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
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
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
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.
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