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THE SYSTEM FOR PRODUCT QUALITY

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 team focus, project specific support for every customer

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

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

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

HOW DO YOU INSTALL CAST STONE?

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

AAS provides three different product materials for architectural stone applications – dry vibrant-tamp cast stone, wet-pour architectural precast concrete and GFRC (Glass Fiber Reinforced Concrete (GFRC).

Dry Vibrant-tamp Cast Stone

 

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

Learn more about the vibrant-tamp casting process in this video:

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

 

LA Sports Hall of Fame | Cast Stone | Architect: Trahan Architects | Masonry Contractor: Masonry Arts | SEE CASE STUDY ...

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.

 

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

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 longer span or length for individual stone pieces.

Different finishes can be achieved on 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 surface finishing of the stone 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

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

 

AAS has a number of 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.

GFRC (Glass Fiber Reinforced Concrete)

 

The GFRC also known as light weight concreate offers 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.

 

> 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

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

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

 

> Refer to the products comparison guide to learn more about product properties.

 

Advanced Architectural Stone (AAS) has dedicated customer projects team with experience to work closely with customers right from the design phase. As required, the team is able to support customers with selection of the most appropriate product(s) application for projects of any size.

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

 

GFRC: LARGE SIZE COLUMN COVERS

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)

 

BALUSTERS MANUFACTURED IN ONE PIECE: GFRC

Balusters are used for design accent with commercial as well as residential buildings for centuries.

AAS GFRC manufacturing technique is able to cast balusters in one piece without any seams. This enables superior design aesthetic while also simplifying the installation of the balusters at the construction site.

The fabrication method uses mold for each side or half of the baluster. The inside of the molds is sprayed with a thin layer of the GFRC mix for the desired finish.

Mold for for casting balusters

Mold for for casting balusters

Spraying outer layer of GFRC mix for desired look and finish of balusters

Spraying outer layer of GFRC mix for desired look and finish of balusters

Inspection, hand packing using brush for uniform surface finish quality

Inspection, hand packing using brush for uniform surface finish quality

Inspection, hand packing using brush for uniform surface finish quality

Inspection, hand packing using brush for uniform surface finish quality


After that the two mold pieces are held together to fill in the GFRC admixture inside. The center of the cylindrical space has 2” wide PVC, so that way the finished GFRC baluster has hollow core in the middle.

GFRC balusters cast in one piece

GFRC balusters cast in one piece


In a typical installation, threaded rod is passed through the hollow core in the middle. The rod is attached to the steel channel for securing balusters in place. The AAS team is able to custom design the handrail for the balustrade system so that it has groove from inside to conceal the steel channel inside.

The AAS team is able to make project specific molds as required for the custom size and shape of the balusters.

AAS is able to match color of any control sample provided by the customers.

The AAS team is able to guide customers with selection of the product material, as well as the most appropriate installation details that would achieve the desired design intent.

Balustrade System, Columns, Cladding Design for Harold Clark Simmons Hall, SMU

Balustrade System, Columns, Cladding Design for Harold Clark Simmons Hall, SMU

 

> LEARN MORE ABOUT DESIGN OF BALUSTERS, BALUSTRADE SYSTEM DESIGN

CONCRETE: UNPARALLELED DESIGN FLEXIBILITY, OPTIONS

Concrete has captured the imagination of designers for thousands of years offering options and flexibility to mold it in different shapes and surface finishes.

GFRC (Glass Fiber Reinforced Concrete), also known as lightweight concrete, is able to extend the range of possibilities that can be realized using concrete. It uses the casting flexibility of traditional concrete to create a wide range of shapes and surface finishes difficult to achieve using traditional production methods. GFRC panels are much lighter and much easier to shape and are typically offered with pre-engineered support systems, making easier to install.

The Glass Fiber Reinforced Concrete (GFRC) panels can match the color and finishes of virtually any kind of stone products including natural lime stone, dry vibrant-tamp cast stone, wet our precast concrete stone, terracotta stone, etc. GFRC can be integrated with brick veneer or other exterior façade applications that include steel and glass as well.


GFRC - Glass Fiber Reinforced Concrete - Design options, flexibility

GFRC – Design options, flexibility

DESIGN FREEDOM, FLEXIBILITY

 

  • Concrete finishes that match a wide range of stone products.
  • The manufacturing process can achieve virtually any shape or color.
  • Consistent look and finish for projects of any size.

> LEARN MORE


GFRC - Structural, Engineering, Installation Advantages

Structural & Installation Advantages

TECHNOLOGY ADVANTAGES

 

  • Light weight, high strength to weight ratio.
  • Much simpler structural support, easier onsite installation.
  • Customize panel shapes, anchorage connections as required.

> LEARN MORE


GFRC - Project Specific Manufacturing, Support

Project Specific Fabrication, Support

PROJECT SPECIFIC MANUFACTURING

 

> LEARN MORE ABOUT MANUFACTURING PROCESS


GFRC Design Process Case Study - SMU Delta Gamma Sorority House Project

GFRC Design Process Case Study

DESIGN PROCESS CASE STUDY

 

  • See examples of project specific design of GFRC products.
  • See videos of GFRC manufacturing process.
  • Collaboration with customers for design assist, as well as construction assist.

> LEARN MORE


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

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

 

 

 

> LEARN MORE: ARCHITECTURAL GFRC

ARCHITECTURAL DETAILING OF GFRC

Architectural detailing needs to be a shared responsibility between the architect, the manufacturer and the manufacturers engineer. An attachment design by the manufacturer, rather than the architect, is often appropriate for many GFRC projects. The shop drawings will provide the architect and installer an opportunity to review the attachment and make the final detailing.

 

General Rules for attachment

 

  •   GFRC pieces up to about 4 feet x 6 feet can often be produced without an additional structural back-up. The manufacturer will add a stiffener-rib to the product back side for added support. A stiffener usually runs the height of the piece every 24 to 30 inches of the product and has very concentrated glass fiber to cement mix. The product can be attached via a veneer tie and strap, kerf and clip, or similar attachment to the structure of the building.
  • Larger pieces or pieces where a stiffener-rib is not appropriate are generally hung with a metal stud back-up. The metal stud system is designed and attached to GFRC piece by the manufacturer as part of the cost of the GFRC on the project. Metal stud back-up is very similar to metal stud framing on most commercial projects, but designed with more precision. The metal stud back-up is usually attached with a grade #2 bolt to the structure of the building. There are occasions where the metal stud framing is welded to the structure. Again the specifications on the welding should follow AWS standards.
  • Very large pieces (larger than 8 feet x 20 feet) will have tube steel back-up. The process is much the same as with metal studs discussed above. This back-up will be engineered by the manufacturer.

 

Installation

 

  1.  AAS is able to provide type of connection that is preferred by customer. GFRC provides flexibility with selection of the connection type.
  2. Once the connections are selected, the AAS manufacturing and design process is able to pre-engineer the connections support in the products.
  3. GFRC is much simpler and less expensive to install compared to other much heavier stone products. GFRC installation doesn’t require extensive support structure and heavy construction equipment at the project site.
  4. AAS GFRC products provide flexibility to select/use right application of caulk or sealants making it easier for masonry contractors not only in their installation process, but also with long term reliability of the installed projects.

 

> LEARN MORE: ARCHITECTURAL GFRC

CUSTOM DESIGN COLUMNS: HIGHLIGHT OF THE SHOPPING CENTER

The architect had vision to add an elevator and clock tower to the Highland Park Village shopping center that has unified architectural style. Developing intricate design details in the stone and matching the color and finish so that the new building would connect to the surrounding area that had been in existence for over 80 years.

Highland Park - Ornate Architectural Design Integrating Specialized Colums, Highly Decorative Design Elements

Highland Park – Ornate Architectural Design Integrating Specialized Columns, Highly Decorative Design Elements

Clock tower connected with seventy five years old shopping center area | columns at the top accentuate the design accent and shopping mall experience

Clock tower connected with seventy five years old shopping center area | columns at the top accentuate the design accent and shopping mall experience

Highland Park High Design Custom Columns

Highland Park High Design Custom Columns

 

 

Rubber mold for column cap design

Rubber mold for column cap design

The AAS project team developed the drawings for the project from templates without requiring detailed architectural plans. The templates were compared to the existing product and adjustments were made to achieve the precisely matching three dimensional design. The system to capture and communicate in-depth details using CAD drawings assisted the design process confirming the project feasibility in early stages of the project. The integrity of the details was made possible using CNC technology to fabricate the required molds. For high intricate design details in the column caps at the top, rubber molds were used.

Design Details for the top of the clock tower at highland park village shopping center

Design Details for the top of the clock tower at highland park village shopping center

 

Shop Drawing - Clock Tower Design at Highland Park Shopping Center

Shop Drawing – Clock Tower Design at Highland Park Shopping Center

 

Shop Drawing - Details for Support, Anchorage, Installation Connections

Shop Drawing – Details for Support, Anchorage, Installation Connections

 


The AAS team confirmed and communicated installation details for each stone piece used in this tower design. Installers got detailed settings plan with identification of each stone piece.

The clock tower looks as if it were part of the original design of the shopping center. The architectural columns accentuate the overall experience of the shopping center.

Products used: Cast Stone, GFRC (Glass Fiber Reinforced Concrete)
Architect: Omni Planners Architects
General Contractor: W B Kibbler Construction
Masonry Contractor: Metro Masonry

 


> ARCHITECTURAL COLUMNS

 

 

CONCRETE STONE COLUMN COVERS, COLUMN CAPS

Manufactured stone products provide flexibility to create fully customizable column covers, column wraps that can match with the design vision.

 

Colin Library Project - Cast Stone Wall Caps. Columns, Banding, Cornices for Unifying Custom Design AccentCast Stone | Architectural Precast | Architectural GFRC | Columns, Balustrade System, Columns, Pier Caps, Architectural TrimArchitectural-Precast-Columns-options-for-sizes-color-and-finish-1000x600SMU Simmons Hall | Cast Stone, GFRC, Precast Concrete | Large Size Columns Designed using Custom Molds | DOWNLOAD AND LEARN MORE >>Unlimited Design Freedom with Manufactured Architectural Cast Stone, Precast Concrete, GFRC | Seamless Matching with Different Materials for Optimum Value EngineeringCustom Mold Making | Precision and Consistency in Stone Tolerances along with Custom Shapes for High End DesignGFRC Fulted Columns, Corinthian Capitals | SMU Delta Gamma Sorority HouseFluted GFRC Columns, Cornices using Precise Custom Molds and Cutting Edge Manufacturing CapabilitiesColor matching and consistency over the entire project is an advantage with manufactured cast stone | Large stone pieces exceeded stringent tolerance requirementsAdvanced Architectural Stone (AAS) |Technology - Custom Molds using CNC Machining, Consistent Product Quality using Computerized Batch PlantCast stone pieces for column secured using steel plates and anchorsArchitectural Stone Cladding | Wall Coping, Window Trims, ColumnsArchitectural Columns, Cladding for Portico | Project: SMU Simmons HallCustom Shaped Large Cast Stone Pieces Fitting Together without Additional Work at the Construction SiteAAS Project: SMU Simmons Hall | Architect: Perkins and Will | General Contractor: Vaughn Construction | Masonry Contractor: Wilks Masonry | Manufactured PRODUCTS: Architectural Cast Stone, GFRCSMU 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 DesignBuilding Cladding and use of Ionic Columns | Product Used: Architectural Cast Stone | Laura Lee Blanton BuildingAAS Architectual GFRC Project | Gilbert Christian High School | GFRC Eave Moldings Wrap the Entire Roof Line of the Structure ...AAS Architectural GFRC - Material Technology, Precise Mixing for Required Strength and Looks

 

Three Product Material Options

 

Dry vibrant-tamp cast stone provides design flexibility to custom design column covers with complex design while also providing competitive structural properties.

Wet-pour precast concrete enable options to embed structural support for load bearing column applications.

Architectural GFRC (Glass Fiber Reinforced Concrete) column wraps are only ¾” thick and yet have high strength to weight ratio, simplifying structural support requirements for higher elevation applications.

 

Project Specific Support: Custom Fabrication

 

Advanced Architectural Stone (AAS) has extensive track record for integrating columns with overall design for cladding applications, exterior stone veneer or façade applications, cornices and bandings, architectural trim around building entry ways/windows/doors, wall coping, etc. As required, design can be realized while combining different product materials as well while maintaining uniform/seamless design aesthetic.

The AAS team is able to collaborate with design team using SHOP drawings to confirm design feasibility and developing pre-engineered anchoring conditions for easy installation of the columns.

AAS helps contractors with columns covers and wraps for both commercial as well as residential applications.

Customers have flexibility to match any color with the control sample.

When required, designers have option to select column designs from an extensive range of in house molds inventory. This can help with faster turnaround times for stone concrete columns designs.

Use the support request form to ask about in-house inventory of architectural column covers, column wraps.

 

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 installationCustom molds enabling precise matching of intricate cast stone piecesCast stone protection, design accentCast stone cladding for Ft Worth Arena buildingLarge size cast stone pieces for banding, wall coping all around the Ft Worth ArenaLarge size complex shapes with stringent tolerance requirementsArena Tower from the side view at top of the buildingOnsite installation support, coordination, troubleshootingCast 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