From historic restoration in Charleston to modern resort development in Scottsdale, see how Fypon millwork solves real design and construction challenges across North America.
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A 1887 Queen Anne Victorian in Charleston's historic district had lost approximately 40% of its original decorative millwork to decades of moisture exposure and pest damage. The local historic review board required authentic profile replication, while the building owner needed a solution that would not repeat the same moisture failures in the coastal climate.
Fypon's profile-matching service produced cellular PVC equivalents of the original 19th-century gingerbread profiles, including dentil molding, spindle baluster patterns, and ornamental gable brackets. The cellular PVC formulation was specifically selected for its impermeability to Charleston's humidity and salt air.
The design called for Mediterranean Colonial exterior detailing — classical columns, decorative entablatures, and elaborate window surrounds — on a tight commercial construction schedule. Budget modeling showed traditional carved stone and solid wood millwork would consume 28% of the exterior budget and add 6 weeks to the schedule. The architect needed equivalent visual quality at a more workable cost-to-schedule ratio.
Fypon specified 14 classical column sets, over 380 linear feet of entablature, and 28 complete window surround assemblies in high-density polyurethane. The lighter weight simplified the structural integration, and the pre-primed surfaces accepted the project's stucco-tone topcoat directly without additional primer coats.
Building 72 craftsman-style homes with consistent architectural detailing required a supply chain that could deliver dimensional consistency across multiple shipments over 30 months. Any variation in profile dimensions would create visible inconsistencies when painting and installation teams rotated between units. Previous experience with wood millwork had produced measurable variation from batch to batch.
Fypon's blanket purchase agreement program locked dimensional tolerances and material specifications across the entire 30-month project. A dedicated account manager coordinated phased deliveries aligned to the construction schedule, and every shipment included dimensional verification documentation. The pre-primed surface eliminated a full paint coat from the installation workflow.
Whether you're planning a single home or a 100-unit community, our team is ready to help you deliver architectural excellence on time and on budget.