Copyright © 2010 by Robert D. DeFord · All Rights reserved
Our sculptures have a steel rod and wire mesh armatures. We apply a fiber reinforced layer of concrete by hand to the armature to complete cover and seal it. This layer is about 1/2 to 1 inch thick. It has the basic rough shape of the sculpture (arms, legs, head, etc.) with bulges and lumps corresponding to where the modeled details will be placed. The texture is fairly rough with small ridges and scratches.
Once the first layer has set for 6 to 24 hours, we apply the final or outer layer. This layer is a rapid setting, non-shrink grout. The mix is very stiff like modeling clay. We model it with fingers and clay modeling tools while it is still in a plastic state. We work with small batches because the plastic state lasts for about five to ten minutes. This layer varies from 1/4 to 2 inches thick depending on the details. Some radical details, such as saber teeth, dorsal fins, etc., are fabricated separately and attached to the layer when it firms up. The pictures below show these steps. (Click on photos to enlarge them.)
Inner and outer layers
(click to enlarge)
7' tall, 1400 pounds