Duramold™ Pottery Plaster

Applications & Uses

Mixing Instruction

MIX PREPARATION

Use potable water at temperatures between 70 °F (21 °C) and 100 °F (38 °C). Because variations in slurry (USG Duramold Pottery Plaster and water mixture) temperature produce variations in set time, it is important to keep both the USG Duramold Pottery Plaster and water in a stable temperature environment prior to use. The higher the temperature of the slurry, the shorter the set time. Conversely, the lower the temperature of the slurry, the longer the set time.

Weigh both the USG Duramold Pottery Plaster and the water prior to use for each mix. The water-to-USG Duramold Pottery Plaster ratio is critical because it governs the strength and absorptivity of the mold.

SOAKING

Sift or strew USG Duramold Pottery Plaster into the water slowly and evenly. Do not drop large amounts of USG Duramold Pottery Plaster directly into the water as proper soaking of the USG Duramold Pottery Plaster may not occur. USG Duramold Pottery Plaster should be fully dispersed in the water prior to mixing. Small batches require less soaking time than large batches. See USG IG503 Plaster Mixing Procedures for specific soaking instructions.

MIXING

Mixing USG Duramold Pottery Plaster slurry is one of the most important steps in producing USG Duramold Pottery Plaster molds with maximum strength, absorption, hardness and other important properties.

Mechanically mixed slurries develop uniform molds with optimal strengths. USG Duramold Pottery Plaster can be mechanically mixed through both batch and continuous processes. Proper blade and bucket dimensions are important for obtaining the best batch mix (see USG IG503 Plaster Mixing Procedures for details).

Longer mixing times result in higher mold strength and shorter set times.

Pouring

To prevent air entrainment and provide a uniform, smooth surface, careful pouring of USG Duramold Pottery Plaster slurry is necessary. Agitation/vibration of the filled mold is a further step used to prevent air at or near the mold surface. Whenever possible, USG Duramold Pottery Plaster slurry should be poured carefully in the deepest area so that the slurry flows evenly across the surface of the case mold.

Pouring a large amount of slurry directly on the face of the case mold may result in slight densification of the USG Duramold Pottery Plaster mold at the point where it strikes the surface of the case. This produces a hard spot, giving uneven absorption.

Drying

All pottery molds should be dried as quickly as is safely possible after manufacture so that maximum physical properties can develop. Dry to a constant weight.

The best drying rooms or ovens provide 1) uniform and rapid circulation (minimum of 15-30 fps (4.6-9.1 mps)) of air with no “dead spots” having little or no air movement, 2) equal temperatures throughout the entire area, and 3) provisions for exhausting a portion of the air while replacing it with fresh air. High humidity surrounding the drying room or oven inhibits drying efficiency because the air pulled into the room is incapable of picking up much moisture from the molds.

The maximum temperature at which USG Duramold Pottery Plaster molds are safe from calcination is 120 °F (49 °C). With substantial free water in the mold, a higher drying temperature can be used without difficulty. As drying progresses, the temperature must be reduced to prevent calcination. Before removing molds from the dryer, the temperature should approach that of the area around the dryer to prevent thermal shock.

Properties

Typical Properties

	Value	Units	Test Method / Conditions
Machine Mix Vicat Set, Target	14-24	minutes	-
Compressive Strength, One Hour After Set	1200 (8.3)	psi (MPa)	-
Compressive Strength, Dry	2900 (20.0)	psi (MPa)	-
Density, Wet	102 (1634)	lbs./cu. ft. (kg/m3)	-
Density, Dry	75 (1201)	lbs./cu. ft. (kg/m3)	-
Maximum Expansion	0.21	%	-

Technical Details & Test Data

Normal Consistency

60 lbs. water/100 lbs. product (27 kg water/45 kg product)

Storage & Handling

Storage & Use

When properly used, USG Duramold Pottery Plaster is easy to work with and complies with the federal Labeling of Hazardous Art Materials Act, 12 U.S.C. Section 1277 and ASTM D4236. Keep indoors at temperatures between 65 °F - 75 °F (18 °C - 24 °C) and 45% - 55% RH. Do not stack more than two pallets high. Keep from drafts. Rotate stock. USG Duramold Pottery Plaster should be used within 6 months of the manufacturing date located on the package. Always follow handling and use directions and safety warnings on the package.