It’s been many years since I’ve done scenery. I laid plaster soaked brown grocery bags over a cardboard web. I know when adding layers or building up the surface you must soak the previously laid towels with water from a spray bottle. The dry plaster absorbs the water from what you are trying to put on and it will react as you described. Always apply the plaster to a wet surface and keep it damp till it sets. It should dry rock hard and have a warm ness to it when it sets.
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