BEYOND METAL

We created this oil rubbed bronze board room conference table by CNC milling the wood base and replicating aged and rusted real steel plates using our Cold Cast™ epoxy resin mixed with real bronze powder. This process allowed us to authentically replicate the color and texture of oil rubbed bronze with the added flexibility of being able to easily wrap the panels around the curved wooden base. An authentic industrial look and feel without the weight or rust.

AUTHENTIC REPLICATIONS OF ARCHITECTURAL METALS
THE LOOK WITHOUT THE WEIGHT

Any look and less weight. Whether it’s iron, steel, pewter, copper or titanium; plates, beams, pipes or channels; installation is beyond easy.

Our industrial artisans can hand cast materials with steely realism down to the last rivet, weld, hinge and gusset. FORMA Beyond commercial replications are a fraction of the weight of the real thing, yet they stand up to years of real-world use and never rust.

FORMA Beyond: ADVANTAGES OF COMPOSITE MATERIALS OVER METALS

  •  Replications of any type of metal, custom colors, surface textures, wear, antiquity and patina
  •  C-channels, I-beams, trusses, gussets, panels, feature walls, decorative structures, etc.
  •  Design concepts, custom samples, CAD, engineering, shop drawings, project management
  •  Lightweight for ease of transport, fabrication and assembly
  •  Doesn’t rust or corrode
  •  Made from Composite Polyurea, Epoxy Cold Cast™, High Density Urethane or Engineered Wood Fibers™
  •  Custom commissioned artwork
  •  Epoxy Cold Cast and Composite Polyurea panels are flexible, able to be installed over contoured surfaces
  •  Polyurea elements are 7-times lighter than steel and 2.5-times lighter than aluminum
  •  8" Polyurea C-channel = 1.5 PPF, 12" C-channel = 2.7 PPF, 15" C-channel = 3.7 PPF and 36" = 14.3 PPF
  •  Can be easily repaired on site if damaged
  • 10-year color-safe sealers
Epoxy Cold Cast

Railway cargo car replication with wheels, suspension units, rail clamps and spikes created in Composite Polyurea, rail in High Density Urethane (HDU) and cargo body in Engineered Wood Fiber™. Commissioned by Wheelabrator Technologies, Portsmouth, NH

Traditional ODOT Green steel bridge sections replicated in Class A fire retardant Engineered Wood Fibers, complete with rivets and years of hard earned rust.

Traditional ODOT Green steel bridge sections replicated in Class A fire retardant Engineered Wood Fibers™, complete with rivets and years of hard earned rust.

Light weight C-channels replicated in GFRC provide the look of authentic steel. 4-times lighter than real steel for easy installation and provide long term, rust-free maintenance. Celtics and Bruins ProSHop, TD Garden, Boston, MA.

Light weight replicated 12", 16", 20", 22", 24" and 28" C-channels (up to 7-times lighter than real steel), provide the look of authentic steel for easy installation and provide long term, rust-free maintenance. Celtics and Bruins ProSHop, TD Garden, Boston, MA.

Custom, vintage ceiling tins replicated in Epoxy Cold Cast™ installed in the mail room at the Moderna Framingham apartment complex. (Photo courtesy Planeta Design Group)

Custom, vintage ceiling tins replicated in Epoxy Cold Cast™ installed in the mail room at the Moderna Framingham apartment complex. (Photo courtesy Planeta Design Group)

Light weight C-channels and gusset plates with rivets replicated in glass fiber reinforced concrete (GFRC), 3.5 times lighter than steel, 14% liter than aluminum. Peloton shop, The Street, Chestnut Hills, MA.

Light weight replicated 18" steel C-channels and gusset plates with rivets are up to 7-times lighter than steel. Peloton shop, The Street, Chestnut Hills, MA.

desk front with replicated heavy flake rusted steel planels in light weight Epoxy Cold Cast™

Heavy flake steel panel, wrapped around the front of the reception desk, was replicated in lightweight Epoxy Cold Cast™ to provide an authentic look and cool feel of real steel. Hartford Steam Boiler, Hartford, CT

Authentic cold rolled steel trusses, replicated in super light weight Epoxy Cold Cast™ (at 105 pounds per 30' truss), complete with lite flake texture, gussets and rivets. Adding further realism, the 3-monitor media center is mounted directly to the 30' trusses. Rival House, Grand Casino, Hinckley MN.

Authentic cold rolled steel trusses, replicated in super light weight Epoxy Cold Cast™ (at 105 pounds per 30' truss), complete with lite flake texture, gussets and rivets. Adding further realism, the 3-monitor media center is mounted directly to the 30' trusses. Rival House, Grand Casino, Hinckley MN.

I-beams made of lightweight Epoxy Cold Cast™, wood beams from epoxy resin and arches from lightweight GFRC, Bar Rustic, Kingston, MA.

Steel I-beams replicated in lightweight composite polymer, wood beams in Engineered Wood Fibers™ and arches in lightweight GFRC, Bar Rustic, Kingston, MA.

Composite polymer replicated I-beams and Epoxy Cold Cast™ replicated Lite Flake barrel wall with riveted banding, Bar Rustic, Kingston, MA.

Steel I-beams replicated in light weight composite polymer, Lite Flake barrel ceiling arc with riveted banding, authentically replicated in Epoxy Cold Cast™. Bar Rustic, Kingston, MA.

15" C-channels and gusset plates with rivets replicated in Class A fire retardant Engineered Wood Fiber, Fuel America, Worcester, MA

15" steel C-channels and gusset plates with rivets replicated in light weight composite polymer, Fuel America, Worcester, MA

Barrel vaulted ceiling covered with Heavy Flake in Bronze steel panel replications made from lightweight Epoxy Cold Cast™ bring an air of industrial might to the Hartford, CT office.

Barrel vaulted ceiling covered with Heavy Flake in Bronze steel panel replications made from lightweight Epoxy Cold Cast™ bring an air of industrial might to the Hartford, CT office.

Rough sawn oak planks replicated in epoxy resin with a heavy flake angle iron framework complete with nuts and washers all replicated in light weight Epoxy Cold Cast™.

Vintage, hand painted ceiling tins replicated in feather light Epoxy Cold Cast™. Margaritas, Northboro, MA

Heavy Flake with Silver steel panels replicated in Epoxy Cold Cast™ covering pocket doors

Heavy Flake with Silver steel panels replicated in Epoxy Cold Cast™ covering pocket doors

Glass fiber reinforced concrete (GFRC) C-channels around periphery of Snooze AM Eatery Atlanta GA

8" and 15" steel C-channels replicated in light weight materials achieve the desired industrial look without the installation and maintenance costs of real steel.  Photo courtesy: Snooze AM Eatery, Atlanta

Curved rusted steel barrel ceiling section with heavy flake texture and riveted banding replicated in light weight Epoxy Cold Cast™. Bar Rustic, Kingston, MA.

Curved rusted steel barrel ceiling arc with heavy flake texture and riveted banding replicated in light weight polymer composite. Bar Rustic, Kingston, MA.

custom designed UL certified MDF I-beam lights I-beams replicated in MDF engineered wood fiber

Custom designed and UL-certified replicated I-beams and rope lights. Commissioned by Hampton Inn and Homewood Suites by Hilton, Seaport, Boston

Custom stove pipe with Heavy Flake texture and riveted banding and below-counter C-channels with rivets, replicated in Epoxy Cold Cast™, Bar Rustic, Kingston, MA.

Custom steel stove pipe with Heavy Flake texture and riveted banding and below-counter C-channels with rivets, replicated in Epoxy Cold Cast™, Bar Rustic, Kingston, MA.

18" GFRC C-channel canopy (12 pounds per foot), The Street at Chestnut Hill.

Light weight replicated 18" steel C-channel canopy. The Street at Chestnut Hill.

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