Custom Molds Enable Complex Shapes, Intricate Designs, Monolithic Veneers

Jeffersonian Design using Custom Design Manufactured Stone | Old Parkland, Dallas, TX | Specially Designed Columns, Egg-n-Dart Rope Design, Large Dentils, Profile | Project Specific Custom Molds, Product Batch Mixing, Manufacturing, Sequencing, Delivery, Installation Support

Jeffersonian Design using Custom Design Manufactured Stone | Old Parkland, Dallas, TX | Specially Designed Columns, Egg-n-Dart Rope Design, Large Dentils, Profile | Project Specific Custom Molds, Product Batch Mixing, Manufacturing, Sequencing, Delivery, Installation Support


Custom molds create unlimited design freedom to create architectural stone panels with complex shapes.

Following video explains more about the CNC machine technology and the design expertise are used to create custom molds for manufactured cast stone, GFRC and architectural precast.

Project examples in this blog post show range of architectural stone applications.

 


 

PROJECT: SMU COMMONS

 

Custom molds made it possible to create large size, unique cast stone pieces that fit together precisely. Precise tolerances and detailed engineering achieved monolithic design for the facade veneer of the building.

 

Architectural Stone Cladding, Veneer Design using Custom Designed Stone - Mold Making Technology, Design Craftsmanship - cast stone, precast, GFRC

Project: SMU Commons Building Facade | Architectural Stone Cladding, Veneer | Cast Stone, Precast Concrete, GFRC

 

Project: SMU Commons | Architectural Stone Cladding, Veneer Design | Custom Mold Making | Design and Technology

Project: SMU Commons | Architectural Stone Cladding, Veneer Design | Custom Mold Making | Design and Technology

 

Architectural Stone Cladding | Cast Stone, Precast, GFRC

Architectural Stone Cladding | Cast Stone, Precast, GFRC

 


 

PROJECT: The Westbrook Building, Sundance Square, Ft. Worth, TX : Art Deco Panels

 

On The Westbrook Building, cast stone was used in the overall design of the building to be reminiscent of the Art Deco structures located in many areas in Ft. Worth.

AAS Project: The Westbrook - Sundance Square West - Ft Worth, TX | Art Deco Design using Cast Stone | Custom Mold Design | Architect: Bennett Benner Pettit, Inc

AAS Project: The Westbrook – Sundance Square West – Ft Worth, TX | Art Deco Design using Cast Stone | Custom Mold Design | Architect: Bennett Benner Pettit, Inc

 

Architectural Stone made the molds for the Art Deco designs from isometric sketches provided by the architect.  In other words, the sketches provided three sides, all in dimensional proportion, but none were shown as a true shape with 90 degree corners.

The sketch was only a guide to making actual size molds.  Artisan designers created molds for the Art Deco panels combining their design craftsmanship with extensive CAD drafting and also precision cutting using CNC machines.

 

The Westbrook Building at Sundance Square, Ft Worth, TX | Art Deco Design, Custom Design Elements using Cast Stone, GFRC

The Westbrook Building at Sundance Square, Ft Worth, TX | Art Deco Design, Custom Design Elements using Cast Stone, GFRC | Architect: Bennett Benner Pettit, Inc

 

PROJECT CASE STUDY >>


 

PROJECT: High-End Design Element Using Custom Mold – Rockwall County Court House

 

The architect for this project had vision for unique design elements on the exterior of the building. AAS team designed highly intricate mold to create it in cast stone. The precise tolerance and detailed coordination with the construction team helped create the desired look with smooth installation that completed on time.

Advanced Architectural Stone - AAS - Formerly Advanced Cast Stone | Rockwall County Courthouse | Cast Stone, Precast | Technology Allowed Complex Shapes and Desired Aesthetic Design | Brinkley Sargent Architects | DMG Masonry

Advanced Architectural Stone – AAS – Formerly Advanced Cast Stone | Rockwall County Courthouse | Cast Stone, Precast | Technology Allowed Complex Shapes and Desired Aesthetic Design | Brinkley Sargent Architects | DMG Masonry


 

PROJECT: Texas Christian University (TCU) Relief Panels

 

This project consisted of 6 panels installed in the entry to the remodeled and enlarged football stadium at Texas Christian University. The panels were made using architectural percast and cast stone. The purpose of the panels and the project was to honor and recognize the original founders of the University dating to 1895.

Architect for the project, HKS Architects hired an artist to approve and render the murals. The AAS team transferred the original art work to a rubber mold for casting. The panels represent the cultural icon at the heart and soul of the Texas Christian University. It was critical that the panels can be seen within a few feet of viewer. AAS team used its experience and technology to refine every detail within the mold, so that panels accurately depict the original aesthetic appeal so critical to project’s success.

The project won 2014 APA (Architectural Precast Association) Craftsmanship Award.

Here is a composite showing example panels.

AAS 2014 APA Award | TCU Relief Panels | Finish and Precision for Design Appeal | HKS Architects | General Contractor: Austin Commercial

AAS 2014 APA Award | TCU Relief Panels | Finish and Precision for Design Appeal | HKS Architects | General Contractor: Austin Commercial

 

AAS 2014 APA Award | TCU Relief Panels | Forming using Precise Molds, Design Experience | HKS Architects | General Contractor: Austin Commercial

AAS 2014 APA Award | TCU Relief Panels | Forming using Precise Molds, Design Experience | HKS Architects | General Contractor: Austin Commercial


 

PROJECT: LA Sports Hall of Fame – Complex Shaped Panels – LA Sports Hall of Fame

 

Trahan Architects had vision for emulating Cane river channels inside the Louisiana Sports Hall of Fame Museum. This required cast stone panels with complex shapes. Panels were also very large in size. The project execution also demanded stringent tolerance requirements in the mold, so the panels would fit in seamlessly for monolithic look.

LA Sports Hall of Fame | Cast Stone | Architect: Trahan Architects | Masonry Contractor: Masonry Arts

LA Museum & Sports Hall of Fame | Cast Stone | Large Panels with Complex Geometry | Trahan Architects | VCC | Masonry Arts

 

LA Sports Hall of Fame | Large Size Precision Molds for Design That Had Highly Stringent Tolerance Requirements

LA Sports Hall of Fame | Large Size Precision Molds for Design That Had Highly Stringent Tolerance Requirements

 

LA State Museum and Sports Hall of Fame | Cast Stone Realized Cane River Channels | Large Complex U-Shaped Stone Pieces | BIM Modelling | Trahan Architects | CASE STUDY ...

LA Sports Hall of Fame | Cast Stone Realized Cane River Channels | Trahan Architects | CASE STUDY >>

 

LA State Museum Sports Hall of Fame | Trahan Architects | Cast Stone Veneer Developed using Complex Shaped, Large Cast Stone Pieces Fitting within Stringent Tolerance Requirements | LEARN MORE About Design, Manufacturing Process...

LA State Museum Sports Hall of Fame | Trahan Architects | Cast Stone Veneer Developed using Complex Shaped, Large Cast Stone Pieces Fitting within Stringent Tolerance Requirements | LEARN MORE About Design, Manufacturing Process…

 

PROJECT CASE STUDY: LA SPORTS HALL OF FAME >>


 

PROJECT: 714 Main Street – Authentic High Design Roman Heads using Custom Molds

 

This project required matching building exterior color with the terracotta stone that was used to clad the building exterior.

714 Main St - Seamless Exterior Effects of Cast Stone Color Matching - Precision Mold Making

AAS Technology | Seamless Exterior Effects of Cast Stone Color Matching | Custom Molds With Precision

 

The design had the Roman Heads depiction on the outside which were authenticated and designed by artists. AAS team worked closely with the architect and artist to design and create the depictions in cast stone that matched the original rendering of the artist precisely.

 

AAS Custom Mold Making | Roman Head Design in Cast Stone for 714 Main Street Building, Dallas, TX | Cast Stone Cladding

AAS Custom Mold Making | Roman Head Design in Cast Stone for 714 Main Street Building, Dallas, TX | Cast Stone Cladding

 

AAS Project: 714 Main Street | Unique Technology, Craftsmanship to Replicate design of Roman Heads | Product used Architectural Cast Stone

AAS Project: 714 Main Street | Unique Technology, Craftsmanship to Replicate design of Roman Heads | Product used Architectural Cast Stone

 

See more on this project…


 

PROJECT: Grapevine Convention and Visitors Bureau

 

AAS team helped create exterior fronts of the building that used cast stone and architectural precast extensively. The design used grape leaves build from the cast stone panels. The grape leaf design and integration was to connect with the historic name of the city and local culture.

The AAS project team used custom molds to create highly intricate grape leaf design elements that are accurate representation of the original design renderings.

 

AAS Cast Stone | Custom Mold Making | Grapevine Leaf Designed using Dry Cast System

AAS Cast Stone | Custom Mold Making | Grapevine Leaf Designed using Dry Cast System

 

Specialized Rubber Molds for Grape Leaf Design | Cast Stone Design for Grapevine Convention and Visitors Bureau

Specialized Rubber Molds for Grape Leaf Design | Cast Stone Design for Grapevine Convention and Visitors Bureau

 

PROJECT: Grapewine Convention & Visitors Bureau | Cast Stone | Architect: ArchiTexas | Contractor: Thomas S Byrne

Grapewine Convention & Visitors Bureau | Cast Stone | APA Award of Excellence | Architect: ArchiTexas | Contractor: Thomas S Byrne | J & E Masonry

 

AAS Cast Stone Project | Specific Color Contrast Requirements from the Architect of the Project ArchiTexas | Grapevine Convention & Visitors Bureau

AAS Cast Stone Project | Specific Color Contrast Requirements from the Architect of the Project ArchiTexas | Grapevine Convention & Visitors Bureau

See more on Grapevine Convention Center and Visitors Bureau Project…


 

PROJECT: Gilbert Christian High School – Custom Molds for Architectural GFRC

 

Gilbert Christian High School is located in city of Gilbert in the Scottsdale (AZ) area. The school exterior used extensive Architectural GFRC elements that were easy to integrate with the exterior thin brick veneer of the building. The column capitals have Corinthian style.

PROJECT: Gilbert Christian High School | Cast Stone, Precast

PROJECT: Gilbert Christian High School | GFRC (Glass Fiber Reinforced Concrete) – Learn More About It…

 

AAS Architectural GFRC Case Study | Gilbert Christian Case Study

AAS Architectural GFRC Case Study | Gilbert Christian Case Study

See more about the Gilbert Christian High School project in the case study…


 

PROJECT: Texas Christian University (TCU) Worth Hills – Large Sized Molds for Curved Panels

 

This is a new development added to the school campus.

The entry way of the building has very high elevation breeze way. The cast stone and architectural precast panels required custom molds that enabled panels of such a big size that would fit together to create seamless effect in the breeze way.

 

TCU Worth Hills Village | Cast Stone Exterior Design | KSQ Architects | Wilks Masonry

TCU Worth Hills Village | Cast Stone Exterior Design | KSQ Architects | Wilks Masonry

 

AAS Project - TCU - color matching - custom molds for Large Complex Curves - Download case study

AAS (Formerly ACS) | Project: Texas Christian University (TCU) Worth Hills Campus, Entry Gate | Cast Stone, Architectural Precast


 

PROJECT: SMU Simmons Hall Project: Precise molds, Construction Support, Coordination

 

SMU Simmons Hall Construction | Precise engineering, Custom Manufacturing of Architectural Cast Stone for the Portico Columns

SMU Simmons Hall Construction | Precise engineering, Custom Manufacturing of Architectural Cast Stone for the Portico Columns

Precision in Design Details - Complex Curved Cast Stone Pieces Fit Together Seamlessly Without Carving or Retrofitting

Accuracy in Design Details – Complex Curved Cast Stone Pieces Fit Together Seamlessly Without Carving or Retrofitting

Installation of Portico Columns | Cast Stone Pieces Planned in Sequence of Releases and Clear Labeling Simplified Onsite Construction

Installation of Portico Columns | Cast Stone Pieces Planned in Sequence of Releases and Clear Labeling Simplified Onsite Construction

Portico Column from Inside | Columns inset in Radial Wall Installed Easily with Precise Custom Shaped Pieces and Careful Planning

Portico Column from Inside | Columns inset in Radial Wall Installed Easily with Precise Custom Shaped Pieces and Careful Planning

The 40,000 sq. ft. building has large columns that are four-story high with diameter of 5-6 feet. The side of the building has cylindrical portico, the precise integration of the columns in the radius wall required a large number of unique cast stone pieces that fit seamlessly for intended design effect.

SMU Simmons Hall Project Case Study: SEE MORE >>