Instructions for Renaistone Casting Compound

 

Step 1: Preparations for RenaiStone casting

 

Use a clean, plastic non-food container to mix the material and a gram scale to measure the ingredients. Or if you don’t have a scale, you can use the provided measuring cup and follow the second method below to get the proper mix ratio. Use OSHA approved protective gear including goggles, breathing mask, and rubber gloves during measuring, mixing and casting of the RenaiStone material. The liquid is highly alkaline; avoid contact with your eyes, skin and clothing.

 

METHOD 1 – USING A GRAM SCALE

To estimate how much RenaiStone Dry Mix you will need, fill your mold completely with water and then weigh that amount of water. Multiply this weight x2.25. That is the weight of the Renaistone Dry Mix Casting Material you will need to use for your project. Then multiply the dry mix weight by 0.20. That is the weight of the Renaistone Liquid Catalyst you will need to use for your project. We also have an On-Line Calculator to calculate the exact weights of both ingredients.

 

METHOD 2 – USING THE MEASURING CUP

If you do not have a gram scale, you can use the measuring cup included in our kit to estimate how much RenaiStone Dry Mix you will need. First, fill your mold completely with water using your measuring cup. Count how many ml water you need to fill the mold, and then multiply this ml amount x 1.6. That is the ml amount of the Renaistone Dry Mix Casting Material you will need to use for your project.  Dry the measuring cup and then you can measure this ml amount of dry powder with your measuring cup.

 

Then divide this dry mix ml amount by 5.0. That is the ml amount of the Renaistone Liquid Catalyst you will need to use for your project. You can also measure this ml amount with your measuring cup.

 

Step 2: RenaiStone Mixing Instructions

Your mix should have a thick consistency. Mix long enough to give a uniform and lump-free mixture (about 5-8 minutes depending on the quantity). During the mixing procedure avoid entrapping air bubbles. After you have finished mixing let the mixture sit for 5-8 minutes and frequently tap the container to release any air bubbles.

 

Keep the RenaiStone Casting Material cool if you are mixing a larger quantity because higher temperature accelerates setting. Mix and cast the material at room temperature – higher temperature reduces pot life. When you notice that the material thickens you need to hurry up and finish your casting quickly. Do not add water or any additional material to the mix. After mixing, the RenaiStone Casting Compound has a working time of between 1 to 2 hours. You can refrigerate or even freeze the mixed product which will stop the reaction, and allow you to use the mixed material after it comes back up to room temperature even days later.

 

Step 3: Casting with RenaiStone Catalyzed Stone Formation

 

      

Fill the mold with a spoon on a vibrating massage pad or vibrate the mold with a handheld massage device -or- if you do not have a vibrating device just tap the mold frequently and firmly on your work surface. Avoid splashing and always use eye protection!
Start to fill the mold slowly using the more liquid portion of the casting compound first and then spoon feed the RenaiStone casting material on the top of the vibrated spot. Pay particular attention to the first quarter-inch layer when you fill the mold. Vibrate the mold thoroughly and frequently tap the mold on a hard surface to achieve the desired highly textured surface quality in your finished piece without trapped air bubbles. Where you have undercut in the mold you have to tilt the mold to allow the air bubble to rise to the surface. It is a good practice to wait for all the air bubble to dissipate before you add casting compound.

 

Step 4: Topping off and curing your mold of RenaiStone

 

After your mold has been filed to the brim, a large amount of liquid will accumulate on the surface. Tilting the mold and pouring of the top liquid portion will improve the surface quality and eliminate ring formation on the bottom of your finished object. Save the top liquid portion in a separate closed container and put it in the freezer so you can use it later to fix air bubble holes on your finished object. Then it is important to file the mold all the way to the brim again. Pay special attention to the side adjacent to the wall of the mold to eliminate air bubble entrapment especially where there is undercut in the mold. After the casting process is finished it is recommended to leave the mold on a flat surface for 1 to 2 hours, covered before heat treatment. This improves the surface quality of the finished product by allowing the aggregates to settle and tightly pack at the face of the mold. It takes practice to be able to cast bubble-free. While you are taping and filling and handling the mold and RenaiStone materials always use OSHA approved proper safety gear: mask, goggle and rubber gloves, and wear an apron.
After casting the RenaiStone compound into your mold, place a cover over the mold and/or place the mold into a hermetically closed box. You can achieve moist curing by covering the open surface of the material with plastic. /cling wrap from your supermarket works well

 

Step 5: RenaiStone Baking Instructions

 

Cure your mold of RenaiStone Casting Material in the oven at 160-180°F for 4-6 hours depending on the temperature. Place the covered mold in the oven on a flat surface. Always check first to make sure the mold can handle the curing temperature.

*It is a serious fire hazard to place combustible material in the oven.

 

      

Use an oven thermometer to make sure that the temperature does not rise to the softening point of the mold and the recommended temperature limits are properly maintained. Silicon rubber and urethane rubber molds can generally be used safely, also polypropylene /PP and high density polyethylene, HDPE plastic molds are generally Ok. You must always identify the proper working temperature limit of your mold.
Unmolding/baking time is 6 hours at 160°F. Higher temperature can also be used as follows:
4 hours at 180°F
5 hours at 170°F

Use gloves to unmold your cast while it is still warm to the touch but cool enough to handle, and let it dry out for 1 hour before you apply the sealer.

 

Step 6: Sealing your RenaiStone molded stone object

 

      

After curing and drying the piece you must apply the sealer in at least three coats to completely saturate the surface of the piece. It is not necessary to sand or polish the piece to achieve the outstanding surface quality of RenaiStone. It is only necessary to apply the sealer.

      

For the first sealer application, you must saturate the surface with a thick layer of sealer by applying with a brush or Q tip and allowing it to penetrate into the surface for about 20 minutes. It is helpful to go over the object several times to rub the sealer into the entire surface. Repeat the application of the texturizing sealer a few more times until the surface haze no longer develops. This indicates that the surface is now completely saturated. Then you can wipe away the excess sealer with a cloth and buff the object until it shines. If the sealer becomes too sticky on the surface you will need to reapply a fresh coat of sealer and then wipe it off thoroughly. Do not allow the sealer to become too sticky – it might not come off. Repeat the above treatment again after 24 hours.
A minimum 24 hours setting time at room temperature is necessary for the sealer to became water resistant. The freshly cured RenaiStone object will have an alkaline PH chemistry; therefore do not rub your eyes or allow this material to touch your skin until it is completely cured and dry.