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3rd PHASE: tailored manufacturing of the decorations in our laboratory.
This is the phase where decorations are actually created. Casting of gypsum must take place within short time as the plaster's workability is quite limited once the gypsum has been cast.
IAD avoids using retardant substances mixed with gypsum, as they might provoque deformations while the gypsum is setting and therefore damaging the decorations.
In the case of decorations and frames longer than two metres and whose sections are longer than one metre, the presence of two or more people working on the same shape is required. Four castings of plaster gypsum are made for each item:
- the first casting must be very liquid in order to adhere perfectly to every little cavity of the sample;
- the second casting is more plentiful and the mixture is more solid. Before it starts drying up on the surface, manila natural fiber is applied on the top;
- the third casting occurs immediately after and similarly to the previous one. Then, galvanized steel rods of 4mm diameter are inserted; if there are curved elements, then rods will be curved in the same manner. On the top of the rods, an additional layer of manila fiber is added in order to ensure their inclusion and stability;
- the fourth and last casting is a solid mixture, just like the two previous ones.
