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Premium Quality

Faux Wood Trusses Systems

Add warmth and structure to open spaces
25+ years
expirience
5000+
projects
Custom
designs

Who Is This Solution For

From structural post to architectural statement. EPS architectural shapes that look like wood — without the weight, cost, or structural engineering. Built to spec, installed in hours.

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System Architecture
EPS Core + Polyurea Shell vs. Conventional Materials SYSTEM ARCHITECTURE Integrated Multi-Layer System

Our company's architectural products are engineered as a fully integrated system composed of:

  • EPS Core - 1.0-2.0 lb/ft³ density
  • Polyurea Coating - two-component, 30-60 mils
  • Adhesion Primer
  • UV-Stable Finish Coat

This is not a sequence of separate layers. It is a closed engineered envelope where every component has a defined structural or protective role.

Functional Role of Each Layer EPS Core
  • Provides geometric form
  • Maintains dimensional stability
  • Reduces total weight
Polyurea Shell
  • Adds mechanical resistance
  • Provides chemical inertness
  • Blocks moisture intrusion
Primer Layer
  • Ensures bond integrity between materials
Finish Coat
  • Protects against UV exposure
  • Stabilizes final appearance
Why Conventional Materials Fall Short

WOOD

  • Vulnerable to moisture and decay
  • Requires constant maintenance
  • Can structurally degrade in 3-7 years in harsh climates
FIBERGLASS
  • Dependent on rigid molds
  • Limited to prefabricated shapes
  • Custom designs become expensive
PVC
  • Thermal expansion: 5-8 × 10⁻⁵/°C
  • Can warp, open joints, and lose dimensional accuracy under temperature swings
PRECAST CONCRETE / NATURAL STONE
  • Extremely heavy
  • Requires cranes and reinforced substrates
  • Slower, more complex installation process
Performance Advantages of Our Company
  • CNC PRECISION: ±3 mm across any profile
  • WEIGHT REDUCTION: 60-80% lighter than reinforced concrete
  • FASTER INSTALLATION: no heavy lifting equipment required
  • LOWER STRUCTURAL LOAD: reduced dead load on building envelope
  • WIND RESISTANCE: 120-180 PSF
  • CODE ENGINEERING: designed to Florida Building Code requirements
  • PERMIT READY: substrate-specific anchorage by licensed engineer
Final Result

Our company is not a decorative surface treatment.

It is a fully documented, engineered, permit-ready architectural system designed to move efficiently from fabrication to installation without rework.


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Material Composition
Engineering Advantages of EPS/Polyurea Over Wood, PVC, and Fiberglass Engineered Composite System

Our company’s products are built on a composite material architecture that no single conventional material can replicate.

Core Structure
  • EPS TYPE I - 1.0 lb/ft³ density
  • EPS TYPE II - 2.0 lb/ft³ density
  • Classified under ASTM C578
  • Closed-cell EPS foam
  • Water absorption: BELOW 2% per ASTM C272
Why It Matters

This low absorption threshold is critical for facade elements exposed to:

  • Wind-driven rain
  • Condensation cycles
  • Sustained humidity
Protective Outer Shell

Far exceeds conventional paints and gelcoats in durability and service resistance.

Polyurea Coating
  • 30-60 mil thickness applied
  • 70-85 Shore D hardness
  • High impact resistance
  • High abrasion resistance
  • Chemical inertness
Technical Comparison with Competing Materials WOOD
  • Hygroscopic by molecular structure
  • Shrinks, warps, and separates under wet/dry cycles
  • Vulnerable to fungi and insects
  • Structural degradation in 3-10 years in warm humid climates
ENGINEERED LUMBER
  • Reduces variability
  • Still moisture-sensitive
  • Still biologically vulnerable
PVC
  • Elastic modulus loses stiffness above elevated temperatures
  • Creeps under self-weight and wind pressure
  • UV causes embrittlement and pigment breakdown in 10-15 years
FIBERGLASS
  • Often lacks third-party certified data in custom fabrication
  • Gelcoat damage allows hidden water intrusion
  • Internal delamination may remain invisible until failure
Failure Modes Eliminated by Our Company

Our company EPS + Polyurea removes all common substrate failures:

  • No cellulosic substrate to rot
  • No metal component to corrode
  • No thermoplastic matrix to creep
  • No laminate interface to delaminate
Long-Term Client Value Projected Service Life:

15-25+ years

Maintenance Interval:

10-15 years

Topcoat refinishing only.

Delivered Performance

ASTM-traceable performance data.

Based on documented standards, not marketing claims.

Final Statement

Our company is a measurable, testable, engineered exterior product system designed for long-term architectural performance.


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Visual Presence
Architectural Expression as an Engineering Parameter

The visual authority of an architectural product is not a subjective attribute - it is a direct function of measurable geometric precision.

Profile relief depth of 25-150 mm generates shadow lines that establish legible architectural form at distances of 20-50 meters.

Symmetry held to ±3 mm, achieved through CNC milling, eliminates the bilateral distortions inherent in hand-carved wood or hand-laid fiberglass.

Products projection geometry - the proportional system that defines classical and contemporary architectural orders - reads as a quality signal to specifiers, occupants, and the broader market.

These are engineering parameters, and Our company products are manufactured to deliver them consistently across every unit produced.

Conventional materials cannot achieve this level of geometric control in service.

Extruded PVC profiles are constrained to planar cross-sections: three-dimensional transitions, multi-axis relief, and compound curves are physically inaccessible to the extrusion process.

Standard fiberglass in open-mold production exhibits surface irregularities - exposed glass fibers, resin-rich zones, and porosity - that are visually apparent at close inspection and degrade the premium quality signal.

Wood surfaces crack at the interface between growth rings as moisture content cycles seasonally; within the first year of outdoor exposure in a warm climate, sharp profile edges at elements begin to open, compromising the geometric integrity the architect designed into the project.

Our company’s products maintain original fabricated geometry throughout their service life

The EPS core does not absorb moisture, does not swell or shrink, and does not respond to thermal cycling with dimensional change.

The polyurea shell does not crack, peel, or delaminate under normal service loads.

The resulting surface - smooth, dimensionally stable, and uniform in reflectance - performs equally well under direct daylight, at night under architectural uplighting, and in professional photography.

Clients and end-users receive a facade element with a measurable contribution to property value: documented curb appeal, photogenic quality, and architectural identity that directly support occupancy rates, sale price premiums, and brand differentiation for the developer.


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Durability
Systemic Service Performance of EPS/Polyurea in Demanding Climates

Warm, coastal, and high-humidity climates present a compound durability challenge for exterior architectural products: wind-driven rain, sustained UV exposure, biological growth, salt-laden air, and diurnal thermal cycling all operate simultaneously and without interruption for the full service life of the installation.

Any material selection that addresses only one or two of these mechanisms while remaining vulnerable to the others will produce premature failure.

Our company EPS/polyurea products are engineered to resist all active degradation mechanisms in parallel, not in sequence.

The polyurea coating at 30-60 mils functions as a continuous elastomeric barrier - no seams, no capillary channels, no porous zones through which moisture can migrate to the EPS core.

With Shore D hardness of 40-70, it resists pedestrian-level mechanical impacts (tool contact, equipment brushing, incidental loading) at a level unachievable with conventional latex paint or fiberglass gelcoat.

The EPS core is chemically inert: it does not provide a metabolizable carbon source for fungal or bacterial colonization, does not react with moisture, and does not contain ferrous components capable of corrosion.

When joints and terminations are properly detailed and sealed, the assembled system delivers high moisture resistance performance even under sustained wind-driven rain exposure.

COMPETING MATERIALS FAIL BY DOCUMENTED MECHANISMS.

Wood demands repainting every 3-5 years, chemical treatment against insect attack, and annual inspection for decay - cumulative 20-year maintenance expenditure routinely exceeds original installed cost.

PVC embrittles and discolors under UV in 7-10 years; thermal expansion mismatches at joints create pathways for water infiltration.

Fiberglass delaminates internally when the protective gelcoat is breached, a failure mode that is undetectable without non-destructive testing until visible surface collapse occurs.

Clients who specify our company products receive a warranted system service life of 15-25+ years, a predictable maintenance cycle of topcoat refinishing every 5-10 years, and resistance to biological, mechanical, UV, and moisture degradation that does not require the owner to manage multiple separate protection programs.


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Compliance
EPS/Polyurea as a Fully Documentable System REGULATORY APPROVAL OF EXTERIOR ARCHITECTURAL ELEMENTS IS NOT A FORMALITY - it is a critical path item in the construction schedule.

A rejection from the Authority Having Jurisdiction (AHJ), a request for additional engineering data from the HOA, or a code-compliance question from the plan reviewer can delay a project by weeks, trigger contract penalty clauses, and require the design team to produce documentation under time pressure.

Selecting a material system with a complete, pre-existing compliance package is a direct risk mitigation strategy for the owner, developer, and general contractor.

ASTM C578classifies EPS foam by type and provides numerical values for density, compressive resistance, flexural strength, and thermal conductivity - the language of structural engineers and code reviewers.

ASTM C272quantifies water absorption of cellular plastic insulation, providing the test data required for moisture-related code provisions.

ASTM E84establishes surface burning characteristics for flame spread and smoke development, essential for commercial occupancies and interior code compliance.

The Florida Building Code wind load requirements of 120-180 PSF (depending on exposure category and geographic location) are addressed through engineered anchorage design produced by a licensed professional engineer - not generic installation guidelines.

This stands in direct contrast to unstandardized wood assemblies, which have no unified certification system for decorative architectural elements, and to custom fiberglass products that frequently lack third-party material certification entirely.

Our company compliance package includes:
  • Shop drawings with anchorage details
  • Material specifications with ASTM references
  • Engineering calculations for wind load resistance
  • Safety data sheets for all coating components

Everything an AHJ, HOA, or municipal permitting office requires in a single submission.

Clients receive a product that passes code review on the first submission, eliminating the cost of re-engineering, resubmission fees, schedule delays, and legal exposure associated with non-compliant installations.


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Cost Efficiency
Total Cost of Ownership Advantage of EPS/Polyurea Over Competing Systems TOTAL COST OF OWNERSHIP AS THE TRUE ECONOMIC MEASURE

The economic case for any architectural material system cannot be made on unit purchase price alone.

The total cost of ownership (TCO) integrates:

  • Procurement
  • Installation labor
  • Equipment rental
  • Freight handling
  • Routine maintenance
  • Unplanned repair
  • End-of-life replacement

This applies over the full service life - a horizon of 15-25 years for exterior facade elements.

On this complete accounting basis, our company’s EPS/polyurea products consistently outperform every competing material category, including wood, PVC, fiberglass, and precast concrete.

INSTALLATION AND FREIGHT ECONOMICS

Installation economics are driven by weight.

Weight Advantage

At 60-80% less mass than reinforced concrete and natural stone, our company products require:

  • No crane equipment
  • No reinforced substructure
  • No extended cure periods
Labor Efficiency

A crew of 2-4 workers installs a typical product set in 4-8 hours, compared with multi-day schedules for masonry piers, precast element assemblies, or cast-in-place concrete.

Freight Efficiency

Freight economics follow directly: a given truck load carries significantly more EPS product by volume and by count than any masonry or stone alternative, reducing per-unit delivered cost.

CNC Production Efficiency

CNC fabrication eliminates hand-finishing labor inherent to wood and stone production and produces consistent output with a near-zero defect rate:

  • No rework
  • No field modification
  • No waste from material variability
CUSTOM GEOMETRY ECONOMICS

Custom geometry economics are fundamentally different for EPS/polyurea versus competing systems.

Competing Systems

Fiberglass custom profiles require fabrication of molds and counter-molds at $2,000-$15,000 per profile, with lead times of 3-8 weeks.

PVC custom extrusion dies carry comparable tooling costs.

Wood custom millwork requires specialized equipment, skilled labor, and extended production time.

Our Company Advantage

With our company, any geometry is milled directly from a digital model at no tooling premium - a single profile or a full production run carries the same per-unit fabrication cost structure.

LONG-TERM MAINTENANCE SAVINGS

Long-term maintenance includes major advantages:

  • No rot means no chemical treatment programs
  • No pest control contracts
  • No emergency replacement of decayed elements
  • Topcoat refinishing every 5-10 years is the only planned maintenance expenditure
  • Individual damaged components can be replaced in isolation without disturbing adjacent elements
FINAL ECONOMIC RESULT

On a 20-year TCO basis, our company delivers the lowest total cost of any equivalent architectural product category.


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Speed of Installation
EPS/Polyurea as a Construction Schedule Compression Tool IN COMMERCIAL CONSTRUCTION, SCHEDULE COMPRESSION IS A DIRECT REVENUE STRATEGY.

Every day of accelerated project delivery reduces financing carrying costs, advances the revenue start date for the completed asset, and reduces general conditions expenditure - site supervision, temporary facilities, and overhead.

Facade element installation is frequently a schedule-critical activity: it gates exterior envelope closure, painting, and final inspections.

The material system selected for architectural products therefore has a direct and quantifiable impact on project economics, not just on installed appearance.

OUR COMPANY PREFABRICATED PRODUCTS ARRIVE ON SITE FULLY PROCESSED: EPS-SHAPED, POLYUREA-COATED, PRIMED, AND FINISH-COATED.

There is no formwork to build, no concrete to pour, no cure period to observe, no wet-trade sequencing to coordinate.

Fast-cure polyurea coating systems reduce factory finishing cycle time to hours per production run - a throughput rate that fiberglass laminating and wood finishing operations cannot match.

A typical installation of a complete product set requires a crew of 2-4 workers and 4-8 hours of on-site labor, versus multi-day or multi-week schedules for masonry piers, precast assemblies, or site-built wood elements.

The dry-installation method eliminates weather-dependent cure windows that routinely extend wet-trade schedules in high-humidity and rain-prone environments.

CNC FABRICATION PROVIDES AN ADDITIONAL SCHEDULE ADVANTAGE AT THE DESIGN STAGE.

Custom profile geometry is produced by modifying a digital model and initiating a milling run - a process measured in hours, not the weeks required to fabricate new fiberglass molds or commission custom extrusion tooling.

When design changes occur late in the project timeline, Our Company can respond without a schedule penalty.

Prefabrication also reduces site congestion: fewer trades, less equipment, and a compressed installation window mean that other parallel activities on the critical path are not disrupted.

Clients receive a measurable construction schedule advantage, a documented reduction in general conditions cost during facade installation, and earlier building turnover - all direct contributions to project-level return on investment.


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Customization
EPS/Polyurea Delivers Design Freedom Unavailable in Competing Systems CUSTOMIZATION IS BUILT INTO THE PROCESS

Architectural customization is not a feature added to the EPS/polyurea production process - it is inherent to the CNC milling technology on which the process is based.

A CNC mill operates from a three-dimensional digital model and reproduces any geometry the model defines, at the same per-unit cost regardless of profile complexity.

This creates major manufacturing advantages:

  • No tooling penalty for unique geometry
  • No minimum run size for custom profiles
  • No dimensional constraint imposed by the manufacturing process itself
WIDE GEOMETRIC AND SURFACE CAPABILITIES

The practical range of geometric parameters is extensive.

Architectural orders - Doric, Ionic, Corinthian, Tuscan, and Composite - are reproduced from measured drawings or high-resolution reference photography to profile tolerances of ±3 mm.

Contemporary and proprietary profiles developed by the project architect are produced directly from CAD files without intermediate tooling.

DIMENSIONAL RANGE

Dimensional range extends from slender decorative elements to large-scale architectural components exceeding 900 mm in cross-section and 7.3 m in height, fabricated in interlocking segments for shipping and field assembly.

SURFACE TREATMENTS

Surface treatments include:

  • Smooth paint-ready finishes
  • Faux stone textures
  • Custom tactile profiles
  • Applied decorative bands

All achievable within the same production system.

RENOVATION AND WRAP APPLICATIONS

The wrap configuration - EPS/polyurea cladding fabricated to enclose an existing structural post or element - extends the application of Our Company products to renovation and restoration work where structural elements are already in place.

This single capability addresses a major gap in the competing product range:

  • Fiberglass and PVC do not offer field-adaptable wrap systems
  • Wood wraps are limited by available lumber dimensions
  • Wood remains vulnerable to the same decay mechanisms as solid wood elements
DIRECT COMPETITIVE COMPARISON

Custom fiberglass profiles require mold fabrication at $2,000-$15,000 per profile with 3-8 week lead times.

Custom PVC requires extrusion die investment with comparable cost and timeline.

Custom stone or wood millwork involves manual production at hourly craft rates with high variability.

Our company custom product is priced and scheduled on the same basis as standard product.

FINAL CLIENT BENEFIT

Clients receive architectural elements that precisely match the design specification:

  • No dimensional compromise
  • No design simplification
  • No cost penalty for doing the project right

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Engineering
EPS/Polyurea as a Fully Designable Technical System Documentability as the Core Engineering Criterion

The defining criterion for material selection in engineered construction is documentability: the ability to assign specific, defensible numerical values to material properties, use those values in structural calculations, and have the resulting design reviewed and approved by a licensed engineer and the Authority Having Jurisdiction.

Why Competing Materials Fall Short

Wood fails this criterion for decorative architectural elements because its properties vary by species, moisture content, grain orientation, and defect distribution.

Reference standards such as the NDS provide design value ranges, not precise values.

Custom fiberglass often fails because the fabricator cannot provide certified laminate property data for third-party engineering review.

PVC is classified as a non-structural thermoplastic and is not used in engineered resistance calculations for wind or gravity loads.

EPS/polyurea is the only system in this competitive set that can be fully characterized, parametrically adjusted, and submitted to engineering review with complete material documentation.

PARAMETER-BASED ENGINEERING DESIGN

Our company system is engineered by parameter selection, not by default.

EPS Core Selection

Type I: 1.0 lb/ft³, compressive resistance approximately 10 psi per ASTM C578

Type II: 2.0 lb/ft³, approximately 25 psi

Selection is based on service load requirements, exposure conditions, and substrate configuration.

POLYUREA SPECIFICATION

Polyurea coating thickness is specified in the range of 30-60 mils based on:

  • Impact exposure
  • Moisture risk classification
  • Durability requirements for the specific installation
  • Anchorage engineering
Anchorage Engineering

Anchorage design is produced by the engineer of record, with fastener type, spacing, and embedment depth calculated for wind pressures of 120-180 PSF per the Florida Building Code, accounting for:

  • CMU
  • Cast concrete
  • Wood framing
  • Structural steel
  • Element geometry
  • Digital accuracy

CAD/CNC digital workflow ensures that fabricated geometry matches the engineered drawings to ±3 mm tolerance across every unit in the production run.

COMPLETE DOCUMENTATION PACKAGE

Our company technical documentation package includes:

  • Shop drawings with all anchorage details and section cuts
  • Complete material specification with ASTM standard references for every component
  • Engineering calculations stamped by a Florida-licensed professional engineer when required
  • Installation guidelines coordinated with AHJ submittal requirements
CLIENT AND APPROVAL BENEFITS

This package allows a structural engineer of record to defend the installation to any reviewing authority, and allows the owner to verify that the installed system performs to its calculated wind resistance rating specification.

Clients do not receive a product - they receive a fully engineered system with documented design basis, traceable material properties, and professional engineering accountability at every level of the specification.


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Aesthetics
EPS/Polyurea as a Premium Architectural Product AESTHETICS AS AN ECONOMIC VARIABLE

Architectural aesthetics function as a measurable economic variable.

Studies of the U.S. commercial and residential real estate market consistently demonstrate that high-quality facade detailing:

  • Increases perceived property value by 5-15%
  • Reduces time-on-market for sale or lease transactions

For developers and property owners, the selection of architectural products that deliver premium visual quality is not a design preference - it is an investment allocation decision with a calculable return.

Our company products are specified for this reason by architects, developers, and restoration professionals who understand that facade quality is directly priced by the market.

PRECISION ARCHITECTURAL REPRODUCTION

Our company architectural products reproduce classical and contemporary architectural language at a level of precision that competing systems cannot achieve in production.

Geometry Quality

Capital and base projection geometry - the shadow-casting elements that establish architectural order and visual hierarchy - is milled to profile depths of 25-150 mm with edge sharpness and symmetry that extrusion, laminating, or handwork cannot consistently replicate at scale.

Surface Quality

The surface is delivered:

  • Smooth
  • Pore-free
  • Free of process artifacts
  • No exposed glass fiber
  • No resin streaking
  • No tool marks
  • No grain telegraphing through the finish

This surface quality is essential for:

  • High-specular architectural paint systems
  • Architectural uplighting
  • Professional photography of the completed building

All of which depend on a defect-free substrate to perform as designed.

PROPORTION AND DESIGN CONSISTENCY

Proportion control - the ratio of element projections that defines architectural order - is maintained by digital modeling and CNC production, not by skilled tradesperson judgment.

This means that every unit in a project, regardless of production sequence or crew, matches the architect's specified proportions exactly.

SURFACE AND COLOR FLEXIBILITY

Surface texture options extend from smooth through faux stone to fully custom tactile profiles, allowing the facade system to match the material language of the broader architectural composition.

Color specification is unlimited - any RAL, Munsell, or custom-mixed topcoat can be applied to the polyurea shell, providing exact palette coordination with adjacent facade materials.

FINAL MARKET BENEFIT

Clients receive a finished architectural product that:

  • Strengthens the developer's brand identity
  • Supports premium pricing
  • Supports higher occupancy rates for the completed asset
  • Delivers long-term visual impact that does not degrade with age under normal service and maintenance conditions

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Technical specification

Faux Wood Trusses

Faux Wood Trusses 1

Faux Wood Trusses 1

Faux Wood Trusses 2

Faux Wood Trusses 2

Faux Wood Trusses 3

Faux Wood Trusses 3

Faux Wood Trusses 4

Faux Wood Trusses 4

Faux Wood Trusses 5

Faux Wood Trusses 5

Faux Wood Trusses 6

Faux Wood Trusses 6

Faux Wood Trusses 7

Faux Wood Trusses 7

Faux Wood Trusses 8

Faux Wood Trusses 8

Height (H), in Width (W), in Length (L), in
47" 7" 196"
59" 8" 236"
67" 10" 275"
78" 12" 354"
90" 14" 433"
98" 16" 472"
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

Available styles and textures

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 We Work

How to Order from Royal Foam

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!

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 ·

Free Quote Request

Our Partners

Testimonials

Their custom work is unmatched. I had a historic renovation project that required matching existing 1920s archway details, and the team nailed it. The expanded polystyrene significantly speeds up installation times compared to working with actual stone or concrete, my crew loves it.

Timothy Meyer

We ordered decorative window arches and keystones from Royal Foam, and they fit perfectly with the colonial style of our house. I was nervous about ordering online, but the consultation process was thorough and helpful, and they answered all my questions about installation and weather protection. Highly recommend.

Kevin Farley

Thank You Royal Foam for providing me with the gorgeously designed monument sign I had ordered for my newly opened company.

Daniel Bryan

Let's bring your project to life!

Frequently Asked Questions

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They’re not solid wood — they’re high-density polyurethane cast from molds made using real timbers. That means every knot and grain is borrowed from an authentic board. They’re not flimsy or “cheap plastic.” They’re tough, stable, and fool even carpenters.
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Short answer: they look real. Long answer: we’ve had builders who installed them with their own hands still shake their heads and say, “I’d swear this is oak.” Up close you see grain, you feel texture, even the little saw marks. It’s the illusion that wins every time.
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Relax, no kidneys needed. Faux wood trusses almost always cost less than timber once you count cranes, reinforcements, insect treatments, and years of maintenance. Clients often brace for a scary number and end up laughing when they see the final quote.
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You absolutely can. Porches, patios, pergolas — we’ve done them all. With the right finish, they hold steady through blazing summers, salty air, even snowstorms. One Florida client called after hurricane season just to say: “Still perfect.”
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Not necessarily. We use slim profiles and lighter colors for ranch houses and low ceilings. Funny enough, the rhythm of beams can actually make a flat ceiling feel taller. One homeowner admitted: “We thought it would shrink the room. It feels bigger.”
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That’s the beauty — they’re light. Two installers can carry a section that solid oak would need five men for. No structural nightmares, no reinforced foundations.
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They absolutely add value. Realtors say homes with dramatic ceilings photograph better, show better, and sell faster. Buyers walk in, look up, and instantly remember the house.
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They’ll last for decades. They don’t sag, don’t crack, and bugs couldn’t care less about them. We’ve got clients who installed them years ago and haven’t touched them since.
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No way. Black beams in a loft, pale gray on a coastal cottage, espresso in a modern living room — faux wood adapts to whatever style you live in. Rustic is just one option.
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Think of trusses as the framework, the skeleton that sets the rhythm of a ceiling. Beams are accents, the notes between the chords. One defines structure, the other decorates it.
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Nope. Inside? Just dust them now and then. Outside? A quick rinse and you’re good. That’s it.
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Old trick: tape outlines on your ceiling and live with them for a day or two. Morning and evening light will tell you what feels right better than any catalog. Clients swear by it.
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Yes, yes, and yes. They handle heavy snow, salty air, desert heat — they don’t warp, crack, or swell. Different climates, same peace of mind.
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They do. A lot of clients notice less echo, especially in big open rooms. It’s not soundproofing, but it does make conversations feel warmer and less “hollow.

Blog posts

Faux Wood Trusses

Faux Wood Trusses: When Design Meets Common Sense

Picture this. You walk into a mountain lodge in Colorado, or maybe a boutique winery out in Sonoma. Or even a converted warehouse apartment in downtown Dallas. What’s the first thing your eyes do? They wander upward. And what’s waiting overhead is almost always the same: strong lines, a rhythm of beams that tie the whole space together. The surprise? Most of the time, those beams aren’t timber at all. They’re faux wood trusses.

People stop under them, tilt their heads back, and whisper: “Wow, those beams are stunning.” Some even reach up, tap them with their knuckles, and then shoot that look — “No way these are fake.” But yes, they are. And that’s the beauty. You get the look, the weight of history, the craftsmanship — without the pests, without the endless maintenance, and without the crushing costs that real wood brings.

Why People Keep Turning to Faux Wood Trusses

Let’s not sugarcoat it: real wood trusses are gorgeous. They smell like pine in the sun, they creak with character, and they make a brand-new home feel as if it’s been standing for a hundred years. However, they also come with baggage.

Weight. Real timbers are heavy — so heavy they strain foundations.
Logistics. Deliveries mean cranes, blocked streets, and entire crews waiting.
Movement. Wood shifts with the seasons — gaps in January, swelling in July.
Insects. Termites, beetles, carpenter ants… they love wood more than you do.

Faux wood trusses sidestep all of that. Consequently, two installers can carry what would take five men with oak. Humidity won’t twist them. They don’t invite termites to dinner. And the budget? Predictable — therefore no “surprise” invoices months later.

The Magic: How Faux Wood Beams Change a Room

It’s not just about saving money or making life easier. Instead, the real magic is how they change the feel of a room. We’ve seen restaurants where the ceiling — not the food — became the most photographed thing on Instagram. We’ve seen living rooms suddenly feel warmer, almost like they’re giving the family a hug. One couple even told us: “We spend more evenings together now. The ceiling makes the room feel alive.”

That’s not an exaggeration. Once the trusses go up, the atmosphere changes. Period.

The Truth About “Faux”

Not long ago, “faux” meant second-rate. Fake. Something you bought because you couldn’t afford the real deal. But now, step under today’s faux wood beam trusses and the illusion wins.

Every grain, every ridge, every tiny saw mark is cast from actual wood. In fact, the eye buys it instantly. The hand buys it too. Even old-school carpenters — the kind who can spot oak from across a room — often run their fingers across a truss and laugh: “If I hadn’t installed this myself, I’d swear it was timber.”

Unlike natural beams, these won’t crack without warning, sag with age, or darken into shades you never asked for. Instead, they stay as they are: believable, reliable, beautiful.

Where They Really Shine

  • Cabins that want a rustic soul without structural stress

  • Lofts that feel cold until espresso-dark beams warm the space

  • Restaurants where atmosphere matters as much as the menu

  • Outdoor spaces — porches, pergolas, patios — where wood usually fails

One chef nailed it: “If the beams stay beautiful without me worrying, I can focus on the food.” That, ultimately, is a trade worth making.

Custom Faux Wood Trusses: Because One Size Never Fits All

King Post: bold, ceremonial, an architectural handshake.
Queen Post: balanced, elegant, almost musical.
Scissor Trusses: cathedral lift without cathedral drama.
Hammerbeam: the showstoppers — they stop guests cold.

And finishes? They make all the difference. Driftwood gray for coastal calm. Deep espresso to ground a modern loft. Barnwood gray that convinces guests the beams came from a century-old barn. Meanwhile, walnut tones feel timeless and warm.

We once had a client bring an old carved mantelpiece and say: “Match this.” The trusses went up, and the entire house suddenly felt like it was singing in tune. That is what custom design does — it turns beams into storytelling.

Commercial Projects: When Ceilings Become Identity

At home, trusses bring warmth. However, in business, they create memory.

A winery in California wanted aged beams but feared termites. Faux delivered.
A city restaurant needed rustic charm without downtime. Faux solved it.
A resort hotel wanted grandeur without stressing marble floors. Faux made it possible.

Guests don’t just remember the meals or the check-in. They remember the ceiling. That’s branding you can’t replicate any other way.

Real vs. Faux Wood Trusses

Let’s keep it straight:

Real wood trusses: historic, structural, authentic — but heavy, expensive, high-maintenance.
Faux wood trusses: decorative, lightweight, budget-friendly, low-maintenance — and authentic in appearance.

Unless your roof depends on real timber, faux wood trusses are almost always the smarter choice.

A Historian’s Note

Romans spanned basilicas with timber frames. Medieval England gave us hammerbeam halls. Japanese temples curved cedar into poetry. American colonists raised barns with oak skeletons.

Wood trusses were never just supports. They were culture, craft, identity. Today, faux trusses keep that heritage alive — giving modern spaces the same rhythm without the medieval headaches.

Hidden Bonuses Nobody Expects

Clients call months later to share discoveries:

  • Rooms feel quieter — echoes die down.

  • Morning light turns beams into sculpture; evening lights turn them into art.

  • Faux doesn’t radiate heat — it only looks warm.

  • No strange smells.

  • From salty coasts to snowy mountains, they hold steady.

  • Eco-friendly bonus: fewer old forests cut down.

These “little things,” therefore, often become the biggest reasons people fall in love with them.

Light + Faux Wood Trusses = Atmosphere

Light is theater. Natural sun skims the grain by day. At night, uplights turn joints into sculpture. We’ve seen couples toast anniversaries under glowing beams. Restaurants triple their tagged photos after lighting upgrades.

One rule: install dimmers. Always.

Working With Designers and Contractors

Design is part choreography, part diplomacy. Architects sketch. Designers debate palettes. Owners stress about budgets. Meanwhile, our job is to translate. Show how trusses align with fireplaces, how finishes tie into cabinetry, how shadows fall.

Contractors appreciate it. One joked: “You guys are like ceiling traffic cops.” He wasn’t wrong.

Strength Without Stress

Real oak looks strong — and is. But, it stresses everything around it. Homeowners sometimes admit they can’t sleep during storms, afraid beams might sag.

Faux trusses eliminate that fear. They give permanence without pressure.

America’s Way of Building

From desert Arizona to snowy Vermont, Americans want bold design without upkeep.

  • In Arizona, mission-style homes needed arches and trusses — but timber warped. Faux saved the look.

  • In Vermont, a ski lodge wanted tradition but feared snow load. Faux again delivered.

Different climates, same result.

The Small-Space Surprise

Not every home has cathedral ceilings. One ranch had eight-foot ceilings. Owners feared beams would shrink the room. Solution? Slim profiles, lighter finishes.

Surprisingly, the room felt taller. Sometimes the right lines add air rather than steal it.

Architecture That Changes Behavior

This isn’t just about looks. It’s about how people live. Families gather more. Kids do homework in the kitchen. Dinners last longer. One homeowner said it perfectly: “We didn’t just buy faux wood trusses. We bought the atmosphere.”

The Future of Faux

Finishes sharpen yearly. Profiles expand. Hybrid designs now wrap steel in faux wood for strength and authenticity.

The future? Spaces that feel historic without cutting historic trees.

Life After Install

Week one: You can’t stop looking up.
Six months: You forget — but host more.
One year: Still flawless.
Five years: Paint may change, furniture may change — the ceiling stays the anchor.

One client said: “The trusses are the one design choice I’ve never regretted.”

Design Tips That Actually Work

  • Match trusses to floors or cabinetry for harmony.

  • Don’t chase perfection — imperfections sell the illusion.

  • Plan lighting before beams go in.

  • Add one hero detail — people will ask every time.

Faux wood trusses aren’t a compromise. Instead, they’re evolution. They take the language of wood — history, rhythm, presence — and translate it into modern design without the drawbacks. From a ranch in Texas to a hotel lobby in Chicago, ceilings with faux wood beams don’t just cover a room. They complete it.

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