Over the years I've used over 1500# of Hydrocal, and let's not forget Dental Stone,the real deal for casting rock molds.I've always bought these items in 80-90 pound bags.
Now for the not so good news.These products can only be carried by certain U S Gypsum dist.,due to their sensitive storage needs.This is straight from USG Chicago office.When I lived in Chicago ,there were only two places I could get these products,one in Cicero,one on Grand Ave.,and this was Chicago!Moved to rural Colorado,now the fun really began.Yep,I got it!,took weeks of calling and checking around.This is how I learned how hard it was to get if you don't live in a city.First it was going to be loaded on a truck out of San Diego,turns out they weren't allowed to handle Hydrocal.Next I found a place in Grand Junction who would go to Denver just to get my Hydrocal&Dental Stone!You can't stop a model railroader,so $35 a bag,60 mile ride to GJ,Igot my precious supplies.So,you can get large bags,it may take some real effort,but look at the stories you get to tell.Good luck,go for it!