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
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
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
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.
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.
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
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 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
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 Wainscots and Entry Way Trim at Higher Elevation
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 …
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.
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.
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.