Tag Archives: cast stone manufacturing

CAST STONE RIBBONS INTEGRATED WITH BRICK VENEER AND GLASS

Project Name: The Cassidy Building
Location: The Sundance Square, downtown Fort Worth, Texas
Product: Dry Vibrant-tamp Cast Stone

Architect: Bennett Benner Pettit Architects
General Contractor: Beck Group
Masonry Contractor: DMG Masonry

The architect for the project, Bennett Benner Pettit Architects had design vision to incorporate horizontal ribbons in the repeating pattern seamlessly integrated with contours of the building façade consisting of brick veneer and glass.

 

Sundance Square Cassidy Building | Cast Stone Ribbons Integrated with Glass Sundance Square Cassidy Building | Custom Fabricated Cast Stone Pieces for Monolithic Design Sundance Cassidy Building | Timeless and yet Contemporary Design integrating Cast Stone Ribbons with Brick and Glass Exterior Sundance Square Cassidy Building | Large Cast Stone Pieces Coordinated with Glass

 

The AAS team custom fabricated cast stone panels that realized the ribbon design with precision. With the shape and tolerance of each stone piece confirmed using CAD drawings, the stone ribbons look monolithic on the building envelope. The anchorage support was pre-engineered in each stone panel simplifying the installation process.

The design of the 99,000 sq. ft. Cassidy Building feels timeless and yet contemporary at the same time.

 


AAS IS DOUBLING MANUFACTURING CAPACITY


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

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 | Formely Advanced Cast Stone - ACS | Technology | Team | Customer Focus

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:

SMU Simmons Hall Construction | Precise engineering, Custom Manufacturing of Architectural Cast Stone for the Portico Columns

SMU Simmons Hall Construction | Precise engineering, Custom Manufacturing of Architectural Cast Stone for the Portico Columns

Precision in Design Details - Complex Curved Cast Stone Pieces Fit Together Seamlessly Without Carving or Retrofitting

Accuracy in Design Details – Complex Curved Cast Stone Pieces Fit Together Seamlessly Without Carving or Retrofitting

Installation of Portico Columns | Cast Stone Pieces Planned in Sequence of Releases and Clear Labeling Simplified Onsite Construction

Installation of Portico Columns | Cast Stone Pieces Planned in Sequence of Releases and Clear Labeling Simplified Onsite Construction

Portico Column from Inside | Columns inset in Radial Wall Installed Easily with Precise Custom Shaped Pieces and Careful Planning

Portico Column from Inside | Columns inset in Radial Wall Installed Easily with Precise Custom Shaped Pieces and Careful Planning

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 ABOUT GFRC DESIGN PROCESS >>

 



DRY CAST STONE VS WET CAST STONE: WHAT IS THE DIFFERENCE?


Customers often ask the difference between dry or vibrant tamped cast stone and wet cast stone. Both products have their place in design and construction.

Wet cast product is better when a structural product is needed and where much bigger pieces need to span large openings. On the other hand, dry or vibrant cast stone panels generally have finish similar to limestone; they look more like a natural products enhancing the beauty of the building.

Generally dry cast is going to replicate a carved stone where wet cast is going to look like a molded product that does not show detail as well as the dry cast piece. The Louisiana Sports Hall of Fame project is a great example of a project where the architectural requirement was to show great curving detail in the interior walls. Dry-cast stone was chosen for the project over wet cast to achieve a refined, detailed look.

The dry cast product is actually hand-tamped into the mold offering the ability of the production artist to make sure that product follows all of the detail of the mold. The wet cast method does not allow for the additional care in finishing. When a natural looking product with great detail is needed, the dry-tamp choice is often the better method.

See in this video tutorial the dry or vibrant-tamp cast stone manufacturing process:

 


 

AAS COMPUTERIZED BATCH PLANT: TECHNOLOGY, PRODUCT CONSISTENCY


Technology creates opportunities for automation and consistency. Advanced Architectural Stone (AAS) puts it to use for consistent product quality and consistency.

The completely automated and computerized batch plant eliminates the error and guess work while making sure raw materials quality and consistency is same through out a project. A number of gauging points, measurements feeding into the monitoring system enables consistent colors, finish, product strength for projects of any size.

Learn more about the AAS computerized batch plant in this video.

 

AAS Batch Plant in Works: LA Sports Hall of Fame Project

The 27,500 sq ft building embodies Trahan Architect’s vision of cane river channels. The project required large cast stone pieces each unique in its shape and complexity.
See AAS Case Study --- Cast Stone Realized Vision for LA Sports Hall of Fame Project

 

AAS Batch Plant, Craftsmanship in Works: Reagan Place, Old Parkland

 

AAS team has extensive experience in coming up with materials composition to match colors while combining different products such as cast stone, architectural precast, architectural GFRC as well as GFRG.

AAS is integral part of development of the Reagan Place, now known as Old Parkland. The team combined architectural precast, cast stone and GFRC in this project with seamless color matching. The new construction blended naturally in to the overall ambiance, culture and heritage of the site. The batch plant made it all look so uniform and consistently beautiful for this project.

AAS Project: Reagan Place, Old Parkland | AAS Computerized Batch Plant and Craftsmanship Delivered Consistency | Click on the image to see the CASE STUDY...

AAS Project: Reagan Place, Old Parkland | AAS Computerized Batch Plant and Craftsmanship Delivered Consistency | See the CASE STUDY…

Note: See AAS video tour of the plant…