Tag Archives: Architectural GFRC

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

 

  • Fiber glass strands selected to achiEve desired structural strength.
  • Fabrication process ensures consistent structural properties.
  • Achieve complex geometries with precise tolerance.Light weight, high strength to weight ratio.

> LEARN MORE


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 & 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

ART AND SCIENCE OF ARCHITECTURAL STONE CLADDING

Custom design, fabrication of stone panels with unlimited options to customize shapes and sizes enable unparalleled design freedom for cladding applications.

Advanced Architectural Stone (AAS) has a well-developed system to:

  • Review, revise design details while working closely with architects and contractors.
  • Pre-engineer connection & structural support systems in the stone products fabrication process. This simplifies the installation.
  • Precisely control and confirm stringent tolerance requirements.
  • Combine stone products with seamless design effect.
  • Match any color with a control sample.

PROJECT EXAMPLES:

Sundance Square

AAS Computerized Color Lab, Testing - project image - Sundance Square East - Commercial Building - retail shops, offices

Architectural Stone Cladding | Products: Cast Stone, GFRC

Cook Children's Hospital

AAS Architectural Precast Concrete Products - Large Sizes, Custom Finishes - project - cook children's hospital - large sizes, custom shapes

Fabricated Stone Panels for Exterior Cladding | Large Sizes | Custom Shapes

Grapevine Convention Center

AAS Manufactured Architectural Stone - Custom Shapes, High End Design, Products Materials options - cast stone, architectural gfrc, precast, gfrg

Technology | Craftsmanship | Customer Focus

Old Parkland Business Park

Combine Products with Seamless Look, Design Aesthetic | Opens up Design Options, Saves Cost, Simplifies Construction

Combine Products with Seamless Look, Design Aesthetic | Opens up Design Options, Saves Cost, Simplifies Construction | Wall Coping, Cornices and Banding, Unifying Design Accent using Stone Cladding

USC Fertitta Hall

USC Fertitta Hall - North Entry Arch

Jill and Frank Fertitta Hall, USC Marshall School of Business | North Entry Arch

SMU: Delta Gamma Sorority House

GFRC-Connections-Installation-Fluted-Columns-Corinthian-Capitals-SMU-Delta-Gamma-Sorority-House

GFRC Connections, Pre-engineered, Built-in Installation Support | Fluted Columns Corinthian Capitals SMU Delta Gamma Sorority House

ACU Wellness Center

ACU Wellness Center

ACU Wellness Center | Cast Stone Matched Colors of the Brick Exterior for Desired Design Appeal

GFRC ART PANELS ON FACADES OF DICKIES ARENA, FORT WORTH, TX

GFRC Panel with Detailed Design, Design MockupGFRC Panel Precisely Matching with Design DetailsIntricate Horse Head Design Developed in GFRC as per the Design VisionCustom Molds, Fabrication Technique for Large Size GFRC PanelsCustom Molds, Fabrication Technique for Large Size GFRC PanelsMockup for GFRC Panels | Dickies Arena Case StudyCustom Design GFRC Panels on Right Side of this MockupCustom Design GFRC Panels on Right Side of this MockupMockup of GFRC Art Panels | Frame Design on Panels is Asymmetrical by DesignGFRC Panels Installed at Ft Worth Arena

This blog post shows design assist process, as well as custom fabrication of the large size GFRC panels for the Dickies Arena project. The Arena is sited on the Will Roger’s Memorial Center campus in Ft. Worth, TX.

 

Custom GFRC Panels Design, Fabrication

 

The architects for the project aim to develop Art Deco design elements on facades of the arena to match with the 1930s era experience on the campus. The building facade design uses large size GFRC panels with intricate design details in them.

  • The AAS team developed series of custom molds to match the large size and intricate design details required for the project.
  • The mockups are created to confirm the shapes, details in the fabricated stone panels and color matching.
  • AAS works closely with architects and contractors to review details and confirm design feasibility.

 

AAS has capabilities now to manufacture GFRC products in its Ft. Worth plant as well.

Art, Engineering, Design Craftsmanship, Technology for Custom Mold with Specific Design Pattern

Art, Engineering, Design Craftsmanship, Technology for Custom Mold with Specific Design Pattern

Refining Specific Details in the Mold using the Personalized Design Touch after CNC Machining

Refining Specific Details in the Mold using the Personalized Design Touch after CNC Machining

Custom Designed Mold to Match Specific GFRC Panel Size and Shape with Stringent Tolerance requirements

Custom Designed Mold to Match Specific GFRC Panel Size and Shape with Stringent Tolerance requirements

GFRC Art Panels for Art Deco Design Accent at Dickies Arena, Fort Worth

GFRC Art Panels for Art Deco Design Accent at Dickies Arena, Fort Worth

 

Image below shows exterior elevation on the west side with GFRC panels integrated with the brick veneer.

 

Fort Worth Arena Partial Elevation - West Side | GFRC Panels Integrated in Exterior Veneer of the Building Along with Brick Veneer

Fort Worth Arena Partial Elevation – West Side | GFRC Panels Integrated in Exterior Veneer of the Building Along with Brick Veneer

 

CLICK HERE TO SEE HIGHER RESOLUTION IMAGE (OPENS IN NEW TAB/WINDOW) >>

 

DOWNLOAD .PDF FILE FOR DESIGN DETAILS >>



GFRC CONNECTIONS: MUCH SIMPLER INSTALLATION, INTEGRATION WITH BRICK WALL


GFRC (Glass Fiber Reinforced Concrete) is much simpler to install because of its light weight and pre-engineered connections for anchorage with substrate.

See in this video details of GFRC connections, and how different stone pieces are custom designed and anchored for installation.

The AAS design team provides settings plan that clearly shows how different stone panels install together for overall design aesthetic.


 

 

The seamless integration of manufactured architectural stone panels makes it much simpler to design exterior cladding, and veneer applications with monolithic design accent.

 

This project also show how cast stone and GFRC can be combined with seamless color matching  opening up opportunities for simplified construction, value engineering, and at the same time unparalleled design freedom.

 


 

MANUFACTURED ARCHITECTURAL STONE: PRODUCT SPECIFICATIONS

PRODUCTS COMPARISON GUIDE

How do different manufactured cast stone products compare? How do you select? SEE COMPARISON GUIDE >>

GFRC (GLASS FIBER REINFORCED CONCRETE) CEU COURSE: EARN CREDITS

VIDEO: GFRC CONNECTIONS SIMPLIFY INSTALLATION, OPEN UP DESIGN OPTIONS

GFRC products have pre-engineered, built in connections that simplifies the onsite installation.

See in this video, examples of drawings and images of products being installed at the SMU Delta Gamma Sorority House project.

AAS has bandwidth and a well developed system to work closely with architects, contractors and masons for every project. Installation support details are designed with intent of not only realizing architect’s desired design vision, but also simple, easy installation.

As required, project team works with customers in selecting combination of products that would achieve design cost effectively.


GFRC PRODUCTS: SEE MANUFACTURING IN WORKS

 

Custom Design GFRC Cornices

GFRC cornices with pre-engineered connections for simple, easy installation: see the manufacturing process for GFRC cornices in this VIDEO BLOG POST >>

 

Architectural GFRC Cornice Manufacturing Process - Video Clips

Fluted Tapered GFRC Columns, Corinthian Capitals

Custom design fluted, tapered GFRC columns and corinthian capitals … VIDEO CLIPS show manufacturing process for creating different components of the modular design >>

 

Fluted GFRC Columns - Architectural GFRC Manufacturing Process


GFRC Project: Architectural Stone Cladding, Columns for 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

 


GFRC Project: High Elevation Entry Way Design for Dry Creek Elementary School

 

GFRC Panels for Dry Creek Elementary School - AAS - formerly ACS - Case Study V01

GFRC Panels for Dry Creek Elementary School – AAS – formerly ACS – LEARN MORE >>

 


GFRC Project: High Design Fully Integrated Cladding, Columns, Architectural Accent

 

AAS Architectural GFRC Case Study | Gilbert Christian Case Study

AAS Architectural GFRC Case Study | Gilbert Christian High School  | SEE MORE >>

 

FLUTED GFRC COLUMNS FOR SMU: VIDEO CLIPS WITH MANUFACTURING STEPS

The architectural design of the new Sorority House building at SMU uses fluted columns for a unique accent. AAS team worked with the architect and contractor to come up with an answer of using architectural GFRC product for this. See the manufacturing process in these video clips.


Step One: Designing and Creating Custom Molds

 

AAS used CNC technology and craftsmanship to design the fluted column using modular molds that would create different components of the column – the base, tapered column split over parts, and uniquely sculpted Corinthian capital.

See the molds in this video…

 

Molds are lined up in the plant to begin the GFRC casting process…

 

Step Two: GFRC Casting Process – Applying Face Mix and Spraying, Packing Back up Mix

 

See in these video clips application of the face mix and back up mix.

 

Smooth layer of face mix applied …
Back up mix is sprayed and packed …

 

 

 

Step Three: GFRC Casting Process – Thickening the Edges

 


 

GFRC (Glass Fiber reinforced concrete) has a three forth of an inch thick wall with hollow space in the middle. So, it is much lighter in weight. GFRC is also called light weight concrete.

With fibers in the cast mix, GFRC still provides very good strength to weight ratio. This simplifies the structural and installation requirements.

See products comparison guide to compare the three manufactured stone products – architectural dry cast stone, architectural wet precast and GFRC.