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CLADDING FT WORTH ARENA: LARGE SIZES + CUSTOM SHAPES + PRECISION

The new Ft. Worth Arena design has used exterior stone cladding all around the building. The AAS team custom fabricated cast stone for this application.

 

Pre-engineered anchoring connections simply installation Custom molds enabling precise matching of intricate cast stone pieces Cast stone protection, design accent Cast stone cladding for Ft Worth Arena building Large size cast stone pieces for banding, wall coping all around the Ft Worth Arena Large size complex shapes with stringent tolerance requirements Arena Tower from the side view at top of the building Onsite installation support, coordination, troubleshooting Cast stone pillasters, baluster design

 

The AAS team confirmed design feasibility working closely with the architect and contractor  using CAD drawings. AAS leveraged manufacturing flexibility to mold both sides of the stone pieces using the dry vibrant-tamp casting process for the stone panels. Custom molds were developed using the CNC technology. With each custom designed stone panel matching stringent tolerance requirement, the bandings, cornices, wall coping, pilasters, balusters and large size architectural trim match the complex angles and wide range of shapes precisely.

The cast stone matched color with wet-pour precast concrete used on stair trades and also large size GFRC panels.

With detailed planning and close coordination with customer, the manufacturing schedule matched with the construction milestones for smooth execution of this massive cladding application for the arena.

AAS worked closely with the installers for onsite troubleshooting.

 

> FT WORTH ARENA CASE STUDY

 

PRECAST CONCRETE: PRECISION ENGINEERING FOR CIRCULAR STAIR TREADS

The Ft. Worth Arena has circular stairs leading to the entry level as shown in the image below. The AAS team custom fabricated the stone pieces using wet-pour architectural precast concrete to realize the design vision of concentric circular pattern.

 

Ft Worth Arena Project | Concentric Circles of Stair Treads Achieved using Wet-pour Architectural Precast Concrete

Ft Worth Arena Project | Concentric Circles of Stair Treads Achieved using Wet-pour Architectural Precast Concrete

 

Precision Engineering, Design Assist, Construction Assist

 

  • The AAS team developed custom molds for unique radial shape of the stone pieces required for stair treads at every step/level.
  • The molds design included the circular grooves required on each stone piece.
  • The shape, size and tolerance for each stone piece was confirmed in the design phase using CAD drawings.
  • The project team provided detailed settings plan that identified position of every stone piece.

 

Ft Worth Arena | Wet-pour Architectural Precast Concrete Stone for Circular Stair Tread Design Project Specific Fabrication of Stone Panels | Product: Wet-pour Precast Concrete Grooves in the Stone Pieces to Match Overall Pattern of Circular Stair Tread Designed using Precast Concrete Stone Design Freedom, Flexibility with Custom Manufacturing of Architectural Stone | Precast Concrete Pieces Fitting Flawlessly to Realize Design Vision Precise Custom Molds with Stringent Tolerance Requirements Confirmed using CAD Drawings | Project Specific Manufacturing for High-end Design, Smooth Project Execution AAS Project Planning, Collaboration Matched Manufacturing Schedule with Building Construction Milestones

 

The in-house color lab developed batch mixes to coordinate color of the precast concrete panels with the dry vibrant-tamp cast stone, and GFRC panels used on the exterior façade & surrounding support buildings of the arena.

Detailed engineering enabled stair treads design to dissolve with the overall end user experience.

 

> WET-POUR ARCHITECTURAL PRECAST CONCRETE

 

> FT WORTH ARENA CASE STUDY

 

 

CAST STONE RIBBONS INTEGRATED WITH BRICK VENEER AND GLASS

Project Name: The Cassidy Building
Location: The Sundance Square, downtown Fort Worth, Texas
Product: Dry Vibrant-tamp Cast Stone

Architect: Bennett Benner Pettit Architects
General Contractor: Beck Group
Masonry Contractor: DMG Masonry

The architect for the project, Bennett Benner Pettit Architects had design vision to incorporate horizontal ribbons in the repeating pattern seamlessly integrated with contours of the building façade consisting of brick veneer and glass.

 

Sundance Square Cassidy Building | Cast Stone Ribbons Integrated with Glass Sundance Square Cassidy Building | Custom Fabricated Cast Stone Pieces for Monolithic Design Sundance Cassidy Building | Timeless and yet Contemporary Design integrating Cast Stone Ribbons with Brick and Glass Exterior Sundance Square Cassidy Building | Large Cast Stone Pieces Coordinated with Glass

 

The AAS team custom fabricated cast stone panels that realized the ribbon design with precision. With the shape and tolerance of each stone piece confirmed using CAD drawings, the stone ribbons look monolithic on the building envelope. The anchorage support was pre-engineered in each stone panel simplifying the installation process.

The design of the 99,000 sq. ft. Cassidy Building feels timeless and yet contemporary at the same time.

 


HARDSCAPE – COPING STONES & STONE CAPS, WALL COPING

Custom manufactured coping stones and caps can be integral to a unifying hardscape design theme while also providing vital protection from rainfall penetration.

The AAS team is able to match the color and finish of the wall coping seamlessly with other manufactured stone design elements of a building such as stone cladding and veneer design, building elevation design, door and window trims, banding, cornices, etc.

Customers are able to:

  • Select and combine from three different products – dry vibrant-tamp cast stone, architectural wet-pour precast concrete, or GFRC (Glass Fiber Reinforced Concrete)
  • Customize stone products for curved walls, complex shapes, ramped walls, stepped walls, etc.
  • Match any color with control sample.

Cast Stone Caps, Signage

Old Park Land Exterior Hardscape | Wall Coping, Signage, Column Capitals | Designed Contrast with Brick Work

Old Park Land Exterior Hardscape | Wall Coping, Signage, Column Capitals | Designed Contrast with Brick Work

Unifying Design Accent

Texas State University (TSU) Wall Coping Matching with Cast Stone Signage as well as Natural Limestone Work, Building Cladding

Texas State University (TSU) Wall Coping Matching with Cast Stone Signage as well as Natural Limestone Work, Building Cladding

Custom Wall Cap Design

Cast Stone Wall Coping, Custom Signage

Cast Stone Wall Coping, Custom Signage

VIDEO: MAJESTIC SPIRES, DETAILED ARCHES, STONE CLADDING FOR ST. FRANCIS CHURCH

The American Gothic style design for the St. Francis Xavier Catholic Church in Stillwater, Oklahoma required very detailed arches, window ornamentation, and large spires that weighed over 7,000 lb:

 

The custom cladding design combined three different product materials:

  1. Wet-pour precast concrete was used for large size stone pieces used in the spires.
  2. Detailed design work on arches, banding, cornices was realized using dry vibrant-tamp cast stone panels.
  3. Cornices, coping and design accent panels at higher elevation were developed using GFRC (Glass Fiber Reinforced Concrete).

Color and finish matched seamlessly among the three product materials developing high-end design accent to the multi blended brick veneer.

 

> LEARN MORE: PROJECT CASE STUDY – ST. FRANCIS XAVIER CHURCH

 


> COMBINE STONE PANELS FOR OPTIMUM DESIGN: CASE STUDY

 

> AAS PROJECT EXECUTION: DESIGN SUPPORT


 

FLUTED COLUMNS

The AAS team is able to design project specific columns to integrate with the overall theme of the designer.

 

See video clips to understand steps for manufacturing Fluted GFRC columns.

 

Fluted GFRC Columns - Architectural GFRC Manufacturing Process

Fluted GFRC Columns – Architectural GFRC Manufacturing Process

 

GFRC Fulted Columns, Corinthian Capitals | SMU Delta Gamma Sorority House

GFRC Fulted Columns, Corinthian Capitals | SMU Delta Gamma Sorority House

 

 

HOW DO YOU GET THE COLOR YOU NEED FOR YOUR DESIGN?

Advanced Architectural Stone (AAS) has developed a number of admixture compositions that provide a range of options. See below in this blog post the options for standard as well as premium colors available to designers.

  • When customers have a specific color requirement to integrate the stone in the overall design vision, the AAS team has experience to develop any custom color to match the control sample.
  • AAS has computerized color lab to develop the right mix for the stone panels. Since the color is achieved using the mix used for casting the panels, AAS stone panels don’t fade with time.
  • With the computerized batch plant, the fabricated stone products have consistent color for project of any size. AAS is able to guarantee accurate color matching even when a project continues for a number of years over number of phases.
  • AAS is able to combine three different types of stone panels for a project with seamless color matching.
  • The AAS team develops the required admixture and provides samples for customers to confirm the color and texture of the stone panels.

 

> PROJECTS GALLERY: CUSTOM COLORS

 

 

AAS COLORS CHART

 

AAS Stone Panel Color Chart | Standard Colors

AAS Stone Panel Color Chart | Standard Colors

 

 

PREMIUM COLORS

AAS Stone Panel Color Chart | Premium Colors

AAS Stone Panel Color Chart | Premium Colors

 

> COMPUTERIZED COLOR LAB: VIDEO

 

 

CREATIVITY, PRECISE DESIGN MATCHING FOR SUNDANCE PALACE THEATER

2017 APA Design Craftsmanship Award - Sundance East - Palace Block GFRC Keystone, Banding, Architectural Trim with Fish Pattern, Cornice with Denteel Pattern Retail, Entertainment Building Design Accent using Cast Stone, GFRC Intricate Fish Pattern, Key Stone Matched Exactly with Architects Renderings | GFRC product material Hand Carving in Clay on Top of Custom Design Wooden Piece to Match Architects Rendering for Keystone Creative Hand Design Touch in Clay to Develop Rubber Mold Exactly Matching with Original Design Renderings

The AAS team worked closely with the architect and contractor to realize elevation design for the Sundance Palace Theater  in Fort Worth, TX.

Preserving the original theme of the theater building while carrying out this renovation project was the key to success. The stone pieces for this are custom manufactured using cast stone and GFRC.

The stone panels for the fish design pattern on the jamb and arch used not only the AAS technology, but also the design craftsmanship and experience of the AAS team.

AAS developed the large protruding decorative keystone in architectural GFRC product material. The original design piece was hand carved. AAS artist developed the matching replica of the keystone using clay. Once it was approved by the architects, the team used that to develop rubber mold for the piece. This mold was used in turn to fabricate the keystone with intricate design details in GFRC.

The precise matching of stone pieces for the massive cornice and dentil design at the top of the theater elevation achieved monolithic stone look.

 

Project Name:
Sundance East – Palace Block

Architect:
David M Schwarz Architects, Inc.

General Contractor:
Dennet Construction

Products:
Cast Stone, Architectural GFRC

Award: APA Design Craftsmanship Award

Cornice work and banding, particularly decorative and protruded banding, are a particular specialty for Architectural Products. The ability of Advanced Architectural Stone (AAS) to produce massively projecting elements with light weight shapes allows architects not only to achieve unattainable results in other materials, but also to achieve the form at a practical and economical cost.

 

> PROJECTS GALLERY: INTEGRATED CORNICE AND BANDING DESIGNS

COMPLEX GEOMETRY, BIM COORDINATION FOR LA SPORTS HALL OF FAME

The Louisiana State Museum and Sports Hall of Fame building houses the cultural heritage of memorabilia contributed by diverse cultures shaping the state of Louisiana and the Gulf South.

To celebrate the region’s history and location, Trahan Architects envisioned passages inside the museum to emulate fluid shapes of the braided corridors of the Cane River channels, leading the visitor through a meandering path of galleries. The AAS team manufactured large size stone panels with complex shapes to achieve architect’s vision.

 

 

Complex Geometry: Never before had stone been used as veneer with such complex geometry and size. The AAS team used BIM (Building Information Modeling) to coordinate between the design and manufacturing. This BIM effort was headed by CASE, Inc. in New York.

Smooth Finish: The AAS team verified the geometry of molds used to cast the stone, and delivered unique shaped, large pieces with stringent tolerance requirements. The stone pieces fit like a glove to achieve the fluid shapes of the museum corridors with a smooth monolithic finish.

Large Size Stone Pieces: The biggest panel used in the building was about 18’ x 12’; it weighed 9,600 lbs. The AAS team molded both the front and back sides of every panel, so that the stone pieces would fit in the narrow wall space available. The vibrant-tamp cast stone panels weighed much less compared to wet-pour cast stone products of similar size. The AAS team designed every panel with the required thickness and attachments needed for precise installation.

MODULAR COLUMNS: CUSTOM DESIGN FLEXIBILITY, FREEDOM

AAS project team works with architects, contractors and building owners in design and manufacturing of modular columns in variety of shapes and styles. AAS has a lot of experience with very large size columns as required for a project.

 

Manufactured vibrant-tamp cast stone pieces | Sequencing of products delivery, detailed palletization and labeling, settings drawings simplified installation | AAS Project: SMU Simmons Hall

Manufactured Vibrant-tamp Cast Stone Pieces | Column Design Integrated with overall Building Elevation Design at SMU Simmons Hall | Sequencing of Products Delivery, Detailed Palletization and Labeling, Settings Drawings Simplified Installation

 

Cast stone pieces for column secured using steel plates and anchors

Cast Stone Pieces for Column Secured using Steel Plates and Anchors

 

SMU Simmons Hall | Cast Stone, GFRC, Precast Concrete | Large Size Columns Designed using Custom Molds | DOWNLOAD AND LEARN MORE >>

SMU Simmons Hall | Cast Stone, GFRC, Precast Concrete | Large Size Columns Designed using Custom Molds | DOWNLOAD AND LEARN MORE >>

 

SMU Caruth Hall Architectural Stone Cladding | Cast Stone and Wet-precast Products Combined for Desired Design Accent | Large Column Porches and Entries, Design of Eaves, Window Surround Trim | Modular Columns Design

SMU Caruth Hall Architectural Stone Cladding | Cast Stone and Wet-precast Products Combined for Desired Design Accent | Large Column Porches and Entries, Design of Eaves, Window Surround Trim, Modular Columns Design

 

PROJECT: Collin Library | Architectural Cast Stone Columns

PROJECT: Collin Library | Architectural Cast Stone Columns

 

AAS | Cast Stone, Precast, GFRC | Seamlessly Integrated Custom Columns for Reagan Place, Dallas, TX | Combine Panels with Matching Color, Finish | Good Fulton & Ferrel Architects