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Series editors' preface - Wood Tools

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486 Conservation of Furniture<br />

they dried. Reproduction of detail is only fair<br />

due to rapid gelling, though cost is low.<br />

Gypsum plaster is one of the most ancient<br />

moulding and casting materials. It generally<br />

consists of calcium sulphate hemihydrate<br />

(CaSO 4. 1 ⁄2H 2O) prepared from gypsum (calcium<br />

sulphate dihydrate) by heating at about 145 °C.<br />

When mixed with water, the plaster rehydrates<br />

to CaSO 4.2H 2O and recrystallizes, forming a<br />

dense network of interlocking needle-like crystals<br />

as it does so. This is an exothermic reaction<br />

resulting in a set plaster that hardens more<br />

fully as excess water evaporates. Gypsum plasters<br />

are actually a family of related materials<br />

because of the variety of ways they can be<br />

modified in manufacture and use to yield<br />

different setting rates, final hardness and other<br />

properties. This means that there is considerable<br />

choice in terms of working characteristics.<br />

Plasters with different setting times are available<br />

and those with faster setting times result<br />

in a greater temperature build up. Most plasters<br />

show expansion in setting between 0.05 to<br />

1.0% by volume, though this may be reduced<br />

by the addition of a small quantity of ethanol<br />

before the plaster is poured. Plaster formulations<br />

can also be made to shrink slightly.<br />

Plaster is inexpensive and relatively safe in use<br />

but burns have resulted from very quick setting<br />

plasters and plaster dust should not be<br />

breathed, especially where silica has been used<br />

in the formulation. Optimum and reproducible<br />

results are only obtained if ingredients are<br />

carefully weighed, following the instructions in<br />

the manufacturer’s literature. Plaster should be<br />

well sieved before being sprinkled into water<br />

until a cone has been formed. When this has<br />

become saturated with water the plaster mix is<br />

gently stirred to a creamy consistency, as free<br />

from air bubbles as possible. As with<br />

animal/hide glues and gelatines, additives such<br />

as glue, borax or dextrin have been used to<br />

manipulate the final working properties. Set<br />

and dried plaster is highly inert and may be<br />

considered permanent. The surface may be<br />

sealed with a coating such as shellac, followed<br />

by a suitable release agent, before the mould<br />

is used. Plaster cannot be used against moisture<br />

sensitive surfaces. There is a large body of<br />

literature on plaster and plaster casting techniques,<br />

including manufacturer’s technical literature,<br />

which should be consulted when using<br />

this material.<br />

Thermoplastic polymers have been used for<br />

various applications in moulding and casting.<br />

Historically they have been used to produce<br />

rigid moulds. Decorative plasterers have used<br />

mixtures of waxes, resins and fillers to produce<br />

moulds for repeat patterns. Many nineteenthcentury<br />

moulds for composition ornaments<br />

were made of pitch mixtures enclosed in a<br />

strong frame and squeezed over an oiled carving<br />

while hot and pliable. Gutta percha was<br />

also used as a mould material. Modern<br />

synthetic resins can also be used in this way.<br />

Dental impression compounds have been used<br />

in picture frame restoration to make small<br />

squeeze moulds for the replacement of lost<br />

composition ornament.<br />

Poly(vinyl chloride) hot-melt rubbers, which<br />

melt between 120 °C and 170 °C, have been<br />

used extensively by commercial mould makers<br />

for large flexible moulds. Their melting range<br />

means they cannot be used where the original<br />

artefact cannot tolerate such temperatures. Like<br />

most thermoplastics, they shrink somewhat as<br />

they cool but have moderate to good permanence<br />

and are relatively inexpensive. PVC hot<br />

melts release toxic gases when hot and fume<br />

extraction is essential. They should not be used<br />

in contact with metals.<br />

PVC gels are available as modelling<br />

compounds in toy and hobby shops under<br />

trade names such as Fimo, Sculpey etc. They<br />

consist of colloidal particles of polyvinyl chloride<br />

mixed with a plasticizer. The plasticizer<br />

diffuses into the PVC when it is heated and<br />

fuses the mass together. These compounds are<br />

very useful for squeeze impressions because<br />

they have an unlimited working time and<br />

capture a high degree of detail. They may be<br />

used at room temperature, for high fidelity<br />

one-off castings in plaster, or oven-hardened at<br />

approximately 130 °C. There are no apparent<br />

chemical interactions, dimensional change is<br />

less than 1.0% upon hardening and permanence<br />

is good, but cost is moderate to high.<br />

Toxic gas is released if the material is overheated<br />

and fume extraction should be used<br />

whilst it is hardening. Unpolymerized vinyl<br />

monomer may be absorbed through the skin.<br />

A wide variety of thermosetting polymers is<br />

available for moulding and casting including<br />

epoxies, polyesters and polyurethanes for rigid<br />

castings, and polysulphides, polyurethanes and<br />

silicone rubbers for flexible moulds. These

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