Waffle Ceiling Beams
Elevate luxury interiors with prestigious, Class-A Fire Rated Hybrid Plaster ceiling beams.
Meticulously engineered to provide sophisticated architectural depth without the weight of solid gypsum, these one-piece profiles ensure a seamless, monolithic finish for coffered and waffle ceilings.
Achieve a permanent, maintenance-free masonry aesthetic with the enduring durability and high-opacity finish of advanced modern interior engineering.
Mouldex Hybrid Plaster beams provide the hand-run smooth finish of traditional plaster without the weight or fragility of MDF. Discover why our Hybrid Plaster is the specified interior alternative for 2026.
Waffle Ceiling Beams Specifications
High-density foam core encapsulated in an ultra-smooth architectural plaster finish for a premium interior aesthetic.
85% lighter than solid plaster, allowing for long, seamless spans without structural wall or ceiling reinforcement.
We manufacture large-scale profiles in single, seamless pieces, eliminating the need to layer multiple wood or plastic members.
Unlike rigid wood or brittle plaster, our EPS-core composition provides structural flexibility that reduces cracking and handling damage.
Mouldex Interior Hybrid Plaster: Technical Engineering & Material Science
Mouldex Interior mouldings represent a shift in high-end architectural trim, combining the authentic aesthetic of traditional plaster with modern material performance. Engineered to meet the demands of both historical restorations and contemporary luxury design, our Hybrid Plaster technology addresses the structural and labor-related failures inherent in wood, PVC, and solid gypsum casting.
The Hybrid Advantage: EPS Core Technology
Mouldex interior profiles utilize a high-density, CNC-cut Expanded Polystyrene (EPS) core encapsulated in a proprietary polymer-modified plaster. Unlike brittle solid gypsum, this hybrid composition is ultra-lightweight and physically resilient, providing a rock-hard, smooth surface with internal flexibility that prevents cracking.
Seamless Single-Piece Manufacturing
We eliminate the need for "built-up" multi-member wood assemblies. While wood requires 3 to 5 separate pieces to achieve large-scale 12-inch profiles, Mouldex manufactures massive cornices in a single, seamless span.
- Zero Visible Seams: Eliminates joint separation caused by humidity.
- Labor Efficiency: Reduces installation time and costs by up to 70%.
- No Structural Blocking: 90% lighter than wood or solid plaster assemblies.
Dimensional Stability & Material Memory
Mouldex is engineered for structural stability. While traditional plaster shatters and wood warps, our composite core possesses "Material Memory," allowing it to absorb building settlement without hairline fractures. Our profiles remain dimensionally stable, keeping miters closed permanently regardless of seasonal humidity shifts.
Engineered for Indirect LED Lighting
Standard polyurethane and plastic mouldings often suffer from "light bleed." Our architectural coating is engineered for High Opacity, effectively blocking light transmission. This makes our Light Cove and Ceiling Beam series the industry standard for integrated indirect LED systems.
Precision Customization & Heritage Replication
Using advanced CNC technology, we can replicate historical heritage profiles or create bespoke contemporary shapes with an average 7–10 day turnaround. This agile manufacturing process eliminates the long lead times and high waste associated with traditional plaster casting.
Integrated High-Performance Wall Systems
Extend your architectural synergy with our coordinated wall claddings.
- StoneRox & Natural Stone Panels: Prestigious masonry aesthetics without the structural weight liabilities.
- StoCast Wood Series: A rot-proof, resin-cast alternative to cedar, ideal for curved feature walls.
- System Synergy: Ensures identical standards of durability and moisture resistance across the entire building envelope.
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