Surfaces-Final by xiaohuicaicai


									Load Bearing Surface
  MCC L 100C, Minneapolis, 2003
   Saturday, 2:30 PM to 3:50 PM
Panel Chair:
• Stirling Shelton

Lead Technical
Cincinnati Playhouse
in the Park,
Cincinnati, Ohio

• Greg Bell

He is an Associate
  Professor and
  Technical Director at
  Otterbein College in
  Westerville Ohio.

• Tracy Fitch
Technical Director
University of North Carolina,

   • Katherine R.
She is a sophomore at
  Otterbein College and
  has previously worked
  for The Huron
  Playhouse, The
  Sandusky State Theatre,
  and The Great Lakes
  Theater Festival.
• Claire Dana
Claire Fretts Dana is in
  her fourth year as the
  Charge Scenic at
  Indiana Repertory B.A.
  (1987) in English from
  Oberlin College; and
  has painted and
  charged for several
  regional theatres and
• Michael
Michael is the Technical
  Director at the University of
  Massachusetts, Amherst.
  Prior to that he has spent
  most of his 35+ year career
  in professional theatre as a
  technical director.
OK, Lets talk
Greg Bell

Using the sprayed-on stucco mix
  over metal lathe (the same
  technique Katherine Sieg has
  used on her rigid facings)
  attached to a plywood armature-
  type structure. The stucco has
  cracked and crumbled away at the
  top portions of the "rock",
  where I stood on it after it had
  cured for a couple of days.
Greg Bell
What does NOT Work:
• I started thinking about
  regular old papier
  mache. "Sculpty-Mold" or
  something like that,
  that was basically a dry
  form of papier mache.
  "Just add water and
  press into a mold"...
  The "paper" in this dry
  stuff was almost in
  powder form. It was too
  expensive for theatre
  use, but I thought maybe
  I could duplicate it
TRY it again!
• I had used some blow-in
  cellulose insulation at
  home that was pretty
  powdery, so I bought a
  bag of it and started
  mixing it with various
  binders. I mixed it with
  joint compound, latex
  paint, yellow glue, and
  wheat paste. I troweled
  the mixtures over a
  plywood armature covered
  either with multiple
  layers of chicken wire
  or that stucco mesh.
  None of the mixtures
  became rigid or able to
  bear much of a load.
• The elastomeric roofing compound we used was
  called Kool Seal. EPS foam hand-sculpted
  with saws and sandpaper.

• It's not the easiest to mix but certainly
  easier than joint compound. We pretty much
  poured off half a bucket of the elastomer
  into another 5 gallon and then made the
  whole batch in the 2 buckets. We were hand-
  mixing with a good solid 1x2.
  UNC, Charlotte’s Inexpensive Flexi Glue
1) 5 Gallon bucket of inexpensive elastomeric
  roofing compound from your local home
  improvement center
1 Gallon bucket of fine powdered sawdust
  (imagine you've been cutting a heck of a
  lot of mdf--use that)
3/4 of a gallon of play sand
1 dash of scenic paint to add a slight base

Add cheesecloth for detailed edges or
  broadcloth for sturdy walkable areas.

Smear on a thin layer (less than
  1/8"). Apply cloth working it
  into the goop. Apply a second
  thin layer for smoother scenery
  or a thicker layer to texture.
  For heavy texture it might be
  best to do the thin coat and let
  it dry. Then apply again over
  the top of the whole mess.
      Kool Seal

MSDS is at

   • Katherine R.
She is a sophomore at
  Otterbein College and
  has previously worked
  for The Huron
  Playhouse, The
  Sandusky State Theatre,
  and The Great Lakes
  Theater Festival.
   Technology Exhibit 2003

Exhibit Number 21:
       Rigid facing using sprayed
       on stucco compound.
Stucco Net (metal lathe)
Base-coat Stucco Mix (80 lb bag)
Drywall hopper gun
• Michael
Michael is the Technical
  Director at the University of
  Massachusetts, Amherst.
  Prior to that he has spent
  most of his 35+ year career
  in professional theatre as a
  technical director.
POLYGEM, Inc.                              
Ph: (630) 231-5600
  Polygem, Inc.
  manufactures epoxies,
  vinyl-esters and silicones
  for various industries and
  markets such as:
  Waterproofing, Mining,
  Industrial, Electrical,
  Zoological, Golf and
  DIY. Polygem, Inc. has
  been custom formulating
  epoxies in excess of
  twenty-five years and has
  created over 1,500
  unique formulations.

  Polygem, Inc. continues to reformulate and improve existing products to meet current test standards and
  industry demands. Polygem, Inc. produces only 100% solid epoxies of the highest possible quality utilizing the
  finest raw materials and ingredients available.

  Polygem, Inc. develops, manufactures, packages and ships all products direct from our 25,000 square foot
  facility in West Chicago, Illinois located 30 miles west of Chicago. A strict quality control program inspects
  each product for consistency, color and stoichiometry ensuring product performance and customer satisfaction.

                                                          Information complied by Stirling
The Tree was made with:
POLYBAC #307: A general purpose sculpturing putty formulated specifically
for artificial exhibit construction. It is a flexible system, exhibiting excellent shock
and impact resistance along with excellent adhesion to any two porous surfaces.
Typical applications include bonding clean metals to concrete, wood, fiberglass,
concrete, gunite, drive-it and each other.
POLYBAC #307 is manufactured of 100% solids, two component epoxy.
All grades are capable of being applied horizontally or vertically and overhead.
Uncured products can be cleaned up with water.
POLYBAC #307-M a thicker version (clay consistency) of #307 has been specially
formulated for overhead applications.
POLYBAC #307-FR is the “Fire Retartent” version of #307.
It has the consistency of “cold taffy” and is the definative product when building indoor
All three of these products can be colored with epoxy pigments or dry pigments.

The cured products may also be coated with epoxy or latex paints.

                                              Information complied by Stirling
Dino-Goo            (As seen on the Discovery Channel's Monster House )
Dino-Goo is a thick epoxy paste specially formulated to be easily shaped,
textured and sculpted. Dino-Goo will provide a hard and durable surface
that is sandable, paintable and fire retardant.
Dino-Goo is also known as our #307 FR-Lite which has been used for
artificial environments at leading zoos, aquariums, museums, casinos and
theme parks around the world. Dino-Goo is an easy to mix one Part of A to one Part of B
pre-thickened epoxy paste that is ready to texture or emboss and water can be used as
the release or smoothing agent. Dino-Goo can be pigmented with liquid
or dry powder pigments and can be additionally thickened up to a modeling
clay-like consistency by using the Polygem Thickening Agent. Dino-Goo
will bond to most surfaces including Fiberglass, Foam, metal and concrete.
Dino-Goo can be coated with any paint, urethane, acrylic or latex paint and Dino-Goo
can even accept stains. Dino-Goo is available in 2 gallon, 10 gallon and 100 gallon
kits and is available in custom blended batches.

                                                  Information complied by Stirling
Level-All is the latest in a new family of "thixotropic resin"
levelers. Thixotropic means that it levels and stays where you
put it. It will not move on its own. When you brush it on a foam
surface, it minimizes the cut lines and minor imperfections. This
is a water-based product that is used in conjunction with a final
waterproof coating. It is not waterproof if used alone. It must be
coated with a waterproof coating to insure weatherability.
Level-All helps most all coatings adhere superbly.

UreCoat is an emulsion of high-grade urethane and acrylic resins
in water. It dries by evaporation to yield a tough, non-yellowing,
water-repellent surface with exceptional abrasion resistance and
ultra-violet light stability. UreCoat can be tinted.
UreCoat is designed to have exceptional adhesion to many types
of foam. The composition of UreCoat still allows the coating to be
spray applied evenly wile leaving a smooth, glossy finish, and
UreCoat exhibits increased tensile and Ureural strength versus
other toxic epoxy coatings. When ambiently cured, UreCoat dries
rapidly and exhibits excellent toughness and superb adhesion to
other substrates as old concrete and masonry, brick, wood,
metals, and many other surfaces.

                              Information complied by Stirling

Foam Coating: Not very structural !! :(

            Water-based, elastomeric coating. Allows definition to show. For
            either interior or exterior surfaces. Works well over EPS foam and
            other surfaces. Dries white. Can be brushed, rolled, or sprayed.
            Covers 320 sq. ft. at 5 mils

          A safe, odorless coating that has been specifically formulated for the
          entertainment industry to provide a sand-like finish for interior or
          exterior applications. Stonewall's unique, thin flow quality reveals
          definition detail when applied over any extruded or expanded EPS
          foam boards or shapes. Unlike sand stucco Stonewall has an
          elastomeric characteristic that permits movement, reducing the
          possibility of cracking. Stonewall comes ready to brush, roll, or spray
          on EPS with little preparation.

          Dries clear. Water-soluble, flexible shield protects EPS foam for
          general handling. Will act as an adhesive for applying fabrics if they
          are applied while Elasta-Shield is wet. Can be brushed, rolled, or
          sprayed. Covers 320 sq. ft. at 5 mils

                                      Information complied by Stirling
Now these products are hard.
        Liquid Rock is a 2-part, epoxy-based coating that can be applied on
        interior and exterior surfaces. It has extraordinary flow
        characteristics. It leaves a hard, glossy, smooth shell finish. It works
        well on props and backdrops when a hard finish is preferred. It can
        be brushed or rolled. Average working time is 20-25 minutes. One
        gallon covers approximately 320 sq. ft. at 5 mil thickness.
        Dries off-white and can be painted

         UreShell is our latest offering in fine foam coatings. UreShell is a
         marvelous hard-coat, 2-part, urethane-based coating. Its average 25-
         minute pot life allows for rolling or brushing. Applications cover both
         interior and exterior surfaces. It leaves a hard, glossy, smooth shell
         finish. It works great on props, backdrops, signs, molds, etc. One
         gallon covers approximately 320 sq. feet at 5 mil thickness. Dries to a
         tan color and can be finished-coated with most all paints and
         synthetic stucco.

                                     Information complied by Stirling
Last product, not great for floors

                Styrothane is a 3-part, urethane-based
                coating that can be applied on interior and
                exterior surfaces. It leaves a hard, glossy,
                smooth-shell finish. It works well on props
                and backdrops when a hard finish is
                preferred. It can be brushed or rolled.
                Average working time is 10-15 minutes.
                One gallon covers approximately 320 sq.
                feet at 5 mil thickness. Dries off-white and
                can be painted. Its "tile-like" finish allows
                easy cleaning.

                              Information complied by Stirling
              Claire Fretts Dana
Charge Scenic Artist, Indiana Repertory Theatre
                                      Let it Shine!
1/2” MDF deck was waxed and buffed: mirror image ceiling was sealed with same
 but finished with gloss acrylic urethane. 3rd show at IRT to have this treatment.
                 Copenhagen, Set Design by Michael Ganio for IRT, Fall 2002
 Conventional Mop Bucket with disposable liner (trash bag)
               Nylon, no-loop applicator mop
         Commercial floor sealer & “soft” floor wax
Optional “spray and buff” touch-up solutions with spray bottle
First coat of sealer moved paint applied previously with a Preval sprayer.
                  No other trouble where encountered.
        The mighty, mighty high speed burnisher: 2000RPM
Electric (pulls about 19amps at startup and 15-17amps while running)
                              20’ cord
      The pads come in a range of color-coded abrasion types.
We found the pink “eraser” pads worked best for removing most scuffs
                    while restoring a good shine
  Maintenance requires a dust mop treated with an attractant;
buffing as needed for scuffs and re-application of wax as needed
The deck after 25 performances
You can see
some marks
will stay, but
they are always
reduced by
buffing and re-
Painted spike
marks are not
Wood grain and stone texture using powdered clay
    Lion in Winter, set design by Rob Koharchik, IRT 2003
Powdered clay and Flexbond glue was used
 for wood and stone textures on 3/8” MDF
The mixture for the deck was 4 parts clay,
  2 parts Flexbond and 2-3 parts water
Powdered clay is cheap and easy to get but
contains silicates which require respiratory
 protection and containment precautions
We used cut squeegees to grain the planks and
 brushes and trowels to work the stone tiles
 Due to winter shipping restrictions on Flexbond, the last
batches made with Elmer’s white glue, clay and no water.
    Mixture was stiff and sticky yet settled quite a bit.
                   Horrible to handle.
Another type of stone texture and a paper floor
     Cyrano, set design by Rob Koharchik, IRT 2002
Stone texture was done with Jaxsan-600 on 3/8” MDF tiles.
11”x 17” sheets of paper were painted and attached to deck
        and sealed with an acrylic wallpaper paste.
 Model of Deck with three (3) surface treatments: Painted rough
wood planks, grass and stone. “Red Badge of Courage”, Designer:
                    Rob Koharchik, IRT, 2003
CDX planks and homasote are the load-bearing substrates laid
over the permanent stage. Foam is added in for “stone” facings, as
shaping under non-walkable grass and where weeds need to be
Burlap adhered to homasote and foam with Elmers’s clay mix
and/or jaxsan 600; painted “Funeral grass” is stapeled down,
        painted rubber mulch helps soften the edges.
Looks just like the model! YEA ! Grass needs some maintenance
due to shedding:;blood gets wiped off planks every performance.
Three part ground cloth for “As you like it”. Designer: Bill Bloodgood, IRT
 Lots of traffic on 2 curved, raked areas and 1 US ramp. The rakes
are triscuit and studwall construction with half-lapped MDF sheets,
               a layer of cushy foam for sound quality.
    A full length facing piece was created for each level and
upholstered with more painted fabric. Maintenance includes a hot
                           water spray.
• Stirling Shelton

Lead Technical
Cincinnati Playhouse
in the Park,
Cincinnati, Ohio
Macbeth, Brian Jones, Indiana University of Pennsylavina
A product of Poly-Form LLC

 • A waterproof cement base sealant in dry
   powder form.
 • Mix in two quarts of water per 50-lb bag.
 • Contains portland cement and fiber
   reinforcing fibers
 Made to be used over polystyrene Surfaces.

 Preparation of surfaces: Clean and structurally sound
        If over masonry surfaces using a mild solution of
 muriatic acid, will remove efflorescence.

 How to mix: Two quarts of water to a 50-lb bag @ about
 ($11.95). Add more water if needed to obtain a paste-like
 consistency. Apply with trowel or spray. One bag will
 cover 30-50 sq-ft at 1/4” thick. Spray will cover more
 almost double.
Added Cheese cloth between layers of
 Other resources: (go get this
  book and this product info)
The Epoxy Book,
    System Three Resins, INC
West System,
    Gougeon Brothers
More resources not demonstrated by panel


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