1. Producing Plaster Components
 Casting a flood mould

2. Producing Plaster Components
For this presentation you are required to take notes for your records

3. Ten thing you should know about Producing Plaster Components
1 A release agent is used to allow the cast to be removed
 2 Plaster is applied to moulds using a splash brush
3 Flood mould are used to cast repeat pieces of work
4 Reinforcement in plaster casts from flood moulds is comprised of canvas hessian
 5 The type of plaster used for casting is Class A

4. Ten thing you should know about Producing Plaster Components
6 When casting in plaster the two coats are know as firstings and seconds
7 The reinforcement in plaster casts is placed in the second coat
8 Lath reinforcement in plaster casts run parallel to the strike offs
9 Timber bearers for a plain faced cast should be at least 30mm x 30mm
10 Shellac is used as a sealant

5. A selection of materials used for producing plaster components
Shellac is a painter’s knotting or button polish
Plasterers mix it with meths to thin it down
Shellac is an all-natural resin secreted by the female lac bug to form a cocoon, on trees in the forests of India and Thailand
Shellac is used to seal the surface of the mould and prevents water from other coats been dried out
Apply 3 thin coats to the plaster surface to give a polish
Shellac is also used on bench surfaces

6. Lac (Laccifer Lacca) are scale insects (insects that attach themselves in great numbers to plants and trees) which drain the sap from the bark of their host tree, allowing them to secrete lac resin which is scraped off and manufactured into shellac. Around 300,000 insects are used to produce 1kg of lac resin 6

7. Alum This is an accelerator used in casting.
Why do you think you would use this? 7

8. Grease/release agent/Raw Linseed Oil
Raw Linseed Oil 500ml Bottle. Has many uses and works well as a releasing agent on fibreglass or sealed plaster moulds.
(Tallow) Used to prevent the plaster from sticking to the bench, and also helps with the running of the mould along the bench.
Made from animal Fat 8

9. A selection of materials used for producing plaster components
Tri-sodium citrate (sodium citrate) is a very potent retarder to plaster setting time.
Just a pinch of it added to the gauging water prior to adding the plaster will retard the set for several minutes
 Fine Casting plaster is probably the most common plaster for fibrous work

10. A selection of moulding tools used for producing plaster components
Small tool ideal for moulding
Joint rule mainly used for mitre work, also used for bench work

11. A selection of moulding tools used for producing plaster components
Spring steel busks ideal for scraping shaping and filling plasters
 A good bowl for bench work with plaster. Flexible crack resistant black polythene

12. The materials required to cast a flood mould
Hessian
Mixing Bowls
Scissors
Rule
Class A Casting Plaster
Latex Gloves
Flood Mould used for the plaster cast

13. Casting a flood mould
Using a gloved hand , the casting plaster is mixed in a bowl of clean cold water
Question which piece of P.P.E is missing
Answer
Dust Mask

14. Casting a flood mould
Once mixed to a creamy consistency the plaster is poured into the centre of a clean flood mould , making sure that all the mould is covered.
This is called the firstings.

15. Casting a flood mould
The flood mould is carefully vibrated to remove any air pockets and making sure that all the enrichments are fully covered

16. Casting a flood mould
Canvas Hessian is now laid onto the cast this will provide reinforcement, and give the plaster cast strength

17. Casting a flood mould
The plaster cast is now ready for the second pour (seconds).

18. Casting a flood mould
Once it is poured, it can be ruled of to produce a flat, and true surface that ca be fixed to a ceiling once set and dried.

19. Casting a flood mould
When the plaster cast is finished it is then left until it has set and all the heat given off while setting has died away.
 The cast is placed at the edge of the bench , and slowly the fence of the mould is removed from the cast. 
Continue all the way around the flood mould until the plaster cast is free.

20. Clean the flood mould ready for making another cast
Casting a flood mould
The flood mould is now turned over and removed from the plaster cast
Once the cast the been removed from the flood mould , make a check for any imperfections, then store in a clean and dry location until fully dried
Clean the flood mould ready for making another cast