SYSTEM ARCHITECTURE
Integrated Multi-Layer System
Engineered Composite System
REGULATORY APPROVAL OF EXTERIOR ARCHITECTURAL ELEMENTS IS NOT A FORMALITY - it is a critical path item in the construction schedule.
TOTAL COST OF OWNERSHIP AS THE TRUE ECONOMIC MEASURE
IN COMMERCIAL CONSTRUCTION, SCHEDULE COMPRESSION IS A DIRECT REVENUE STRATEGY.
CUSTOMIZATION IS BUILT INTO THE PROCESS
Documentability as the Core Engineering Criterion
AESTHETICS AS AN ECONOMIC VARIABLE
Arcade & Colonnade Systems for Modern Architectural Facades
Some buildings simply command attention. Arcades and colonnades define architectural elements and shape the character of a façade more than almost any other detail. From grand neoclassical entrances to modern covered walkways, they appear everywhere. At Royal Foam US, we design and manufacture custom arcades and colonnades for high-end residential and commercial projects throughout Florida and across the country. We use a lightweight expanded polystyrene core coated with a factory-applied hard polyurethane resin, outperforming stone, concrete, and fiberglass in every practical respect.
Designing a Mediterranean villa, a resort hotel entrance, a multi-functional shopping complex façade, or a public landmark? A properly selected exterior colonnade system transforms a building into a work of art. In this article, we explore the definitions, materials, applications, fabrication, and specific engineering advantages that make Royal Foam US the preferred choice for architects and developers.
What Are Arcade Systems in Modern Architecture?
An architectural arcade is a series of arches carried on columns or piers. It creates a covered walkway or passage along the face of a building. The term comes from the Latin "arcus" (arch). In classical architecture, arcades defined the ground floors of civic buildings, basilicas, and markets. Today, facade arcade systems serve the same dual purpose. They provide shade and shelter and create a powerful visual rhythm across a facade.
Where are arcade systems used?
Arcade systems appear across the following:
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Hotel and resort main entrances and pool terraces
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Shopping center facades and pedestrian streetfronts
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Luxury residential entries and courtyard screens
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Civic and institutional buildings with public walkways
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Mixed-use development ground floors with retail frontage
Why are arcade systems popular in luxury architecture?
Luxury architecture requires depth, shadows, and visual complexity. A flat façade looks bland. Decorative arched systems solve this problem instantly. Repeating arches create visual rhythm. Projecting elements cast deep shadows that change throughout the day. Covered walkways have practical value, providing shade in the summer and protection from the rain. This greatly enhances the property's appeal and adds comfort to guests and residents.
What Is a Colonnade System?
A colonnade system is a row of evenly spaced columns. It supports a horizontal entablature or roof structure. An arcade uses arches between columns. A colonnade uses flat lintels or beams. The effect is clean, ordered, and monumental. Colonnades are central to neoclassical architecture, Greek Revival, Beaux-Arts, and Mediterranean architecture. They remain highly relevant in contemporary luxury design.
Are colonnade systems decorative or structural?
This depends on the application. Traditional stone colonnades are load-bearing. However, the vast majority of modern exterior colonnade systems in residential and commercial architecture are decorative facade systems. They enhance appearance without carrying structural loads. Royal Foam US specializes in this category. Our lightweight architectural systems are applied to existing or new structures using adhesive and mechanical fastening. It adds visual impact without adding structural burden.
Which architectural styles use colonnades most often?
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Neoclassical & Greek Revival: Grand symmetrical colonnade entries with Doric, Ionic, or Corinthian capitals
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Mediterranean & Tuscan: Rounded arched colonnades with stucco finish, rusticated columns, and decorative capitals
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Colonial & Georgian: Slender white-painted columns with simple entablature, porch colonnades
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Modern Contemporary: Minimalist colonnade screens with clean profiles and monochromatic finish
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Craftsman & Mission: Tapered square piers with exposed bracket details
The Difference Between Arcade and Colonnade Systems
Architects and developers often use these terms interchangeably. However, there is a clear distinction.
An arcade uses arches between piers, creating curved openings. A colonnade uses flat lintels or beams between columns, creating rectangular openings. Modern architectural arcades and colonnades often combine both types of structures. People prefer columns with arched vaults or colonnade screens with decorative arched inserts. Royal Foam US produces both systems, depending on the architectural design.
Key differences in brief:
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An arcade involves arched openings, a stronger historical reference, and greater visual expression and is often used in Mediterranean and Romanesque styles.
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A colonnade involves openings with flat tops, a cleaner and more formal appearance, and is prevalent in neoclassical and modern styles.
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Combination systems include arched colonnades—columns supporting arches. They are found in Spanish mission, Venetian, and Tuscan architecture.
What Materials Are Used in Modern Arcade & Colonnade Systems?
Each element of the Royal Foam US arcade and colonnade is created using a two-component material system consisting of a core of EPS foam as a structural filler and a rigid polyurea coating as a mandatory protective outer shell.
EPS Foam - the lightweight core
It is the internal volume material that gives arcade columns, arch forms, pilasters, and entablature sections their shape and mass. We use EPS foam with a density of 1.0–1.5 lb/ft³ as standard (2.0 lb/ft³ is available for specific applications). This density range delivers the optimal balance between structural integrity and weight.
EPS foam is extremely lightweight. Its density of 1.0–1.5 lb/ft³ means a complete column weighs significantly less than any alternative material.
EPS foam does not absorb moisture. The foam structure itself does not swell, rot, or promote mold growth. It maintains its precise shape for decades. Under normal operating conditions, there is no deformation, shrinkage, or creep.
We cut EPS foam blanks on CNC hot-wire machines and milling machines with a tolerance of ±0.5 mm. This allows us to create an unlimited number of custom profiles.
EPS is only a core filler. It is not impact-resistant as a standalone product. It is not designed for load-bearing applications. We do not use it as a finish for exterior applications.
Hard Coat Polyurea - the protective shell
We apply Hard Coat Polyurea to every exterior EPS foam element. It's not paint or a decorative coating. This high-performance structural material determines the mechanical, climatic, and moisture resistance of the finished product.
We apply the coating using a reactive spray method. We mix two chemical components under high pressure at a controlled temperature. The components immediately react and cure directly on the EPS foam surface. The result is a seamless, monolithic, void-free shell with excellent adhesion to the EPS foam core.
Hard Coat Polyurea provides impact resistance. The cured shell reaches a Shore D hardness of 60–80. This makes the EPS core resistant to accidental mechanical impacts from tools, wind-blown debris, and maintenance equipment.
The seamless polyurethane shell is 100% waterproof. Moisture cannot reach the expanded polystyrene core, eliminating any risk of water saturation, freeze-thaw damage, or internal delamination.
The coating is resistant to UV degradation. Accelerated weathering tests according to ASTM G154 confirm greater than 90% surface hardness retention after over 5,000 hours. Polyurea maintains flexibility over a service temperature range of -40°F to +250°F. It accommodates micro-movements of the substrate without cracking or delamination.
The shell is resistant to standard outdoor chemical exposure—rain, cleaning agents, and pollutants common in urban environments.
A solid polyurea coating is required for all exterior work at Royal Foam US. This includes all facade arch systems, external colonnade systems, external columns, architectural arch systems, perimeter fencing, and any decorative elements exposed to weather, UV radiation, or mechanical stress.
How do fiberglass and GFRC compare to this system?
Glass fiber reinforced concrete and fiberglass are weather-resistant. However, GFRC is significantly heavier and requires expensive molds to create custom profiles. Fiberglass degrades under prolonged exposure to UV radiation unless specially stabilized. No other system can match the customization flexibility or installation efficiency offered by CNC-machined EPS foam with a hard polyurea coating. For information on the performance characteristics of EPS materials for outdoor applications, see the EPS Industry Alliance technical library.
The following table compares the Royal Foam EPS + Hard Coat Polyurea system with alternative materials across all key performance criteria:
|
Property |
EPS + Polyurea |
GFRC |
Fiberglass |
Precast Concrete |
Natural Stone |
|
Weight per lin. ft. |
0.5 – 1.2 lb |
8 – 12 lb |
3 – 6 lb |
15 – 30 lb |
30 – 80 lb |
|
Water Absorption |
Zero |
Low (2–4%) |
Very Low |
Moderate (5–8%) |
Low–Moderate |
|
Freeze-Thaw Resistance |
Excellent |
Good |
Good |
Moderate |
Good (varies) |
|
UV Resistance |
High (coating) |
Moderate |
Moderate |
Good |
Excellent |
|
Custom Profiles |
Unlimited / CNC |
Moderate |
Mold-limited |
Mold-limited |
Labor-limited |
|
Install Time |
Fast (adhesive) |
Moderate |
Moderate |
Slow (crane) |
Very Slow |
|
Structural Load |
Negligible |
Moderate |
Low |
Very High |
Extreme |
|
Lifespan (years) |
25 – 40+ |
20 – 30 |
15 – 25 |
20 – 40 |
50+ |
|
Cost (relative) |
Moderate |
Moderate–High |
Moderate |
High |
Very High |
Why Are Lightweight Architectural Systems Becoming More Popular?
How do lightweight systems reduce load-bearing loads?
Traditional stone and concrete colonnades impose enormous static loads on foundations and supporting structures. A stone colonnade at a hotel entrance can add 50-150 tons to the dead load. This will require foundation upgrades, deeper piers, and higher steelwork requirements. A complete lightweight EPS foam exterior colonnade system adds less than 2-5% of the equivalent stone's weight. Structural engineers are increasingly specifying precise requirements for EPS architectural finishing systems to avoid costly structural retrofits.
Why are lightweight systems installed faster?
Construction speed is critical. Lightweight architectural systems completely eliminate the need for a crane. A two-person crew can install a complete residential arcade in one to two days. The same installation with precast concrete requires a crane operator, riggers, and structural inspection and typically takes at least 3-5 days. Royal Foam US supplies all components pre-assembled and pre-finished, eliminating the need for site preparation, sanding, and priming.
Are lightweight architectural systems weatherproof?
Yes, and the answer lies in understanding both components. The EPS foam core is non-hygroscopic. It does not inherently absorb moisture, so it will not swell, rot, or mold, regardless of climate. The hard-coat polyurea shell adds a second layer of protection. It is a seamless, 100% waterproof barrier resistant to UV radiation, chemicals, and mechanical impact. Together, this system eliminates all weather-related failure modes that affect conventional materials.
How do lightweight systems reduce labor costs?
Weight reduction directly translates into labor savings. No crane. No structural reinforcement. Faster installation. Lightweight façade systems reduce overall installation labor costs compared to precast concrete equivalents. For a large commercial project—for example, a hotel façade with over 40 columns and numerous arcades—labor savings alone can reach six figures.
Arcade & Colonnade Systems in Residential Architecture
How are arcade systems used in luxury homes?
In luxury residential design, architectural arcade systems are most often located at main entrances, carports, pool decks, and garden pavilions. A three- or five-bay arcade at the main entrance transforms a standard doorway into a majestic architectural threshold. Poolside arcades provide shade and beautifully frame the garden view. Mediterranean-style arcade systems with arched openings, stucco, and decorative keystones are particularly popular in the Florida luxury residential market.
Why are colonnades popular for entrances and courtyards?
Colonnades create a sense of procession. For residential entrances, a colonnade system located on either side of the front door signals quality and durability. For courtyards, colonnades define the boundary between indoor and outdoor spaces while maintaining a sense of visual openness. The repeating rhythm of the columns visually increases the perceived width of the façade.
Which house styles benefit most from colonnades?
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Mediterranean and Spanish Colonial styles feature arched colonnades with rough plaster, decorative consoles, and a terracotta color palette.
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Neoclassical and Georgian styles feature symmetrical entrances with four or six columns, Ionic or Corinthian capitals, and a full entablature.
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Tuscan and Italianate styles feature square or round rustic piers with stone trim and a massive entablature.
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Modern transitional styles are more often associated with strict rectangular column partitions with flat capitals and monochrome trim.
Colonnade Systems in Commercial Projects?
Commercial applications for custom colonnade systems and decorative arcade systems span virtually every building type. The table below summarizes the most common project categories, system types, and primary benefits:
|
Project Type |
Typical System Used |
Key Benefit |
Common Style |
|
Luxury Residence |
Residential colonnade + arch system |
Curb appeal, property value |
Mediterranean, Neoclassical |
|
Hotel & Resort |
Exterior arcade with colonnades |
Covered walkways, guest experience |
Grand Classical, Tuscan |
|
Shopping Center |
Facade arcade system |
Brand identity, shade & shelter |
Modern, Contemporary |
|
Office Park |
Decorative colonnade systems |
Professional facade, signage zones |
Modern Classical |
|
Government / Civic |
Architectural entry colonnade |
Authority, landmark identity |
Neoclassical, Greek Revival |
|
Healthcare Campus |
Covered arcade walkways |
Patient comfort, wayfinding |
Clean Modern |
|
Mixed-Use Development |
Full facade arcade system |
Unified design language |
Contemporary Mediterranean |
A key advantage of Royal Foam US systems in all commercial projects is design scalability. We produce identical column and arch profiles in any quantity, ensuring visual consistency on the façade of a 200-room hotel or a 40-store shopping center. Our dedicated account managers coordinate delivery schedules according to construction stages, minimizing on-site storage requirements.
How Does the Custom Design & Fabrication Process Work?
You provide drawings, reference images, or architectural specifications. Our team reviews the dimensions, profile requirements, column spacing, arch radii, and finish requirements. A dedicated account manager assists you during this stage.
Our designers create complete 2D CAD profiles and, if necessary, 3D renderings for client approval. Complex capitals, keystones, and entablature details are digitally modeled before material cutting begins.
For commercial projects and complex residential orders, we produce a physical sample for approval. This eliminates costly on-site adjustments, allowing the client to see the precise finish before full-scale production begins.
Approved profiles are programmed into our CNC hot wire equipment. EPS foam blanks are cut to a tolerance of ±0.5 mm. Colonnades manufactured on CNC machines ensure precise consistency across the entire batch. This is critical for repetitive facade work.
We apply a factory-applied polyurethane hard coating to each component using a reactive spray method. At this stage, we check the surface hardness, uniformity of the coating, and absence of voids or pinholes. The EPS foam core is completely sealed before further finishing.
We pre-assemble column shafts, capitals, bases, arch forms, and entablature sections where site conditions permit. Each part is checked for dimensions and finish quality before packaging.
We deliver components pre-finished and ready for installation. Our team provides installation consultations and is available throughout the entire installation process.
Why Are EPS Foam + Hard Coat Polyurea Systems Replacing Traditional Materials?
Why are EPS foam systems lighter than stone and concrete?
Stone and concrete achieve their structural function through mass. A massive stone column provides load-bearing capacity due to its density of approximately 150-175 pounds per cubic foot. EPS foam weighs approximately 1.0-1.5 pounds per cubic foot. When the column is purely decorative, this mass represents engineering waste. EPS foam arcade systems provide an identical visual result while weighing approximately 95% less than stone. Meanwhile, the hard-coat polyurea coating provides surface durability that EPS foam alone cannot.
How does hard-coat polyurea improve durability?
It is a two-component reactive system, not a standard topcoat. It cures to a Shore D hardness of 60-80, making it significantly harder than acrylic or latex exterior paints. It's 100% waterproof and seamless, with no joints or voids through which moisture could penetrate the expanded polystyrene core. It operates continuously in temperatures ranging from -40°F to +250°F and accommodates micro-movements of the substrate without cracking. Columnar systems with hard-coat polyurea perform reliably in all climate zones of the United States.
Are architectural systems made with EPS foam cost-effective in the long term?
Absolutely. The total cost of ownership is superior in three areas: initial installation, maintenance, and replacement. Installation costs are 40-65% lower due to weight and labor savings. Maintenance is minimal—hard coat polyurea requires only periodic cleaning. And since individual components can be replaced without structural work, repair costs are a fraction of those of concrete or masonry alternatives. Over 20 years of operation, polystyrene foam facade systems have consistently provided a lower overall cost than any similar structures made of heavy materials.
Pros and Cons Summary
Let's discuss the advantages of arcade and columnar systems made of EPS foam and hard-coat polyurea in more detail.
The EPS foam core has a density of 1.0–1.5 lb/ft³, making it 95% lighter than precast concrete and stone. It is non-hygroscopic by nature, meaning it does not absorb moisture, nor does it mold or rot.
The Hard Coat Polyurea shell has a Shore D hardness of 60–80, is seamless, and is 100% waterproof. The coating is UV-stable according to ASTM G154 and has a temperature range of -40°F to +250°F. It accommodates micromovement without cracking or delamination.
We can provide an unlimited number of custom profiles using CNC machining, meaning no tooling costs.
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Prefabricated, prepainted elements require minimal on-site labor. We guarantee compatibility with stucco, EIFS systems, and all exterior finishing systems.
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Service life of 25–40+ years with minimal maintenance. Installation costs are 40–65% lower than concrete's.
There are also some limitations that should be considered.
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EPS foam is not intended for load-bearing structures. For all exterior applications, application of hard-coat polyurea is required. The uncoated core must not be left exposed.
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Sharp impacts from tools or machinery can damage the EPS foam core if the skin is damaged. These elements are not suitable for areas with a high risk of mechanical impact (dock areas, loading areas).
Start Your Custom Arcade or Colonnade Project with Royal Foam US
Royal Foam US delivers custom arcade systems and exterior colonnade systems for luxury residential and commercial projects across Jacksonville, Florida, and nationwide. Our team has over 25 years of in-house manufacturing. We provide fast estimates, dedicated account management, CNC precision fabrication, and pre-assembled delivery.