Tag Archives: 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 Mockup GFRC Panel Precisely Matching with Design Details Intricate Horse Head Design Developed in GFRC as per the Design Vision Custom Molds, Fabrication Technique for Large Size GFRC Panels Custom Molds, Fabrication Technique for Large Size GFRC Panels Mockup for GFRC Panels | Dickies Arena Case Study Custom Design GFRC Panels on Right Side of this Mockup Custom Design GFRC Panels on Right Side of this Mockup Mockup of GFRC Art Panels | Frame Design on Panels is Asymmetrical by Design GFRC 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.

 

 


 

ARCHITECTURAL GFRC FOR BUILDING VENEERS: INSTALLATION VIDEO


The Architectural GFRC panels are only 3/4 of an inch thick making them easy to ship, handle and integrate.

This opens up new design options for building veneer applications.

 

Project Story: GFRC veneer at Gilbert Snooze Restaurant

 

Gilbert Snooze is located in the city of Gilbert in Phoenix, AZ area. The designers and planning team have created feel of an old country style industrial township in this area.

AAS team used Mesa Precast plant for supporting design of veneer for Gilbert Snooze. The team created color samples and worked with owner in matching the veneer with the wood and steel elevation of the restaurant. See videos of thin GFRC wall panels being placed in position and installed for this veneer.

 

See in this video, the panels being placed at higher elevation. Light weight of GFRC makes it easy to handle…
GFRC panels are installed in place by mason very easily. See a panel being installed in this video…

 

 

AAS Plant: Mesa Precast in Tempe, AZ | Architectural GFRC Panels Veneer Adding Accent to Wood and Steel Elevation - Gilbert Snooze Restaurant, AZ

AAS Plant: Mesa Precast in Tempe, AZ | Architectural GFRC Panels | Veneer using Thin Wall Panels Add Accent to Wood and Steel Elevation – Gilbert Snooze Restaurant, AZ

 

AAS Mesa Precast Plant | Custom Architectural GFRC Panels for Building Veneer - Gilbert Snooze Restaurant, Gilbert, Phoenix, AZ

AAS Mesa Precast Plant | Custom Architectural GFRC Panels for Building Veneer – Gilbert Snooze Restaurant, Gilbert, Phoenix, AZ

 

GFRC Veneers at Gilbert Christian High School

Gilbert Christian High School has a brick veneer enveloping the building.

The wainscots, window trims and entry way trim installed very easily.

 

AAS Architectural GFRC Integrates Well with Brick Veneer | It Requires Less Depth Compared to Other Materials such Cast Stone or Precast Concrete

AAS Architectural GFRC Integrates Well with Brick Veneer | It Requires Less Depth Compared to Other Materials such Cast Stone or Precast Concrete

AAS Architectural GFRC Wainscots and Entry Way Trim at Higher Elevation

AAS Architectural GFRC Wainscots and Entry Way Trim at Higher Elevation

 

AAS Formerly ACS Project: Gilbert Christian High School | Light Weight Architectural GFRC with Customized Colors, Finish, Simpler Higher Elevation Construction, Installation | See Case Study ...

AAS Formerly ACS Project: Gilbert Christian High School | Thin GFRC Panels Attached to the Structure Gives it Feeling of a Uiiform Structural Element | Light Weight Architectural GFRC with Customized Colors, Finish, Simpler Higher Elevation Construction, Installation | See Case Study …

 

 

ARCHITECTURAL GFRC CORNICES FOR SMU: SEE MANUFACTURING IN WORKS


What does it take to design and manufacture Architectural GFRC products?

What makes Architecture GFRC ideal for higher elevation applications?

 

See the manufacturing process and technology used for cornices of the new sorority house building at the Southern Methodist University (SMU) in step-by-step sequence of videos in this blog post. These video clips are captured at the Mesa Precast plant of Advanced Architectural Stone; this plant is located in Tempe, AZ.

 

Step One: Custom Molds

 

AAS team used the in house custom mold making technology and craftsmanship to create the required molds of specific shape for each GFRC panel used on this project. For the exterior cornices of the building, these molds are big in size as well. See more on it in their video.

 

 

 

Step Two: Spray Mix for GFRC

The Architectural GFRC (Glass Fiber Reinforced Concrete) products are manufactured by spraying specific mix. AAS has automated batch plant system to create the right mix with precise control over proportions and consistency.

See spray mix getting ready for the manufacturing in this video.

 

 

 

Step Three: Facing Mix

The first step in creating 3/4 ” thick GFRC panel is, applying the face mix. It doesn’t have any fibers in it. It helps create a smooth finish on the outside. In this project, the cornices are going to be acid etched, so the smooth surface is very helpful for creating that finish later on.

See facing mix being applied…

 

 

The face mix is brushed to make sure all surfaces are covered, and also there are no air bubbles…

 

 

Step Four: Applying Back up Mix

Next step in the manufacturing is applying back up mix that has fibers in it. This is applied over three layers typically with brushing and packing in every step to eliminate bubbles and gaps in the panels.

Material technology to create the right mix is one of core differentiators of the Advanced Architectural Stone.

 

 

Watch back up mix being compacted using brush and rollers in this video clip…

 

 

Step Five: GFRC Frame for Attaching Cornice to the Building During Installation

 

The idea with this GFRC cornice is to simplify installation with per-engineered steel installation frame attached to the GFRC skin, so that from outside it looks like a solid concrete piece…

 

 

While the frame is being integrated into the GFRC panel structure, edges are also thickened to make the product stronger and structurally more sound.

 

 

LEARN MORE ABOUT PRE-ENGINEERED, BUILT IN CONNECTIONS WITH AAS GFRC PANELS, CUSTOM DESIGN >>

 

GFRC Cornice Ready for Surface Finishing and then for the Installation

 

The the manufactured Cornice piece realized with custom molds, right materials selection, and specific technology and expertise in creating an engineered piece precise in tolerance, ready to install.

 

 

 

While it looks like solid concrete from the outside, this Architectural GFRC cornice is so light in weight when compared to concrete or other cast products such as cast stone or architectural precast. This makes Architectural GFRC ideal for higher elevation applications.

 

 

 

 

VIDEO: DEDICATED PROJECT FOCUS TEAMS FOR SMOOTH EXECUTION


AAS sales team members are experienced project coordinators.

AAS has been able to complex a wide range of complex projects, and deliver consistently good quality of products because it is able to dedicate and align team members and manufacturing resources for customer projects.

AAS project team is able to answer questions, track and manage project design as well as follow through on molding, manufacturing schedule, products sequencing and delivery. With technology support, and dedicated bandwidth, customer project leads are able to track and monitor progress of every project.

Learn more in this video.

 

Project Stories: Dedicated Support for Execution – From Design to Installation

 

Click on any of the three images below to learn more about that project.

 

Cooks Children's Hospital | Monolithic Structure using Cast Stone and Architectural Precast | Seamless Addition of the Building to Existing Hospital Complex

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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

SMU Caruth Hall Architectural Stone Cladding | Cast Stone and Wet-precast Produc [...]

Reagan Place, Old Park Land | Cladding using Architectural Cast Stone, Precast Concrete, GFRC Products

Reagan Place, Old Park Land | Cladding using Architectural Cast Stone, Precast C [...]