Sprayable Plastic Coatings for Theming & Attractions

The main job of a sprayable plastic coating for theming and attractions is to protect foam surfaces from various environmental elements. When you create a new themed environment out of EPS or Styrofoam, you’ll want it to last. That won’t happen unless you have the proper protection. Even though this part is unseen by the audience, it’s one of the most important steps. This step also prepares the surface for priming and painting to create a more uniform and professional finish. So, you need to find the best material to do so.

What Is a Themed Environment?

Themed environments are physical spaces that should transport guests and visitors to different times and places. An effective way to do this is by creating an immersive world using architectural sets, lighting, sound, and technology. If done right, your environment should invoke emotion, engage the senses (sight, hearing, touch, etc.), entertain, and give your audience a reason to want to come back.

These themed environments can help businesses differentiate themselves from the crowd. An environment like this can also foster a good work culture. Businesses can even get brand exposure from people taking pictures or videos and sharing them online, helping bring in more people. Themed environments are not limited to theme parks like Disney World and Universal Studios; you can create a unique experience for showrooms, restaurants, stores, and more as well.

What Makes up a Themed Environment?

Just about every part of queue areas, theme park rides, and even the streets of a theme park can be themed. Theming elements can be as simple as faux rocks and trees or as extravagant as large 3D sculptures. The following are used to add to the overall theme in amusement parks:

• Sculptures: While not always directly surrounded by an environment they’re meant to be in, theme parks can use larger-than-life 3D character sculptures throughout the park to further connect with guests, elicit nostalgia, and generate photo opportunities.
• Props: Many theme parks, as added entertainment, put on stage productions that use various stagnant and handheld props. These props create much-needed visual elements for stories. Without props, costumes, and sets, much is left up to the imagination. When props are used, it further enhances the imaginative experience.
• Scenery: The architecture is meant to engulf your audience in a new world with visual elements that captivate them the second they enter. Setting a scene can include a handful of things, including simple architectural elements like columns, shutters, crown molding, etc. or, memorable objects, sets, and characters that tell a story.
• Signage: Signs are typically the first thing an audience sees as they approach a building. They may even help them decide if they want to continue into a location, whether that be a shop, restaurant, or ride. It also directs them where to go since they’re high up in places everyone can see.

How to Design a Themed Environment?

The type of materials you use to create a themed environment will depend on several factors, including:

• What is your budget?
• Will the project be for indoor or outdoor use?
• Will people be able to touch it?
• Is it a one-time project or long-lasting?
• What are your safety requirements?
• Is there a weight requirement?

While various materials have been used to create themed environments in the past, it has become much more common for designers and artists to use foam to make massive landscapes, sculptures, signs, and more. This material is desirable because of its cost-effectiveness and lightweight nature. Compared to other building materials like natural stone, wood, and metal, foam is much more affordable and easier to move or transport to a permanent location.

The most common foam used in these instances is EPS (expanded polystyrene). XPS/Styrofoam (extruded polystyrene) and polyurethane foam have been used as well. EPS is much easier to cut, shape, and mold using CNC, hot wire cutters, and wire brushes, among other tools. This method allows designers to create pieces with less skilled artistic labor and more easily than if they used heavy, solid, and expensive materials.

How to Protect EPS Foam Theming Projects

While foam is an excellent material for theming, it can’t be placed in an environment without a protective shield because it’s not very durable. Without protection, it would be exposed to the sun, wind, rain, and other weather conditions that could cause damage. The foam could also become damaged from transport or during installation if unprotected. Also, if you want to be able to sand, prime, and paint the foam, a rigid material that creates a smooth surface is needed. The best thing to do would be to harden the foam.

A sprayable plastic coating like urethane is a good material that hardens and protects foam for indoor and outdoor use. It is versatile and can be formulated with varying properties, including Shore hardness and tensile strength. The recommended durometer is around 65-75 D and will provide a plastic-like appearance and feeling while not being able to shatter or crack.
When undertaking large-scale projects or many small projects, the best application method is by spray. There are two distinct spray methods VFI recommends:

• High pressure – For high volume projects, artists and applicators use a sprayable plastic coating through a two-component high pressure spray rig on large projects. VFI recommends VFI-6170 70 D Spray Hard Coat, as it provides a durable shell over large structural shapes made with EPS foam. A benefit of this material is that it is Class A fire tested to meet strict indoor and outdoor safety standards.
• Qwik spray – An alternative to expensive spray equipment is to find a sprayable plastic coating formula that is applied with a cartridge-based applicator gun. This method is best for portability if you must take your projects on the go. It is also only recommended for smaller projects under 4 feet. Otherwise, you’ll have to spray in much thinner passes and must be comfortable with the overspray it will generate. VFI-6171 70 D Qwik Spray Hard Coat is VFI’s cartridge-based hard coat compatible with the VFI-7500 Qwik Spray Gun.

Interested in a brushable hardcoat? Check out VFI’s blog for more information.

Benefits of Using a Sprayable Plastic Coating

While foam is lightweight, the coating is also fairly light, so it doesn’t add too much weight to the entire piece, making it just as easy to move and transport finished objects. This solves a lot of logistical problems with large pieces that have to be hung up or mounted above the ground.

Because the coating forms a seamless finish, it is able to withstand damage from weather, which is essential if the foam piece is placed outside. Its hardness makes the foam incredibly strong and resists cracking, so it’s capable of lasting long-term. It is also impact and abrasion resistant, so it holds up in the event that people are constantly touching, leaning against, or sitting on it, which is expected in theme park environments where children are present.

Polyurethane, as a sprayable coating, is incredibly versatile in what it can be applied to. It conforms to curves and does not diminish details as long as it is not sprayed on too thick. While the finish typically comes out smooth, it can be sanded to enhance aesthetics before applying a paint or top coat.

Contact VFI if you are interested in any of our EPS theming hard coats and need assistance choosing the best one for your project.