Concrete walls- sprayed over polystyrene

Hi everybody
Just wanting some advice really,have a project on the go at the moment which is a replica of the inside wall of a castle, I have made the shape of the walls, windows and doors from polystyrene- budget is tight and at least I can get straight edges. And give the appearance that they are really thick the walls are around 10ft high. Is it a good idea to cover the poly in mesh, I have plasterers mesh pinned and spray with concrete. Scratch coat first. Then build up after that. Is this standard practice?
My worries is the weight. And the fact it may just peel away from poly. Do i need spacers?
Any advice and ideas would be greatly appreciated.
Thanks

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Permalink Reply by Roger Esch on March 5, 2013 at 7:40am

I am interested in the replies to this question as well. I was a general contractor before I made another career change but in New Mexico traditional stucco was scratch-brown-texture over chicken wire stucco lath which had a eighth inch factory bend in it periodically to stand the wire off the paper a bit. The total thickness was 5/8 inch. When expanded metal was used though for corners and offsets no spacers were used. Over time some cracking would evolve at various places. The new premixed polymer stuccos offer less weight , less thickness, and very few imperfections. All the new make it yourself receipes for a concrete /stucco /plaster mixes offer so much that I have know idea yet what is tried and true.

What kind of gun did you use to shoot your mix ?

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Permalink Reply by Nathan Giffin Vertical Artisans on March 5, 2013 at 11:28am

Mortar Sprayer at MortarSprayer.com

Shoots any number of mixes at about 1/2 to 1" thickness per lift

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Permalink Reply by Roger Esch on March 5, 2013 at 2:44pm

I don't know if this is the appropriate place to ask about the mortar sprayer because crimpbiscut is the one who started this post but which model works best for boulder art. The plasterer model or the stucco sprayer model ? I am going to order one as soon as I know.

Nathan Giffin Vertical Artisans said: