stone or precast concrete. It is available in twelve standard colors and we can also match custom colours.
The primary benefits of using GFRC:
LIGHTWEIGHT - Only 4-7 lbs. per square foot.
UNMATCHED STRENGTH - Can reduce the amount of structural steel required, and is far lighter than precast concrete or cast stone (40 lbs. per square foot).
LOWER COST - Much more cost-effective than many other traditional materials, particularly when casting repetitive parts.
EASY INSTALLATION - Can be engineered to reduce installation time and cost.
FIRE RESISTANT - Non-combustible and meets ASTM E84 requirements.
DURABLE - Will not rot with exposure, and is strong and abuse-resistant.
ODORLESS AND EMISSION-FREE - Safe for indoor use.
LOW MANTENENACE - Requires little maintenance to retain its aesthetic appeal.
WEATHER RESITSTANT - Can withstand the elements over time, and is strong enough for use in earthquake and hurricane zones.
FLEXIBLE - Has unlimited design possibilities.
12 STANDARD COLORS AVAILABLE - With custom color matching also available.
Manufacturing process
The raw materials are mixed into a slurry and sprayed into molds. After a mist coat is applied, a chopper gun introduces fiber to the matrix to reinforce the GFRC. The GFRC part is allowed to dry in the mold. It is then trimmed and demolded. Depending on the finish, the surface may be sandblasted, then protected with a factory applied concrete sealer.
FRP
Glass Fiber Reinforced Polyester Resin (FRP) is a composite consisting of polyester resin and glass fibers. The resin is a byproduct of oil, natural gas, sand and other minerals. FRP has been used as a construction material since the 1950s and has been used as a non-architectural material since the 1930s.
A weather resistant material, FRP can be used in hurricane and earthquake zones and can be submerged in water.
Benefits and uses
FRP is typically used as an exterior product, but can also be used for interior settings. It can be made into shapes such as columns, cornices, domes, panels, planters and cupolas and it has several non-architectural uses such as car parts and recycling containers.
FRP is extremely versatile. It can be supplied opaque, translucent, paint grade or pre-finished, and can be textured and pigmented to simulate stone, wood or steel. It is also ideal for part consolidation: it can be used to create traditional multi-tiered and multi-part cornices, columns and cupolas in one lift/part.
The primary benefits of using FRP:
LIGHTWEIGHT - Only 2-3 lbs. per square foot.
HIGHT STRENGTH / LOW WEIGHT COMBINATION - Stronger than steel, yet light enough to make installation fast.
EASY INSTALLATION - Easy to handle and place.
EASY PART CONSOLIDATION - Can be used to create traditional multi-tiered and multi-part cornices, columns, and cupolas in one lift/part.
LOW TO ZERO MAINTENANCE - Long-lasting and will retain its shape and beauty.
WEATHER RESISTANT - Strong enough for use in hurricane and earthquake zones.
HIGHLY RESISTANT TO IMPACT AND ABUSE - Ideal for applications in high traffic areas such as shopping centers, convention centers, churches and airports.
DURABLE WITH VERY GOOD COLOR RETENTION - Does not easily fade, and will not rot or corrode with exposure.
FIRE RESISTANT - Meets ASTM E84 requirements. Plasterform uses only fire-retardant resin.
HARDINESS - Can be submerged in water, making it ideal for use in fountains and water displays.
FLEXIBLE - Can be painted in any color or matched to your desired color.
Manufacturing Process
FRP is usually manufactured with open mold. First the mold is sprayed with gelcoat, a durable non-fading polyester coating. The FRP matrix (resin and fiber), is then applied to the mold with a chopper gun or the hand lay up process. The FRP is then compacted to remove excess air and allowed to cure.
Custom Products - If You Can Imagine It, We Can Make It
Plasterform is a design and technological innovator at the forefront of the industry, capable of accurately executing extremely creative, detailed designs. We thrive on challenges and excel at custom work. We have the experience, talent and technology to make your vision a reality.
We love working with architects and designers. Challenging, complex and innovative designs drive us to succeed and inspire us to find innovative solutions. We pride ourselves on taking on challenges other manufacturers would not - challenges such as perforations, complex compound curves, tight deadlines and large projects.
Our experienced computer assisted design (CAD) operators create comprehensive shop drawings prior to manufacturing. We use the latest design software and manufacturing techniques, including using computer numeric control (CNC) routers for pattern making, which allows us to achieve tighter tolerances than traditional pattern making. With this technology, we can create virtually any shape.
We don’t just make beautiful forms, however. Competitive pricing ensures your project is on budget and our dedicated drafting technicians focus on practical construction and installation techniques to reduce site labor. Plus, we create in-house or on-site mockups to ensure parts are made within tolerance and meet design intent and other requirements.
To find out why more than 80% of our business if from repeat clients, contact us at sales@plasterform.com
LEED
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.
The U.S. Green Building Council (USGBC) introduced LEED in 1998 and it has become the national standard rating system for new construction, renovations and existing buildings. The hallmark of LEED is that it is an open and transparent process whereby technical criteria is publicly reviewed for approval by the almost 20,000 member organizations that currently constitute the USGBC.
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:
Material 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 for 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 measureable environmental performance not addressed in LEED. Plasterform's materials are significantly lighter then conventional 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.