Each sculpting day we set an ambitious goal of how much we want to realistically accomplish. We want to complete as much as possible without having a panic situation as the concrete cures. Even though our special mix has retarders and extenders in it, fresh concrete carves very differently than concrete that is beginning to kick. Several factors play into our decision of how much we tackle. Typically, bricks take longer to sculpt than rock work and woodgrains take more skilled labour. How many experienced crew are on hand dictates how ambitious we get each day. Other factors such as temperature play into our calculations as the concrete sets up much quicker when it is warm and the humidity is low. We also use different grades of sand for different applications, depending on the final texture we desire. How many upside-down surfaces are also a consideration as they take longer to trowel on the mud and are trickier to sculpt. We like to start applying the concrete to the upper portions first thing in the morning and work our way down. We trowel on concrete for three or four hours at most. Then it is time for a quick lunch break and by that time the first concrete is beginning to kick and it is time to start carving in the detail. How many sculptors work at any given time is determined by the rate the concrete is setting up. We need to sculpt at close to the same pace as it was applied. Our most skilled sculptors do key areas and the highest details, with less experienced crew filling in behind. We also switch positions often because everyone has a personal style and the finished product must appear to be sculpted by one hand. We also need time at the end of the day to check everything over and clean the tools and work areas. Last Friday we accomplished an amazing amount of sculpted area, with three large detailed pieces made ready for paint. Tomorrow is sculpting day once again and you can bet the crew is up for another big day. Stay tuned…