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The impurities, called slag, harden almost immediately when removed. The molten bronze is poured into the shells. A protective ceramic piece resembling a mushroom cap is placed over the fresh bronze to ensure even cooling. After one hour, some of the ceramic shell can be hammered off. Once the bronze castings are adequately cooled, they are completely freed from their ceramic shells. All gates protruding from the sculptural elements are sawed off. The surface of the bronze pieces is smoothed and refined by a process …
New pieces for the Grant Memorial are being cast in a Philadelphia foundry under the watchful eye of the conservator and the Architect of the Capitol team. On a recent visit, AOC employees observed the casting process in action, including the dramatic moment when the molten bronze is poured.