HYDROCAL® C-BASE

Mix Preparation:

Use potable water at temperatures between 70 °F (21 °C) and 100 °F (38 °C). Because variations in slurry (USG Hydrocal White Gypsum Cement and water mixture) temperature produce variations in set time, it is important to keep both the USG Hydrocal White Gypsum Cement 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 Hydrocal White Gypsum Cement and the water prior to use for each mix. The water-to-USG Hydrocal White Gypsum Cement ratio is critical because it governs the strength and the density of the final cast.

Soaking:

Sift or strew USG Hydrocal White Gypsum Cement into the water slowly and evenly. Do not drop large amounts of USG Hydrocal White Gypsum Cement directly into the water as proper soaking of the USG Hydrocal White Gypsum Cement may not occur. USG Hydrocal White Gypsum Cement 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 Hydrocal White Gypsum Cement slurry is one of the most important steps in producing USG Hydrocal White Gypsum Cement casts with maximum strength, absorption, hardness and other important properties. Mechanically mixed slurries develop uniform casts with optimal strengths. USG Hydrocal White Gypsum Cement can be mechanically mixed through both batch and continuous processes. Proper blade and bucket dimensions are important for obtaining the best batch mix.

Pouring:

To prevent air entrainment and provide a uniform, smooth surface, careful pouring of USG Hydrocal White Gypsum Cement slurry is necessary. Agitation of the filled mold is a further step used to prevent air at or near the mold surface. Whenever possible, USG Hydrocal White Gypsum Cement 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 Hydrocal White Gypsum Cement mold at the point where it strikes the surface of the case. This produces a hard spot, giving uneven absorption.

Drying:

All casts 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

• 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,
• Equal temperatures throughout the entire area
• 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 Hydrocal White Gypsum Cement 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.

All casts 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

• 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,
• Equal temperatures throughout the entire area
• 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 Hydrocal White Gypsum Cement 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.

The Typical Physical Properties in the above table were achieved under controlled laboratory conditions with freshly produced material, results may vary. Other set times may be available; call your USG Sales Representative for more information. Hand mix times will be longer.