Finishing foam cores
The foam core can be finished using one of several different methods, including traditional brick, stone, exterior insulation and finish systems (EIFS), urethane and plastic hardcoat finishes. While these methods can all lead to a beautifully finished product, however, it is important to keep in mind they are not created equal.
An EIFS or urethane finish will be relatively lighter and less expensive than other options at the start, which makes them a great alternative to traditional stone or brick signs, but they are also prone to dry rot and moisture retention and more vulnerable to impacts. When these factors ultimately destroy a once-beautiful sign, it ends up costing the client more money in the long run.
In addition to their relatively high failure rate, some components of EIFS or urethane-finished sign structures—including their seamed and jointed pieces—must be completed during the on-site installation process, rather than in the controlled environment of the sign shop.
For many years, sign shops were forced to choose between the heavy, traditional monument signs and these lighter EIFS and urethane signs that did not last. There was no high-quality alternative finishing system available.
Over the last decade, however, that has changed, with the development of plastic hardcoats that can be sprayed onto solid blocks of foam to provide improved resistance against rot, moisture, damage and pests (e.g. termites). The encapsulated foam can then be sprayed again with a stucco finish to simulate the appearance of concrete.
Several foam-core monuments finished with specific ‘hybrid’ plastic hardcoats have withstood the test of excessive winds, hurricanes and floods. Some proprietary materials have even been independently tested and approved to withstand extreme winds at speeds up to 282 km/h (175 mph), have performed well under thermal shock conditions and have proven impervious to freezing. Those that will not crack or warp as temperatures change are particularly well-suited for outdoor installation in Canada, allowing foam-core monument signs to offer virtually the same durability as concrete, but without nearly as much weight.
Ease of installation
Installing a monument sign need not be a monumental task. These types of signs can be set up in the field in two to three hours by two people using some basic supplies, with no need for heavy equipment, on-site construction or specialty concrete. This ease of installation is another reason they are becoming an increasingly mainstream option for signmakers across Canada.
The EPS foam core is what makes them much lighter than brick, stone or concrete structures of the same size. The average foam monument sign weighs about 68 kg (150 lb), whereas a traditional concrete monument sign would be 10 times heavier, weighing 680 kg (1,500 lb).
Meanwhile, the embedding of polyvinyl chloride (PVC) pipes into foam monument signs’ structure during the manufacturing process is what eliminates the need for a concrete base, additional stabilizing equipment or metal bracing.
Instead, the two aforementioned sign installers simply need a shovel, a level, 51-mm (2-in.) wide galvanized steel pipes, ready-mix cement, a hole digger/auger, a wheelbarrow, a clean tarp and two cans of sprayable expanding foam sealant, such as Dow’s Great Stuff.
The sign can be installed directly into the ground or on a concrete pad. The only requirement in this respect is for it to be sitting on a solid surface. Long-term durability and wind-load specifications are based upon the sign being ground-supported.
After the sign’s exact installation location is determined (and verifying it will keep the sign level), the sign should be put down on a soft surface that will protect its face, such as a tarp or an array of foam blocks. This will allow the galvanized steel pipes to be aligned with it.
