Original statues can be found in a number of places, whether new in store, online, borrowed, in a second-hand store, market or garage sale. When looking for a potential moulding project; there are a few things to consider. Ease of casting is a major factor, with items that have too complex a structure and/or very thin areas not being the best choice for concrete casting. Metal materials and some metallic paints are off limits as they damage the latex.

The original statues are cleaned and scrubbed, especially those from second-hand stores, as contamination with dust can also be damaging. Some statues undergo repairs and/or minor modifications with clay before moulding. 

Latex Moulding

Latex is the most commonly used material for concrete moulds. Made from the rubber tree, latex is a natural sap that is then processed, thinned and cut with ammonia. 

The first layers are applied with a brush, thinly and carefully to avoid air bubbles that would affect detail. Once dried, another layer is applied, and the process is repeated 5 to 20 times depending on thickness needed. 

The thinner the mould the easier to demould, but the thicker the mould, the more supportive it is. Once complete, the mould is left to fully dry and cure. A supportive outer shell may be created from foam, plaster or fibreglass for large, heavy pieces. Smaller moulds can simply be hung during casting with no extra support. 

Silicone can be used for moulds but it is much more costly, less flexible, less durable and uses more material than latex. Silicone moulds can be purchased premade, fairly cheaply, as a good way to use up leftover concrete mix. 

Casting

Casting is usually done in large batches to maximise efficiency. Moulds are set up and then ratios of cement, sand and fine gravel is mixed with water to create concrete in a bucket. The mix is carefully scooped into each mould, as they are rotated and tapped, so the concrete gets into all areas and reduces the amount of air bubbles. 

Once filled, moulds are left for the concrete to cure, with plaques having wire hooks added for hanging. After a few days (dependant on temperature) the casts are removed from the moulds and then left to soak in a water bath for at least a week. Statues may be painted right away or stored indefinitely in the garden until an order is made. 

Painting

Painting is the longest and most detailed process in the making of concrete statues. Firstly, the raw statue is base coated in a 50/50 mix of paint and water and left to dry. Pieces are painted in batches according to colours required, which saves on constantly changing colours and reduces having to wash numerous brushes. 

Darker colours are usually used first with each layer getting lighter until the highlighting stage. Alternatively, watered down washes can be used to add depth and detail. Black is generally the last colour to be used, to add final details and eyes are usually the last thing overall to be painted. Painting is generally done with a variety of brush types and sizes, but sponges and dotting tools are used for some pieces, especially to add detail.

Sealing and Final Touches