Arches and Keystones - Royal Foam US Skip to content
Premium Quality

Decorative Arches and Keystones

Integrated arch systems that combine several elements into a single stylistic design
25+ years
expirience
5000+
projects
Custom
designs

Who Is This Solution For

Arches and Keystones

Arches 1

Arches 1

Arches 2

Arches 2

Arches 3

Arches 3

Arches 4

Arches 4

Keystones 1

Keystones 1

Keystones 2

Keystones 2

Keystones 3

Keystones 3

Keystones 4

Keystones 4

Type Height (H), in Depth (D), in Length (L), in
ArR_W 8" 2" 24"
8" 2" 30"
8" 2" 36"
8 1/2" 2 1/4" 42"
8 1/2" 2 1/4" 48"
8 1/2" 2 1/4" 60"
9" 2 1/2" 72"
9" 2 1/2" 84"
9 1/2" 2 3/4" 96"
9 1/2" 2 3/4" 108"
10" 3" 120"
10" 3" 144"
ArG_W 10" 2 1/2" 24"
10" 2 1/2" 30"
10" 2 1/2" 36"
10 1/2" 2 3/4" 42"
10 1/2" 2 3/4" 48"
10 1/2" 2 3/4" 60"
11" 3" 72"
11" 3" 84"
11 1/2" 3 1/4" 96"
11 1/2" 3 1/4" 108"
12" 3 1/2" 120"
12" 3 1/2" 144"
ArS_W 10" 2" 24"
10" 2" 30"
10" 2" 36"
10 1/2" 2 1/4" 42"
10 1/2" 2 1/4" 48"
10 1/2" 2 1/4" 60"
11" 2 1/2" 72"
11" 2 1/2" 84"
11 1/2" 2 3/4" 96"
11 1/2" 2 3/4" 108"
12" 3" 120"
12" 3" 144"
Length (L), in Depth (D), in Height (H), in
24" 4" 65"
26" 4" 65"
28" 4" 65"
32" 4 1/2" 70"
34" 4 1/2" 70"
36" 4 1/2" 70"
48" 5" 90"
52" 5" 90"
56" 5" 90"
60" 5 1/2" 105"
64" 5 1/2" 105"
68" 5 1/2" 105"
Width (W), foot Height (H), in Depth (D), in
10' 8" 7"
10' 10" 7"
12' 8" 8"
12' 10" 8"
14' 8" 8 1/2"
14' 10" 8 1/2"
16' 8" 9"
16' 10" 9"
18' 12" 9 1/2"
20' 12" 9 1/2"
24' 12" 10"
32' 12" 10"

Door Surround-Door 016

Door Surround-Door 016

Door Surround-Door 014

Door Surround-Door 014

Door Surround-Door 011

Door Surround-Door 011

Door Surround-Door 002

Door Surround-Door 002

Width (W), in Height (H), in Depth (D), in
48" 72" 7"
48" 80" 7"
54" 72" 8"
54" 80" 8"
60" 80" 8 1/2"
60" 82" 8 1/2"
72" 82" 9"
72" 84" 9"
110" 82" 9 1/2"
110" 84" 9 1/2"
120" 82" 10"
120" 84" 10"
Length (L), in Depth (D), in Height (H), in
24" 4" 65"
26" 4" 65"
28" 4" 65"
32" 4 1/2" 70"
34" 4 1/2" 70"
36" 4 1/2" 70"
48" 5" 90"
52" 5" 90"
56" 5" 90"
60" 5 1/2" 105"
64" 5 1/2" 105"
68" 5 1/2" 105"
Width (W), foot Height (H), in Depth (D), in
10' 8" 7"
10' 10" 7"
12' 8" 8"
12' 10" 8"
14' 8" 8 1/2"
14' 10" 8 1/2"
16' 8" 9"
16' 10" 9"
18' 12" 9 1/2"
20' 12" 9 1/2"
24' 12" 10"
32' 12" 10"

Door Surround-Door 036

Door Surround-Door 036

Door Surround-Door 042

Door Surround-Door 042

Door Surround-Door 025

Door Surround-Door 025

Door Surround-Door 023

Door Surround-Door 023

Width (W), in Height (H), in Depth (D), in
48" 72" 7"
48" 80" 7"
54" 72" 8"
54" 80" 8"
60" 80" 8 1/2"
60" 82" 8 1/2"
72" 82" 9"
72" 84" 9"
110" 82" 9 1/2"
110" 84" 9 1/2"
120" 82" 10"
120" 84" 10"
Length (L), in Depth (D), in Height (H), in
24" 4" 65"
26" 4" 65"
28" 4" 65"
32" 4 1/2" 70"
34" 4 1/2" 70"
36" 4 1/2" 70"
48" 5" 90"
52" 5" 90"
56" 5" 90"
60" 5 1/2" 105"
64" 5 1/2" 105"
68" 5 1/2" 105"
Width (W), foot Height (H), in Depth (D), in
10' 8" 7"
10' 10" 7"
12' 8" 8"
12' 10" 8"
14' 8" 8 1/2"
14' 10" 8 1/2"
16' 8" 9"
16' 10" 9"
18' 12" 9 1/2"
20' 12" 9 1/2"
24' 12" 10"
32' 12" 10"

Our material vs Competitors

Property Our Material (EPS) Wood Concrete Polyurethane Fiberglass
Weight Very lightweight Medium Very heavy Light Light
Thermal Insulation Excellent Moderate Poor Excellent Good
Moisture Resistance High (does not absorb water) Low (absorbs moisture) Medium High Medium
Durability Long-lasting, stable Can rot or warp Very durable Durable Fragile over time
Fire Behavior Melts under high heat Burns Fire-resistant Flammable (treated variants available) Non-combustible
Ease of Installation Easy, fast, low labor cost Moderate Difficult, labor-intensive Moderate Requires protection gear
Customization Highly customizable shapes & sizes Limited Very limited Moderate Limited
Cost Affordable Medium to high High High Medium

We offer 9 finish types. For custom color, we have mixes that allow us to make arhitectural products in almost any color.

All textures and colors are fully customizable for each individual project, ensuring complete flexibility in design and appearance.

Each our decorative architectural foam product is unique. We don’t “print” identical beams — we craft them as individual architectural pieces.

Discuss my project
Color palette

Why choose us

Value / Service Our company Competitors
Free Design Support Included in every project Usually not available
Product Customization Fully customized solutions Limited options
Engineering Consultation Direct access to engineers Rare or paid
Unique Prototype Development Yes, tailored prototypes Not offered
Personal Project Manager Dedicated manager for each client Not standard
Speed of Production Fast turnaround Slower processes
Client Support Ongoing support at all stages Limited after-sales support
Flexibility Tailored to any client requirements Standard solutions only

How it Works

Step 1. Adaptation
If you have a finished project, we adapt it for production and installation, preserving every detail.

Step 2. Define your vision
Capture a clear picture of the client’s ideas before moving to design and rendering.

Step 3. Plan specifications
Outline measurements, production methods, and finalize materials, components, and finishes.

Step 4. Installation
Our team ensures precise setup, perfectly aligning your custom surround with the space.

Step 1. Define your vision
The aim of this step is to capture a precise picture of the client’s vision before proceeding to technical design and visual rendering.

Step 2. Plan specifications
During this phase, we define the specifications, production methods, and measurements, while finalizing the look by selecting materials, elements, and finishes.

Step 3. Installation
Once fabrication is complete, our installation team will handle every aspect of the setup, ensuring your custom surround is fitted with accuracy and seamlessly integrated into your space.

Let's bring your project to life!

Map of the United States with the cities Royal Foam serves marked

Areas We Serve

We proudly serve clients across the United States, including major cities such as

· Jacksonville · Orlando · Miami · Atlanta · Dallas · Los Angeles · New York City · Chicago · Washington · San Francisco ·

Our Partners

Let's bring your project to life!

Voices of our clients

Been using Royal Foam for about 2 years now on various projects. Their CNC cutting capabilities mean I can get literally any design my clients wish, especially when it comes to complex arch structures. The EPS material is a real treasure for exterior work, cause it’s lightweight, weather-resistant, and looks absolutely authentic once painted. The turnaround time is also inspiring. As a rule, parts are manufactured within a couple of weeks at most. It's great when projects don't get stuck.

Phillip Cameron

We wanted to make our brick house fancier and decided on decorative arches over the windows. Honestly, I wasn't sure about foam at first, but the guys at Royal Foam explained the properties and installation details to me very clearly (btw, the consultation was free). The keystone details are so realistic - our neighbors think we added real cast stone, lol. Best part is they handle the Texas heat perfectly, don’t deform, and don’t fade even after a whole summer.

Raymond O'Neal

After installing an arch from Royal Foam not only the look has improved but also my home has become a lot more spacious. I suggest and thank Royal Foam. I will contact again to Royal foam for my new arch work at my home. Designs are very good and finishing is also good.

Amy Corey

If you're not using EPS for architectural details yet, you're behind the curve. Royal Foam has the best quality material I've found, and their range of equipment means they can produce any shape, even super complex ones. Just completed a luxury home in Florida with their custom arches and keystones - client thought it was real limestone until I told them otherwise.

Thomas Welsh

Frequently Asked Questions

+
Yes, even in non-standard climatic conditions. EPS architectural arches with a polyurea coating retain their appearance for more than 25 years, whether in coastal areas of Florida or northern regions with temperature fluctuations. The coating protects the surface against moisture, UV rays, extreme temperatures (from -40°F to 180°F), and salt exposure.
+
Sure, this is one of our company's core capabilities. Thanks to CNC technology, we can create unique geometric shapes with perfect precision, whether it's elliptical arches with a radius of 15 feet or four-centered Tudor-style structures. Custom orders increase the manufacturing time by 1-2 weeks with a minimal additional charge.
+
Properly installed decorative EPS arches will perform for more than 25 years when used outdoors. Indoor installations can last virtually indefinitely, as they are not exposed to the weather.
+
Only minimal. They need to be pressure-washed every 2-3 years, and the sealed joints need to be checked every 3-5 years. If necessary, foam arches can be repainted (acrylic latex paint is suitable).
+
It depends on the complexity of the arch shape and the number of parts that need to be installed. In general, our EPS arches are light enough for DIY enthusiast to mount them on their own. However, for large-scale projects, you’ll need the help of professionals. In any case, we include detailed installation instructions with your order and number the components to facilitate the assembly process.

Blog posts

Decorative arches help create elegant architectural accents for doors, windows, and facades. These curved elements frame openings and add visual depth to exterior design. In addition, keystones emphasize the center of the arch and complete the overall composition.

Traditional stone arches often create serious structural challenges. They are heavy, expensive to install, and require significant support. However, modern decorative arches manufactured from EPS foam solve many of these issues. Because the material is lightweight, builders can install arch systems without complex structural reinforcement.

As a result, architects and contractors frequently choose decorative arches for both residential and commercial projects.

Decorative arches for doors, windows, and facades

Decorative arches appear in many architectural styles. For example, residential homes often use them to highlight entrances and window openings. Commercial buildings also install decorative arches to create visually strong facades.

In addition, EPS foam construction makes installation significantly easier. Contractors can position and secure arch elements quickly because the material remains lightweight.

Therefore, decorative arches provide the classic appearance of masonry structures while simplifying construction work.

EPS foam decorative arches and keystones

EPS foam technology allows manufacturers to produce detailed architectural components with minimal structural load. Decorative arches produced from expanded polystyrene weigh far less than stone or concrete alternatives.

Because of this reduced weight, builders can install decorative arches without reinforcing existing walls. Moreover, protective polyurea coatings strengthen the surface and protect it from environmental exposure.

These coatings improve resistance to:

  • moisture

  • UV radiation

  • temperature changes

  • surface wear caused by outdoor conditions

As a result, decorative arches maintain their appearance even in demanding climates.

Precision manufacturing with CNC technology

Modern CNC equipment allows manufacturers to produce accurate curved shapes. Engineers first create digital models using CAD software. Then CNC milling machines cut EPS blocks according to programmed tool paths.

This process ensures precise symmetry and consistent dimensions. For example, paired decorative arches for doorways remain identical during production.

In addition, multi-axis CNC systems allow manufacturers to create complex shapes such as elliptical arches and detailed keystones.

Types of decorative arches

Architectural design often determines which arch form works best. Different shapes help create specific visual effects.

Roman arches

Roman arches feature a semicircular profile. This classic design distributes visual weight evenly and works well in traditional architecture.

They are commonly used in:

  • residential entrances

  • window surrounds

  • exterior facades

  • commercial buildings

Segmental arches

Segmental arches use a shallow curve rather than a full semicircle. Therefore, they work well in buildings where ceiling height is limited.

Architects frequently include them in Craftsman and Prairie style designs.

Elliptical arches

Elliptical arches feature elongated curves that emphasize vertical space. Designers often install them in large entryways or high-ceiling interiors.

Because of their geometry, these structures require precise manufacturing methods.

Decorative keystones as architectural accents

Keystones complete the visual structure of an arch. Historically they helped lock stone blocks together. Today decorative keystones serve mainly as design accents.

Manufacturers produce keystones in several styles:

  • smooth minimalist designs

  • fluted decorative profiles

  • scrollwork elements

  • cartouche panels for monograms

When combined with decorative arches, keystones create a complete architectural frame.

Advantages of lightweight arch systems

EPS decorative arches offer several practical advantages compared with masonry construction.

First, lightweight materials reduce structural load. Therefore, builders can install arches without major reinforcement.

Second, installation becomes significantly faster. Construction teams can position and secure arch components without heavy equipment.

Third, protective coatings improve durability.

EPS arch systems resist:

  • moisture exposure

  • UV radiation

  • temperature variation

  • outdoor surface wear

As a result, decorative arches remain stable and visually consistent for many years.

Decorative arches in modern construction

Architects continue to use decorative arches because they create strong visual rhythm across facades. At the same time, modern materials simplify installation and reduce construction costs.

EPS foam technology allows builders to achieve classical architectural designs without the engineering challenges of traditional masonry. Therefore, decorative arches remain a practical solution for both residential and commercial architecture.

Request a fast quote!

Contact Us

Catalog