Waffle Ceiling Beams
Mouldex waffle ceilings beams utilize a proprietary plaster coating to provide the sophisticated architectural depth of hand-run plaster without the weight or fragility of solid gypsum. Engineered for waffle and coffered ceilings, these lightweight, one-piece profiles ensure a seamless, monolithic finish that eliminates the joint separation and labor intensity common in Wood/MDF assemblies.
The Pillars of Interior Coated Foamcore Technology
100% moisture-inert. Will not rot, warp, or crack.
Expertly bonds to a variety of wall surfaces
Unlimited profile designs including custom arches and circles.
Silky smooth and ultra fine plaster for the ultimate finish.
90% lighter than traditional plaster with better performance.
Zero-joint expansion. Engineered for extreme climate swings.
The 5th Category: Interior Coated Expanded Polystyrene
Interior details typically fall into four categories: MDF (Metrie/Alexandria), Traditional Solid Plaster, Wood, or Synthetics (Ekena/Orac Decor). Mouldex introduces an additiona to the superior 5th category: Plaster Coated Expanded Polystyrene for interiors.
Engineered to provide the prestigious, ultra-smooth finish of hand-run plaster without the extreme weight or fragility, our Hybrid Plaster systems utilize a high-density core protected by a genuine and proprietary plaster coating.
This results in an architectural profile that delivers the authentic aesthetic of traditional plaster while remaining crack-resistant and 90% lighter than masonry alternatives.
By eliminating joint expansion common in MDF and the "plastic" appearance of Polyurethane, Mouldex ensures a monolithic, seamless finish for high-end residential and commercial interiors.
Beyond Traditional Plaster & Wood/MDF: Interior Performance Comparison
| Attribute | Mouldex Interior Mouldings | Traditional Plaster | MDF (Metrie / Alexandria) | Synthetics (Ekena / Orac Decor) |
|---|---|---|---|---|
| Finish Quality | Genuine Smooth Plaster | Hand-Run Smooth Plaster | Painted Fiber (Grainy Texture) | Molded "Plastic" Look |
| Stability | Crack-Resistant Composite | Prone to Hairline Cracks | High Joint Expansion | Brittle over time |
| Fire Safety | Non-Combustible Surface | Non-Combustible | Combustible Wood Fiber | Flammable Polymers |
The Science Behind the Most Versatile Moulding on the Planet
Mouldex interior mouldings represent a definitive shift in high-end trim, combining the authentic aesthetic of traditional plaster with advanced material performance.
Engineered for both historical restorations and contemporary luxury design, our Evolved Foamcore technology addresses the structural and labor-related failures inherent in wood, PVC, and solid gypsum casting. By replacing brittle, heavy materials with a resilient, lightweight core, we provide a rock-hard finish that remains permanently stable regardless of seasonal humidity or building settlement.
1. The Evolved Plaster Core
Mouldex interior profiles utilize a high-density Evolved Foamcore encapsulated in a proprietary polymer-modified architectural plaster. Unlike brittle solid gypsum which is prone to shattering, this system is physically resilient, providing a rock-hard, smooth surface with internal flexibility that prevents surface cracking.
2. Monolithic Seamless Spans
We eliminate the failure points of built-up wood assemblies. While traditional wood requires 3 to 5 separate members to achieve a 12-inch profile, Mouldex manufactures massive cornices in a single, seamless span.
- Zero Visible Seams: Eliminates the joint separation common in wood due to seasonal humidity.
- Labor Efficiency: Reduces on-site installation time and specialized carpentry costs by up to 70 percent.
3. Structural Weight Efficiency
Our interior systems are 90 percent lighter than traditional solid plaster or heavy wood assemblies. This allows for massive architectural impact on standard framing without the need for expensive structural blocking or reinforced headers.
4. Dimensional Stability and Material Memory
Traditional plaster is rigid and shatters during building settlement, while wood warps and shrinks. Mouldex possesses Material Memory, allowing the profile to absorb minor building shifts without developing hairline fractures. Your miters stay closed permanently, regardless of seasonal shifts.
5. High-Opacity LED Integration
Standard polyurethane and plastic mouldings suffer from "light bleed" when paired with modern LEDs. Our architectural coating is engineered for High Opacity, creating a total light block. This makes our Light Cove and Ceiling Beam series the professional choice for integrated indirect lighting systems.
6. Bespoke Heritage Replication
Using advanced CNC technology, we replicate historical heritage profiles or create bespoke contemporary shapes with an average 7 to 10 day turnaround. This eliminates the 8 to 12 week lead times and extreme waste associated with traditional plaster casting.
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