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.
AAS Advantage: Track Record & Experience | Design Freedom for Designers | Support System for Contractors, Masons
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.
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.
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.
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
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.
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.
Tuscan columns are the columns used most frequently in the United States because they are also the simplest. They are not carved and do not have scrolls. They are columns that have a capital that is square with a circle under the square. Think of the circle as being round crown molding. There may be a ring under the circle, all of which would be considered the column capital.
AAS has an extensive range of molds to manufacture columns with a much shorter turn around time. The team is able to customize the column design for any diameter, length, as well as size of the capital.
Vibrant-tamp cast stone columns provide options for design with unparalleled flexibility and design freedom to integrate columns into facades, cladding designs, porticos, or other ornamental design elements.
GFRC column covers are 3/4″ inch think. They provide very competitive strength to weight ratio and are suitable for higher elevation applications, or cladding design elements where they aren’t bearing the load by themselves.
The Ionic columns are usually defined by the scrolls at each corner of the capital. These scrolls are fairly large in proportion to the column itself and the scrolls are also known architecturally as volutes.
For really large size column designs, AAS is able to create modular design with different pieces fitting together at the time of installation with seamless monolithic stone look.
Customers have options to seamlessly integrate the columns with other cladding elements such as stone veneer, entry way elevation designs, balusters, cornices, wall coping, door and window surrounds …etc.
AAS offers a range of options to fabricate column covers or column wraps to envelope structural elements while seamlessly matching color with other stone products.
Advanced Architectural Stone (AAS) is doubling the production capacity to custom design and manufacture architectural precast stone and Glass Fiber Reinforced Concrete (GFRC).
AAS is planning this increase in production in two phases: phase one is an expansion to the Mesa Precast plant in Tempe (AZ), followed by second phase to augment manufacturing capabilities in its Ft. Worth (TX) plant.
Phase One: Tempe, AZ Plant (Mesa Precast)
AAS has used Mesa Precast plant in Tempe (Phoenix) for strategic manufacturing and design support for GFRC and architectural wet-precast products.
Mesa has expanded to a second facility adjacent to the current plant in Tempe. This has doubled the production space available for customer projects.
Staffing has been increased by 25% as well as an increased management team.
Mesa production planning and management systems have been enhanced and integrated with AAS enterprise production management systems.
AAS Expansion of Manufacturing Plants | Phase one – Mesa Precast, Tempe, Phoenix, AZ | New Production Space to the Left in this Image
Phase Two: Ft. Worth, TX Plant (formerly known as Advanced Cast Stone)
The Ft. Worth plant is the largest of AAS plants. With this phase of expansion, AAS is aiming to provide even stronger support and flexibility to customers nationwide.
The expansion is increasing production space by 25%.
New inventory control system is implemented to improve tracking and control all three types of stone panel products used in a customer project: cast stone, wet-precast, GFRC (Glass Fiber Reinforced Concrete).
Implemented new manufacturing line producing wet-pour cast stone.
AAS is also adding GFRC manufacturing capability to the plant in Ft. Worth, TX in this expansion phase.
Alex Campolo, CEO of AAS: “This expansion of our production capacity is a strategic investment that is going to not only enable us handle more complex customer projects efficiently, but also help cut down lead time for the delivery of products.”
“Our design, manufacturing system has been refined over time to work closely with customers on every phase of the project. The new inventory control system will further provide more precise control and traceability simplifying job site management. “, added Tim Michael, VP of Business Development.
Advanced Architectural Stone (AAS) Plant in Ft. Worth, TX | Formerly Advanced Cast Stone (ACS)
The AAS team uses a very well refined customer project management system to work closely with customers on every phase of project execution:
TRT Holdings Headquarters is a new 170,000 square ft, six-story Jeffersonian-style office building. The project is one of several buildings located on the Old Parkland Campus at Dallas, Texas developed by Trammell Crow Holdings, one of the largest developers in the U.S.
The overriding design criterion of this building was to have the same style as all other buildings on the business campus.
Precast and cast stone was used exclusively as the material at all entries, the exterior connecting porches, hallways and veneer panels at the first floor of the building.
Pediments, lintels, sills, water tables, columns and roof coping comprised the remainder of the precast or cast stone on the project.
All entrances to the building have beautiful classical Tuscan columns. The Tuscan columns were repeated at a covered portico connecting the building to a restaurant as well. The columns were connected with a deeply profiled trim. The precast portico runs a length of over 50 feet.
PROJECT: TRT Holdings Headquarters | Case Stone, Architectural Precast | 2014 APA Award of Excellence
Process for Design
All pieces, of the same profile, were scaled to varying sizes due to different size windows, doors, entryways and breezeways around the structure. Precise mold making ability of AAS enabled the required precision over wide range of sizes.
There were 7712 pieces of precast and cast stone on the project. The production was carried out using 153 different molds. The mix design was the company’s standard formula with adjustment to a special color used throughout the campus.
TRT Head Quarters | Cast Stone, Architectural Precast, Architectural GFRC | 2014 APA Award | Product Materials: Cast Stone, Architectural Precast, Architectural GFRC | Entries, exterior connecting porches, hallways, veneers, pediments, lintels, sills, water tables, columns and roof coping
The owner of the Old Park Land campus, with all five of their architects visited AAS production facility throughout the project life cycle to make sure the color, texture, and scale of the precast and cast stone met the overall design intent of the campus.
Project Name: TRT Holdings Headquarters
Location: 4001 Maple Avenue @ the Old Parkland Campus, Dallas, Texas
The Culinary Arts Building is a 48,000 square foot building for an additional phase of the North Side High School campus. The school district’s vision was to stay consistent with the traditional Art Deco styling of the school campus. The project consisted of larger than average size architectural cast stone wall panels and architectural wet-precast concrete pieces in order to illustrate the Art Deco designs.
North Side-High School | Culinary Arts Building | Custom Finish Coordination with architect for size alterations | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors
AAS team replicated the original art deco design using cast stone. There were no architectural plans detailing the elaborate Art Deco style precast designs as used on earlier buildings. Advanced Architectural Stone sent artisan mold designers to the project site to trace the designs in order to make molds. Once all designs were drawn, the employees returned to the job site to measure the various depths of each design for exact replication.
Advanced Architectural Stone (AAS Formerly ACS) | Art Deco Design style design using Cast Stone, Architectural Precast | North Side High School | Closeup of Entry | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors
The design craftsmanship of AAS team and technology to create custom decorative stone delivered for the project.
Advanced Architectural Stone (AAS Formerly ACS) | Art Deco Design style design using Cast Stone, Architectural Precast | North Side High School | Close up Window Header | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors
Project Name: North Side High School, Culinary Arts Building
Location: 2211 McKinley Avenue, Fort Worth, TX 76164
Architect: Corgan Associates, Inc
General Contractor: Steele-Freeman, Inc. Contractors
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.
Jeffersonian Design using Custom Design Manufactured Stone | Old Parkland, Dallas, TX | Specially Designed Columns, Egg-n-Dart Rope Design, Large Dentils, Profile | Project Specific Custom Molds, Product Batch Mixing, Manufacturing, Sequencing, Delivery, Installation Support
The technology and design expertise to develop custom molds enable flexibility to fabricate stone panels with unparalleled range of complex shapes and design details.
VIDEO: Custom mold making for complex shapes, intricate design details, custom sizes:
PROJECT: SMU COMMONS
Custom molds made it possible to create large size custom stone panels with stringent tolerance requirements. Detailed engineering of anchoring connections played a key role to achieve monolithic stone look for the facade veneer of the building.
Project: SMU Commons Building Facade | Architectural Stone Cladding, Veneer | Cast Stone, Precast Concrete, GFRC
Project: SMU Commons | Architectural Stone Cladding, Veneer Design | Custom Mold Making | Design and Technology
Architectural Stone Cladding | Cast Stone, Precast, GFRC
On The Westbrook Building, cast stone was used in the overall design of the building to be reminiscent of the Art Deco structures located in many areas in Ft. Worth.
AAS Project: The Westbrook – Sundance Square West – Ft Worth, TX | Art Deco Design using Cast Stone | Custom Mold Design | Architect: Bennett Benner Pettit, Inc
Architectural Stone made the molds for the Art Deco designs from isometric sketches provided by the architect. In other words, the sketches provided three sides, all in dimensional proportion, but none were shown as a true shape with 90 degree corners.
The sketch was only a guide to making actual size molds. Artisan designers created molds for the Art Deco panels combining their design craftsmanship with extensive CAD drafting and also precision cutting using CNC machines.
The Westbrook Building at Sundance Square, Ft Worth, TX | Art Deco Design, Custom Design Elements using Cast Stone, GFRC | Architect: Bennett Benner Pettit, Inc
PROJECT: High-End Design Element Using Custom Mold – Rockwall County Court House
The architect for this project had vision for unique design elements on the exterior of the building. AAS team designed highly intricate mold to create it in cast stone. The precise tolerance and detailed coordination with the construction team helped create the desired look with smooth installation that completed on time.
Advanced Architectural Stone – AAS – Formerly Advanced Cast Stone | Rockwall County Courthouse | Cast Stone, Precast | Technology Allowed Complex Shapes and Desired Aesthetic Design | Brinkley Sargent Architects | DMG Masonry
This project consisted of 6 panels installed in the entry to the remodeled and enlarged football stadium at Texas Christian University. The panels were made using architectural percast and cast stone. The purpose of the panels and the project was to honor and recognize the original founders of the University dating to 1895.
Architect for the project, HKS Architects hired an artist to approve and render the murals. The AAS team transferred the original art work to a rubber mold for casting. The panels represent the cultural icon at the heart and soul of the Texas Christian University. It was critical that the panels can be seen within a few feet of viewer. AAS team used its experience and technology to refine every detail within the mold, so that panels accurately depict the original aesthetic appeal so critical to project’s success.
Trahan Architects had vision for emulating Cane river channels inside the Louisiana Sports Hall of Fame Museum. This required cast stone panels with complex shapes. Panels were also very large in size. The project execution also demanded stringent tolerance requirements in the mold, so the panels would fit in seamlessly for monolithic look.
Advanced Architectural Stone (AAS – Formerly ACS) Team Supports Contractors, Builders, Masons – construction of LA Sports Hall of Fame Museum
LA Sports Hall of Fame | Large Size Precision Molds for Design That Had Highly Stringent Tolerance Requirements
LA Sports Hall of Fame | Cast Stone Realized Cane River Channels | Trahan Architects | CASE STUDY >>
LA State Museum Sports Hall of Fame | Trahan Architects | Cast Stone Veneer Developed using Complex Shaped, Large Cast Stone Pieces Fitting within Stringent Tolerance Requirements | LEARN MORE About Design, Manufacturing Process…
This project required matching building exterior color with the terracotta stone that was used to clad the building exterior.
714 Main St | Cast Stone for Building Exterior | Quality Experience, Desired Colors and Finish | Cost Effective Solution
The design had the Roman Heads depiction on the outside which were authenticated and designed by artists. AAS team worked closely with the architect and artist to design and create the depictions in cast stone that matched the original rendering of the artist precisely.
AAS Custom Mold Making | Roman Head Design in Cast Stone for 714 Main Street Building, Dallas, TX | Cast Stone Cladding
AAS Project: 714 Main Street | Unique Technology, Craftsmanship to Replicate design of Roman Heads | Product used Architectural Cast Stone
AAS team helped create exterior fronts of the building that used cast stone and architectural precast extensively. The design used grape leaves build from the cast stone panels. The grape leaf design and integration was to connect with the historic name of the city and local culture.
The AAS project team used custom molds to create highly intricate grape leaf design elements that are accurate representation of the original design renderings.
AAS Cast Stone | Custom Mold Making | Grapevine Leaf Designed using Dry Cast System
Specialized Rubber Molds for Grape Leaf Design | Cast Stone Design for Grapevine Convention and Visitors Bureau
Grapevine Convention Center | High End Leaf Design – Exterior Cladding | Cast Stone | APA Award of Excellence | ArchiTexas | J & E Masonry
AAS Cast Stone Project | Specific Color Contrast Requirements from the Architect of the Project ArchiTexas | Grapevine Convention & Visitors Bureau
Gilbert Christian High School is located in city of Gilbert in the Scottsdale (AZ) area. The school exterior used extensive Architectural GFRC elements that were easy to integrate with the exterior thin brick veneer of the building. The column capitals have Corinthian style.
AAS Architectural GFRC Case Study | Gilbert Christian Case Study
AAS Architectural GFRC Case Study | Gilbert Christian High School | Custom Molds and Finish | Simplified Installation with Higher Elevations, Brick Veneer
This is a new development added to the school campus.
The entry way of the building has very high elevation breeze way. The cast stone and architectural precast panels required custom molds that enabled panels of such a big size that would fit together to create seamless effect in the breeze way.
TCU Worth Hills Cast Study | Large Size Custom Shape Cast Stone Panels for Architectural Design
AAS (Formerly ACS) | Project: Texas Christian University (TCU) Worth Hills Campus, Entry Gate | Cast Stone, Architectural Precast