Architectural Stone | Blog

GFRC CASE STUDY: ENGINEERING, FABRICATION, INSTALLATION

Admin — Thu, 03 Dec 2020 20:33:49 +0000

The architectural GFRC (Glass Fiber Reinforced Concrete) presents a unique opportunity for architects and contractors.

The panels are only 3/4″ thick and yet are strong. This minimizes the structural support requirements. The panels can achieve the look and finish of other stone products. With the AAS technology and fabrication technique, the panels can be large in size when required with intricate shapes.

For renovating the Marriott Hotel in downtown Ft. Worth, the designers wanted to use GFRC panels to conform to existing building profile conditions. The AAS team worked closely with the architect and contractor to achieve panels with more than 20 ft. of length and highly complex angles. The connections to hang the panels were built-in during the engineering and manufacturing process, simplifying the installation.

Images below show an example CAD drawing, a large panel with pre-engineered connections ready for shipment, and installation progress on the site.

CAD Drawing for One Panel

Coordination between a column cap and a cornice – Detailed engineering confirmed design feasibility and simplified installation process

Example: Custom-fabricated Large GFRC Panel

GFRC panel being Cast with Steel Frame Attachments

GFRC panel with Pre-engineered Connections Loaded for Shipping | More than 20 ft long architectural GFRC

Installation Site: Marriott Hotel, Ft. Worth, TX

Detailed Engineering for Seamless Coordination of Columns and Cornices

Marriott Hotel – GFRC Cladding

> SEE MORE: GFRC DESIGN INTENT, ENGINEERING, FABRICATION DETAILS, INSTALLATION

> ARCHITECTURAL GFRC: PRODUCT HOME

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STONE COLOR SELECTION, MATCHING

Admin — Tue, 27 Oct 2020 16:10:35 +0000

The AAS team can create a good color match for a project of any size.

AAS offers customers the option to select from the palette of standard colors or match the stone color to a control sample.

For the standard colors, AAS submits to the customer a box of samples for every project. Once a customer approves a specific color, the project team will use a pre-defined admixture to reproduce that color consistently and precisely.

When a customer provides an existing control sample to match the color, the AAS team uses in-house experts to develop trial samples. After confirming the look and finish on the custom-color stone sample, AAS submits the piece to the customer for approval. Once the customer approves the sample submittal, the color lab technician records the sample number and specific admixture details. AAS uses the computerized batch plant to combine the admixture components precisely, enabling a consistent look and finish for any size project.

When required, AAS develops a mock-up, a miniature wall assembly that shows the combination of cast stone, brick, mortar, stucco, windows, etc. The team works closely with the customers to show different design elements combine to achieve the design objectives.

The AAS project team members can also provide recommendations for color and finish, simplifying the design and planning in the early phase of the project.

AAS 2014 Award | Tarrant County Jail | Color Matching | Architect: Gideon Toal

PROJECT: Higher Education Complex | Cast Stone Color Matching and Finish for Design Effects | Architect: PBK Architects | Mason Contractor: Tim Hughes, Dee Brown Inc

St Jude Catholic Church | Chocolate Brown Color Cast Stone Surrounds for Doors and Windows, Cornices, Banding, Coping, Creative Design Elements

> SEE MORE: MATCH ANY CUSTOM COLOR – PROJECT EXAMPLES

The post STONE COLOR SELECTION, MATCHING first appeared on Advanced Architectural Stone.

ACHIEVE DESIGN GOALS, MITIGATE RISK

Admin — Thu, 22 Oct 2020 20:28:24 +0000

The Advanced Architectural Stone (AAS) team helps clients achieve the design goals, mitigating risk in the construction process.

Design Assist: AAS uses a proven methodology to review CAD drawings with customers. As required, the team can guide customers detailing anchorage connections to hang the stone pieces. Customers can confirm the feasibility of the design early in the project lifecycle.

Construction Planning: AAS develops project-specific product releases that match with the construction milestones. Customers get a detailed settings-plan with the ability to track individual stone pieces.

Installation Support: Customers get a detailed CAD drawing for different sections, each showing specific installation details. AAS also supports customers with onsite troubleshooting during the installation phase.

> SEE MORE: PROJECT-SPECIFIC MANUFACTURING

> LEARN MORE: CUSTOMER SUPPORT SYSTEM

Case Study: Lebanon Trail High School – CAD Drawings Details

Project: Lebanon High School, Frisco, TX | Skinner Masonry | Stantec Architects | Product Applications: Dry Vibrant-tamp Cast Stone, GFRC

Project Example: Parker Square – Innovative Engineering

Parker Square Project | Custom Manufactured Architectural Cast Stone | Innovative Engineering with Large Brackets, Cornices

Case Study: Design Assist, Construction Planning Support, Onsite Troubleshooting

SMU Simmons Hall – Architectural Cast Stone Cladding – Project Planning, Custom Manufacturing, Construction Coordination, Installation Support

GFRC Design Process: Products Fabrication, Connections Detailing

Architectural GFRC | Pre-engineered, Built-in Connections | Installation Support | Installation of GFRC Products at SMU Delta Gamma Sorority House

Advanced Architectural Stone (AAS) is a single source manufacturer for three products – dry (vibrant-tamp) cast stone, wet-pour architectural precast concrete, and GFRC (Glass Fiber Reinforced Concrete).

The post ACHIEVE DESIGN GOALS, MITIGATE RISK first appeared on Advanced Architectural Stone.

STONE ART: RECREATING AN ARTISTIC MEDALLION FOR ORGANIZATION SEAL

Admin — Mon, 21 Sep 2020 18:08:52 +0000

The Dallas Theological Seminary and Graduate School of Theology has a medallion on the exterior for the organization seal. While renovating the building, the designers wanted to recreate a new seal matching the original design.

Photograph of the Pre-existing Seal | AAS Team Recreated a New Medallion Matching this Design

The AAS team took pictures of the original seal and developed a 3D model.

3D Model of the Medallion used as Exterior Organization Seal for the Dallas Theological Seminary and Graduate School of Theology

Once the 3D rendering was approved, the AAS team developed a wooden model using CNC machining.

Seal Model cut on AAS CNC Machine | Project-specific Stone Design, Manufacturing

The next step was to create a rubber form using the wooden model. The manufacturing team used this rubber form and specific admixture for the approved color to fabricate the new cast stone medallion.

The new medallion matched the original shape, intricate design details, and the signage letters with the specific fonts, preserving the school’s tradition and image.

With 3D Modeling and CNC machining capabilities, AAS provides unparalleled design freedom to customers for a range of creative stone art designs. AAS can recreate artistic stone design pieces from photographs. In case if designers have a 3D Model developed, the AAS team can use that as well.

> LEARN MORE: CREATIVE STONE ART

The post STONE ART: RECREATING AN ARTISTIC MEDALLION FOR ORGANIZATION SEAL first appeared on Advanced Architectural Stone.

CREATIVE GRAPEVINE DESIGN IN ARCHITECTURAL STONE

Admin — Fri, 26 Jun 2020 21:21:44 +0000

The design intent with the renovation of the Grapevine Convention Center project was to preserve the cultural heritage of the historic town on the buildings’ exterior. The interior spaces serve as the modern-day city administration offices.

The architect determined to incorporate grapevines into the design elements of the series of buildings. When the project started, the architect had not decided on the material to use for the grapevine pattern. After numerous meetings with our company, the architect settled on cast stone as the material to use to convey the historical beginnings of the community. Cast stone copings, pier caps, and water tables all were produced with a grapevine design.

All that the assignment for the grape leaf design was only a simple 2-dimensional drawing. In order to make the design, Advanced Cast Stone worked with its commercial artist to form a design that was suitable in size and relief. Rubber molds were finally made to capture the creativity of the artwork.

While molds were difficult since the amount of detail desired for the grape leaf is very subjective, its use on the various surface areas of the building further complicated mold production. The design was used on several areas of the structure, such as a typical long flat wall, on radius arches, and at curved sections in the turret areas. At each area of the building, the grape design needed to align with windows, mullions, and other elements of the building. This required careful adjustments to the mold and the pieces of stone to provide overall alignment with the other components of the building.

> LEARN MORE: CREATIVE STONE ART

The post CREATIVE GRAPEVINE DESIGN IN ARCHITECTURAL STONE first appeared on Advanced Architectural Stone.

AAS PRODUCTS CATALOG

Admin — Tue, 21 Apr 2020 18:50:02 +0000

Advanced Architectural Stone (AAS) has a range of standard products available from the catalog. Click on the button below to get the .PDF.

In case of specific questions about a product, submit our support request and someone will be in touch with you shortly.

DOWNLOAD PRODUCTS CATALOG

> CASE STUDY, EXAMPLES FOR RESIDENTIAL PROJECTS

The post AAS PRODUCTS CATALOG first appeared on Advanced Architectural Stone.

THE SYSTEM FOR PRODUCT QUALITY

Admin — Tue, 26 Nov 2019 16:08:58 +0000

The AAS team works closely with customers during every phase of a construction project to ensure consistently high product quality.

DESIGN REVIEW & ASSIST, CONSTRUCTION ASSIST: AAS has well developed system for detailed review of the CAD drawings. As part of this process, the AAS team is able to specify engineering details to hang the stone pieces. Customers are able to confirm the design feasibility for the project before the construction project planning and installation.

AAS System for Design Review, Assist using CAD Drawings

CUSTOM MOLD MAKING: The project specific custom shapes with stringent tolerance requirements are achieved using CNC technology and design craftsmanship for custom molds. The AAS system and capacity to do this for every customer project allows for smooth execution of project while achieving high-end design aesthetic using architectural cast stone.

EXPERIENCE IN CASTING: AAS has experience and track record to fabricate and combine stone panels using three different product materials – dry vibrant-tamp cast stone, wet-pour precast concrete, and GFRC. Based on project requirements, the team is able to recommend combining product(s) applications to achieve the design intent of the project at optimum cost. One of the keys to high product quality is selecting the right casting technique and product materials; AAS has well developed system to understand project requirements and custom fabricate the products.

Advanced Architectural Stone (AAS Formerly Advanced Cast Stone | Knowledgebase, Teamwork, collaboration for Customer Focus

COLOR MATCHING: The AAS team is able to match any custom color with a control sample. The AAS team is able to match color and finish even while combining different product applications.

CONSISTENT PRODUCT PROPERTIES, LOOK AND FINISH: The AAS manufacturing plants are equipped with fully automated batch plants for consistent casting mix for project of any size. Customers are able to get matching structural properties and look and feel even for very long project life cycles.

IN HOUSE QA LAB: AAS has proven methodology to test product properties using the in house testing lab.

CERTIFICATION: The AAS manufacturing plants are certified by the Cast Stone Institute (CSI), Architectural Precast Association (APA), as well as Masonry Contractors Association of America (MCAA). The plants meet their requirements for quality, consistency, testing, structural properties, installation, as well as safety.

Advanced Architectural Stone (AAS Formerly Advanced Cast Stone | Knowledgebase, Teamwork, collaboration for Customer Focus

The post THE SYSTEM FOR PRODUCT QUALITY first appeared on Advanced Architectural Stone.

HOW DO YOU INSTALL CAST STONE?

Admin — Mon, 11 Nov 2019 22:21:31 +0000

The AAS team provides detailed CAD drawings to explain how to install the architectural cast stone.

The settings plan describes drawings for different sections with specific descriptions to hang the stone. Customers get comprehensive installing planning support and drawings that show how to attach every stone panel. This is integrated into the AAS methodology for the project-specific custom fabrication of the architectural stone products.

> DOWNLOAD INSTALLATION GUIDES

The most commonly used technique is kerf slot with strap anchors. Learn more in this blog post with embedded video.

See anchoring and flashing details .PDF from Cast Stone Institute (CSI) – opens in new window or tab.

See connection manual .PDF from Architectural Precast Association (APA) – opens in new window or tab.

Project Example: Lebanon High School

CAD Drawing for a Specific Section | Connection Details for Suspended Soffit of Archway | Project: Lebanon High School

> LEARN MORE: LEBANON HIGH SCHOOL PROJECT

Project Example: SMU Simmons Hall

Architectural Cast Stone Panels | Custom Molds for Precise Design, Manufacturing | Products Sequencing, Construction Planning | Installation Support | Onsite Problem Solving

> LEARN MORE: SMU SIMMONS HALL CASE STUDY

> PROJECT-SPECIFIC MANUFACTURING

> CUSTOMER SUPPORT SYSTEM

The post HOW DO YOU INSTALL CAST STONE? first appeared on Advanced Architectural Stone.

HOW DO I SELECT RIGHT PRODUCT(S) FOR MY PROJECT?

Admin — Mon, 22 Jul 2019 21:44:31 +0000

AAS provides three different product materials for architectural stone applications:

All three products offer considerable design flexibility and durability compared to natural stone products such as limestone. The project-specific detailed engineering and custom fabrication simplify the installation while also achieving a superior design aesthetic.

While cast stone and architectural precast use different casting techniques, the two products have similar structural properties. AAS has a track record for developing custom stone design, using either of the two products or combining the two products as required to achieve the intended design objective for a project cost-effectively.
Architectural GFRC panels are only 3/4″ thick and have an excellent strength to weight ratio, providing unique advantages over other casting techniques. The AAS GFRC product material is much more durable compared to other thin veneer panels. GFRC can match the look of other architectural stone products as well as limestone. The GFRC panels cost relatively more than other architectural stone products; however, it has specific advantages with less structural support requirements and simpler installation.

PRODUCTS SELECTION

SELECTION CRITERION

DRY-CAST STONE

WET-POUR PRECAST

GFRC

LIMESTONE

THIN VENEER PANELS

Design Flexibility

Extreme amount of flexibility

Can mold both sides

Complex shapes

Precision with tolerance

Dry-casting technique enables high-end look & finish

Can emulate look of limestone at much lower cost

Extreme amount of flexility

Complex shapes

No size limitation

Enables longer span or length for individual stone pieces

Suitable for heavy use surface areas such as stair treads

Higher strength to weight ratio enables larger, thin pieces including panels.

Bigger pieces, lighter weight, less structural back up

Comparable design flexibility – you can pretty much do anything using all three products

Can easily match look of other stone products

Natural variation in patterns can’t be avoided

Complex shapes, curves, intricate design details are difficult to achieve – product limitations, challenges with machining/fabrication processing

Highly valued traditionally for design aesthetic

Not easy to match look of other stone products

Cost

Much lower than limestone for custom shapes and precision design elements

Cast stone needs less number of molds and so cost-effectve compared to precast

Lower mold cost, lower overall cost

Slightly more expensive than cast stone

Still much more cost-effective than limestone for high-end design applications

Higher than cast stone or wet-pour precast concrete

Cost is much higher than architectural stone products to achieve different shapes

Veneer (flat pieces) cost is comparable to other products

Much less expensive

Durability

Very good

As good as any stone product

Much better compared to other thin veneer products such as stucco

Not as durable as cast stone

Also variable – depends on type of limestone being used – regional

Not designed for longer term use

Limited testing standards in place if at all – not as comprehensive as cast stone, precast and GFRC

Ease of Installation

Simple installation using any traditional cast stone methods

Usually manually set

Simple installation using any traditional cast stone methods

Equipment is required to set the pieces

Much easier handling of panels

Less construction equipement

Option to build anchorage connections in the products

Relatively less number of pieces required for the target area

Strength-to-weight Ratio

Comparable to other stone products

Higher than any other architectural stone products or limestone

Varies with product time, region, etc.

> SEE DETAILED COMPARISON OF THE STRUCTURAL PROPERTIES, SPECIFICATIONS, OTHER CHARACTERISTICS.

Scroll down this blog post to learn more about the cast stone, wetter precast-concrete and Glass Fiber Reinforced Concrete (GFRC).

Dry Vibrant-tamp Cast Stone

The dry vibrant-tamp fabrication technique allows flexibility to shape both sides of stone panels even when the shape or design of stone panels is highly complex. This offers more flexibility to realize virtually any design shape. The manufacturing process also opens up design freedom to emulate the looks of a variety of different stone types, including natural limestone. AAS has an extensive track record with projects where manufactured stone matched custom color and finish of natural stone samples.

Cast stone is very cost-effective compared to natural limestone. Learn more about the vibrant-tamp casting process in this video:

> PROJECT EXAMPLE: LA Sports HOF: Complex geometry, large size stone pieces for the interior stone veneer that achieved the architect’s design vision of complex channels of nearly Cane River.

AAS Advantage: Track Record & Experience | Design Freedom for Designers | Support System for Contractors, Masons

> CASE STUDY: LA SPORTS HALL OF FAME PROJECT

> PROJECT EXAMPLE: Houston Market Square – cast stone cladding combined applications for stone façade, pilasters, coping, cornices and bandings – custom color emulating Lueders limestone.

Project: Houston Market Square | Custom Dark Color Cast Stone for Veneer, Cladding | Design Accent at the Top of Building

> CASE STUDY: CAST STONE FOR HOUSTON MARKET SQUARE PROJECT

Dry cast-stone has comparable structural properties to wet-pour precast stone.

Wet-pour Architectural Precast Concrete Stone

The wet-pour manufacturing technique allows flexibility to embed structural steel or other reinforcements, making it more suitable for load-bearing architectural elements. In general, architectural precast concrete can achieve a more extended span or length for individual stone pieces.

Different finishes can be achieved on the architectural precast stone using post-cure treatments such as acid etching, sand-blasting, and other techniques. On heavy use application areas such as stair treads, architectural precast can retain the stone’s surface finishing for very long time spans.

> PROJECT EXAMPLE: Circular stair treads for Ft. Worth Arena

Ft Worth Arena | Wet-pour Architectural Precast Concrete Stone for Circular Stair Tread Design

AAS has several projects where the team has been able to work closely with customers to substitute dry-cast stone for the wet-pour stone or vice versa.

Architectural GFRC (Glass Fiber Reinforced Concrete)

The architectural GFRC is also known as lightweight concrete, offers the look and finish, as well as longevity and reliability of other stone products with much lighter weight. The proprietary manufacturing technique enables very high strength to weight ratio for the GFRC panels.

While the cost of architectural GFRC can be more than other cast stone products, it can also help with less structural support requirements and simplified installation equipment requirements.

> Design flexibility, freedom with GFRC: LEARN MORE

> GFRC Design Case Study: SMU Delta Gamma Sorority House

SMU Delta Gamma Sorority House | Architectural GFRC Columns, Cladding for Desired Building Elevation Aesthetic

> ARCHITECTURAL GFRC: PRODUCT HOME

> COMPARE PRODUCT PROPERTIES

> HOW DO I INSTALL STONE PRODUCTS?

COMBINING DIFFERENT PRODUCTS FOR A SPECIFIC PROJECT

Customers have options to combine any of the three product materials with seamless matching of color and finish.

> CASE STUDY: Project Examples where Different Product Materials Are Combined for Design Objectives

> St. Francis Xavier Church: High-end Design Combined cast stone, wet-pour concrete stone and GFRC (Glass Fiber Reinforced Concrete) panels

Advanced Architectural Stone (AAS) has a dedicated customer project team working closely with customers right from the design phase. As required, the team can support customers in selecting the most appropriate product(s) application for any size projects.

In case of specific questions about your project, complete the request support form at the bottom of this page, and someone from our customer projects team will be in touch with you shortly.

The post HOW DO I SELECT RIGHT PRODUCT(S) FOR MY PROJECT? first appeared on Advanced Architectural Stone.

GFRC: LARGE SIZE COLUMN COVERS

Admin — Tue, 18 Jun 2019 01:28:11 +0000

The GFRC products have high structural strength thanks to fibers reinforcement integrated at the time of manufacturing. At the same time, the GFRC panels are only 3/4″ thick enabling much higher strength to weight ratio than any other manufactured stone products.

AAS is able to develop column covers that are more than four feet in diameter. Images below show halves of the column wraps that don’t require any structural support.

Four Feet Diameter GFRC Column Wraps

GFRC Column Covers – Inherent Strength of Glass Fiber Reinfoced Concrete

> LEARN MORE: ARCHITECTURAL COLUMNS

> LEARN MORE: ARCHITECTURAL GFRC (Glass Fiber Reinforced Concrete)

The post GFRC: LARGE SIZE COLUMN COVERS first appeared on Advanced Architectural Stone.