We are now going with foam sections which will be much easier to deal with in the tank 15' x 4'. My initial thought was to use Polygem, a fish-safe epoxy putty, which I already have. It would be a labor-intensive project to mix up putty for 15' x 4' and two 4' x 4' (slightly smaller dimensions than that) and apply it to the foam. When I came across Styrospray last week, it seemed like a really great solution. I came across it while doing an online search on DIY 3D backgrounds. I'm going to have to find the article and see what happened.
I'd love to see that article. Post it if you can. Or PM it to me if you can.
Polygem would be a lot of work. Maybe consider a combination of carved foam, sculpted polygem in areas where it works better for finer detail or whatever and then sprayed on Drylok, which can be applied with an inexpensive hopper gun. You could still do some acrylics with a clear coat if tinted Drylok doesn't give you the look you want.
Honestly I don't see Styrospray being a huge advantage to you. With its self leveling properties I think you'd lose a lot of the detail of your carved foam. But maybe I'm not understanding how you plan to use it.
Your tank is acrylic, correct? Have you tested to see what will stick to it sufficiently to hold the background in place? I know some people have used certain silicone caulks to temporarily fix minor leaks in acrylic tanks but the bouyancy of a 4' tall foam background is really going to test the bond.
I'm sure others have done it but I just haven't paid attention.