Tag Archives: Custom Molds

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.

 


NORTH SIDE HIGH SCHOOL: CAST STONE MATCHES ART DECO DESIGN TRADITION


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

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

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.

There were 576 pieces of architectural cast stone and architectural precast concrete on the project with detailed design at the roof coping, on panel-lintels above windows, and period fluted pilasters around the structure.

 

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

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

 

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.

 

 

 

 

CUCTOM MOLDS ENABLE COMPLEX SHAPES, INTRICATE DESIGNS, MONOLITHIC VENEERS

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

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.

 

Architectural Stone Cladding, Veneer Design using Custom Designed Stone - Mold Making Technology, Design Craftsmanship - cast stone, precast, GFRC

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

Project: SMU Commons | Architectural Stone Cladding, Veneer Design | Custom Mold Making | Design and Technology

 

Architectural Stone Cladding | Cast Stone, Precast, GFRC

Architectural Stone Cladding | Cast Stone, Precast, GFRC

 


 

PROJECT: The Westbrook Building, Sundance Square, Ft. Worth, TX : Art Deco Panels

 

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

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

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 CASE STUDY >>


 

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

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

 

 

PROJECT: Texas Christian University (TCU) Relief Panels

 

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.

The project won 2014 APA (Architectural Precast Association) Craftsmanship Award.

Here is a composite showing example panels.

AAS 2014 APA Award | TCU Relief Panels | Finish and Precision for Design Appeal | HKS Architects | General Contractor: Austin Commercial

AAS 2014 APA Award | TCU Relief Panels | Finish and Precision for Design Appeal | HKS Architects | General Contractor: Austin Commercial

 

AAS 2014 APA Award | TCU Relief Panels | Forming using Precise Molds, Design Experience | HKS Architects | General Contractor: Austin Commercial

AAS 2014 APA Award | TCU Relief Panels | Forming using Precise Molds, Design Experience | HKS Architects | General Contractor: Austin Commercial


 

PROJECT: LA Sports Hall of Fame – Complex Shaped Panels – LA Sports Hall of Fame

 

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

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 | Large Size Precision Molds for Design That Had Highly Stringent Tolerance Requirements

 

LA State Museum and Sports Hall of Fame | Cast Stone Realized Cane River Channels | Large Complex U-Shaped Stone Pieces | BIM Modelling | Trahan Architects | CASE STUDY ...

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...

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…

 

PROJECT CASE STUDY: LA SPORTS HALL OF FAME >>


 

PROJECT: 714 Main Street – Authentic High Design Roman Heads using Custom Molds

 

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

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 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 Project: 714 Main Street | Unique Technology, Craftsmanship to Replicate design of Roman Heads | Product used Architectural Cast Stone

 

See more on this project…


 

PROJECT: Grapevine Convention and Visitors Bureau

 

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

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

Specialized Rubber Molds for Grape Leaf Design | Cast Stone Design for Grapevine Convention and Visitors Bureau

 

Grapevine Convention Center and Visitors Bureau - High End Leaf Design - Manufactured stone cladding

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

AAS Cast Stone Project | Specific Color Contrast Requirements from the Architect of the Project ArchiTexas | Grapevine Convention & Visitors Bureau

 

See more on Grapevine Convention Center and Visitors Bureau Project…


 

PROJECT: Gilbert Christian High School – Custom Molds for Architectural GFRC

 

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 Case Study

 

AAS Architectural GFRC Case Study | Gilbert Christian High School | Custom Molds and Finish | Simplified Installation with Higher Elevations, Brick Veneer

AAS Architectural GFRC Case Study | Gilbert Christian High School | Custom Molds and Finish | Simplified Installation with Higher Elevations, Brick Veneer

 

See more about the Gilbert Christian High School project in the case study…


 

PROJECT: Texas Christian University (TCU) Worth Hills – Large Sized Molds for Curved Panels

 

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.

 

AAS Case Study - TCU Worth Hills - Large Size Custom Shape Cast Stone Panels for Architectural Design

TCU Worth Hills Cast Study | Large Size Custom Shape Cast Stone Panels for Architectural Design

 

AAS Project - TCU - color matching - custom molds for Large Complex Curves - Download case study

AAS (Formerly ACS) | Project: Texas Christian University (TCU) Worth Hills Campus, Entry Gate | Cast Stone, Architectural Precast

 


 

PROJECT: SMU Simmons Hall Project: Precise molds, Construction Support, Coordination

 

Large Size Custom Stone Panels Fit in for Monolithic Stone Look | Fabricated Stone Veneer, Cladding Design

Large Size Custom Stone Panels Fit in for Monolithic Stone Look | Fabricated Stone Veneer, Cladding Design

 

 

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

The 40,000 sq. ft. building has large columns that are four-story high with diameter of 5-6 feet. The side of the building has cylindrical portico, the precise integration of the columns in the radius wall required a large number of unique cast stone pieces that fit seamlessly for intended design effect.

SMU Simmons Hall Project Case Study: SEE MORE >>