Abstract: A process for preparing a resin-coated sand for use in shell molds and cores comprises the steps of mixing the sand with phenolformaldehyde resin and an amount of salicylic acid comprising at least about 3% of the weight of the resin, the mixing being carried out at a temperature above the melting point of the resin so as to form a coating of the resin on the sand and cooling and setting the resin on the sand to solidify the resin coating. The hot mixture of sand and resin is quenched with a mixture of water and hexamethylenetetramine, and it is preferred that at least a portion of the salicylic acid, in an amount equal to at least about 1% of the weight of the resin, be added to the hot mixture of sand and resin in the quench liquid. The sand is heated to a temperature in the range of from about 270.degree. F. to about 320.degree. F. before the sand is mixed with the resin.