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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 Accent Cast Stone | Architectural Precast | Architectural GFRC | Columns, Balustrade System, Columns, Pier Caps, Architectural Trim Architectural-Precast-Columns-options-for-sizes-color-and-finish-1000x600 SMU 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 Engineering Custom Mold Making | Precision and Consistency in Stone Tolerances along with Custom Shapes for High End Design GFRC Fulted Columns, Corinthian Capitals | SMU Delta Gamma Sorority House Fluted GFRC Columns, Cornices using Precise Custom Molds and Cutting Edge Manufacturing Capabilities Color matching and consistency over the entire project is an advantage with manufactured cast stone | Large stone pieces exceeded stringent tolerance requirements Advanced Architectural Stone (AAS) |Technology - Custom Molds using CNC Machining, Consistent Product Quality using Computerized Batch Plant Cast stone pieces for column secured using steel plates and anchors Architectural Stone Cladding | Wall Coping, Window Trims, Columns Architectural Columns, Cladding for Portico | Project: SMU Simmons Hall Custom Shaped Large Cast Stone Pieces Fitting Together without Additional Work at the Construction Site AAS Project: SMU Simmons Hall | Architect: Perkins and Will | General Contractor: Vaughn Construction | Masonry Contractor: Wilks Masonry | Manufactured PRODUCTS: Architectural Cast Stone, GFRC 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 Building Cladding and use of Ionic Columns | Product Used: Architectural Cast Stone | Laura Lee Blanton Building AAS 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 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