Ornamental Plaster Restoration and Custom Fabrication
Since 1835, Balmer architectural gypsum plaster mouldings and ornament have set the industry standards for quality, tradition and elegance. Balmer's finely crafted ornamental plaster mouldings have been the product of choice for architects, designers, contractors, custom builders and developers for use in homes, hotels, courthouses, offices, theaters, churches and government buildings.
Today, the Balmer gypsum shop houses thousands of original patterns created over the past 165 years. Some are stored on racks, others hang from the walls and ceilings. Skilled artists and craftsmen produce both old and new designs by hand in glass reinforced gypsum plaster. Finished products are crated and shipped throughout the world.
Balmer is uniquely equipped to work with architects, designers and plaster contractors to execute your custom designs of moulded architectural art. Our designers and craftsmen are unsurpassed in their knowledge and skill working with clay, plaster, steel, and wood to build original models which we mould and cast in a variety of materials.
Gypsum
Our principal casting materials are plasters and gypsum cements, collectively referred to as gypsum. In most applications, gypsum is reinforced with glass fibres. In other cases, it is reinforced with burlap, jute, or steel. Gypsum castings are intended for ornamental, non-structural use.
Gypsum can be formulated in a wide range of compositions to yield finished products with a range of properties. In all formulations, gypsum is non-combustible and non-toxic. It does not attract or provide any food value to vermin or insects.
Complete, Engineered Custom Parts
One reason for approaching Balmer for a factory cast custom product is the expense and time required to install finicky, small elements of enrichment on site. In the past, most, if not all, architectural art was built in place by skilled craftsmen. Throughout our history, Balmer has completed many such projects.
Today, with tight construction schedules and high construction labor rates, there is a better way to build. It is possible, for example, to have Balmer fabricate a complete, one piece, custom designed panel which might incorporate multiple coffers, beams, and beam intersections. The cast panels can be delivered, ready to install on site as soon as drywall work is completed.
Instead of building up a complex cornice on site from component parts, Balmer can design and cast a complete custom cornice in one piece lengths which install quickly, easily, and precisely. These are just two examples. With this approach, not only are labor costs reduced, but the construction schedule can benefit immensely. Custom manufactured parts can be available as soon as the project requires them: engineered for quick, secure, precise installation.
Imagine, for example, a hallway requiring 20 identical groin vaults 4 feet wide by 4 feet high. The traditional method of lath and plaster construction would require a crew of four no less than three weeks on site and a week or more to dry before being ready to paint. Pre-cast gypsum vaults, manufactured by Balmer to your specifications, on the other hand, can be installed by two men in five days. They require no complex framing and are ready to be painted after one day.
Do you need a three foot high cornice? Are you considering building it on site from separate elements the way it would have to be done working with wood? Consider having it designed and cast in one piece lengths by Balmer. There is virtually no limit to the size of piece we can cast in our mould shop. The only reason a work of architectural art need be broken into pieces is so that it can be shipped and handled on site.
In some cases, it is desirable to design a product such that it is supplied in more than one piece. The custom recessed panel at right was supplied as shown. By joining two pieces, one above the other, with the bottom piece inverted, many complete panels were installed on site. Since the panel halves can be easily cut (across the bottom), panels of varying heights could be quickly and easily constructed.
Installation
The services available from Balmer include installation. Our crews include only experienced professionals dedicated to providing our customers with the highest quality installations possible. We have been engaged to install our gypsum architectural art in many major cities throughout North America. Balmer has also, over the years, established relationships with plastering contractors throughout North America for whom we have provided supervision and training in the techniques we employ in the proper installation of gypsum products.
Enrichments
Balmer's library of patterns is one of the most extensive in the world - over 12,000 patterns in all. Our library includes all classical enrichments in various sizes, shapes, and styles: egg & dart, dentil, pearl, acanthus leaf, water leaf, greek key, lambs tongue, and so on. Enrichments from our library are often used in the creation of the models for custom designs. They are often altered, modified and adjusted to meet the exact requirements of a custom application.
Cost
To give an idea of the cost of custom designed parts, consider the case of a custom cornice with an 8 inch projection and an 8 inch depth to be manufactured in 6 foot lengths. Since costs vary depending on the complexity of the cornice, we consider three cases: a plain cornice with no enrichments (whose model is run); a cornice which incorporates one enrichment; and a cornice with three enrichments. The set up costs consist of the cost of a shop drawing (which must be approved prior to our continuing work), and the costs of a model and mould (combined).
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These are rough examples only because the cost of the model and mould vary depending on the enrichment incorporated and the amount of original sculpting required. They do, however, identify the costs associated with manufacturing a custom design.
Just as important are the costs saved during installation. Installing just one six foot length incorporating several enrichments is far easier and faster than installing the 3, 4, or 5 individual lengths required in the traditional run and plant methods of plaster work or in the use of wood elements.
Contact our Custom Manufacturing Department for an accurate quotation for your custom requirements.
Restoration
According to the Oxford Dictionary, restoration is "an attempt to bring (something) back to (its) original state;" renovation is merely "restoring to good condition." Throughout our history, Balmer has always been heavily involved in both restoration and renovation. Relatively few people today need, want, or can afford to have things exactly as they were. For most, renovation to a particular historical period usually satisfies. The exceptions are historical heritage buildings where the recapturing of yesterday exactly as it was is of paramount importance.
Balmer is proud to have participated in the restoration of Disney's New Amsterdam Theater in New York. One of the many ornamental pieces we were commissioned to replace is the 5 foot by 8 foot peacock assembly shown at right. The mould from which the peacock was cast is in the foreground.
The approach taken in the historical restoration of ornamental plaster depends on the degree of damage or decay of the existing ornament. In situations where there is minimal damage, and no structural danger, repairs are conducted on site by skilled plaster craftsmen. Balmer staff and subcontractors can be supplied for such work.
When there is major damage, Balmer's designers and mould shop become involved. Here, working from sample ornaments retrieved from the site by a plaster contractor, we can model replacement ornament. We then cast the replacement ornament (complete with integral steel structural supports if appropriate.) The result is an engineered part which installs easily on site and is far more secure and durable than the original ornament.
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Balmer has provided custom manufactured glass reinforced gypsum art for many prestigious projects, including:
- Loew's Hotel, Miami
- Portofino Hotel, Orlando
- The Bellagio Casino, Las Vegas
- The Venetian, Las Vegas
- Paris Casino, Las Vegas
- The Carlton Hotel, New York
- The New Amsterdam Theater, New York
- The St. Regis Sheraton Hotel, New York
- Essex House, New York
- The Plaza Hotel, New York
- The Metropolitan Museum of Art, New York
- Hotel Meridien, Boston
- The Washington Hilton, Washington, D.C.
- The Pantages Theatre, Toronto
- The Royal Alexandra Theatre, Toronto
- The King Edward Hotel, Toronto
- The Royal York Hotel, Toronto
as well as numerous private residences in New York, Palm Beach, Toronto and throughout North America.
Contact Us
For help with your commercial or residential new construction, renovation, or restoration project, contact us.