Tag Archives: dry tamp cast stone

HOW DO I SELECT RIGHT PRODUCT(S) FOR MY PROJECT?

AAS provides three different product materials for architectural stone applications – dry vibrant-tamp cast stone, wet-pour architectural precast concrete and GFRC (Glass Fiber Reinforced Concrete (GFRC).

Dry Vibrant-tamp Cast Stone

 

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.

> 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.

 

LA Sports Hall of Fame | Cast Stone | Architect: Trahan Architects | Masonry Contractor: Masonry Arts | SEE CASE STUDY ...

AAS Advantage: Track Record & Experience | Design Freedom for Designers | Support System for Contractors, Masons

 

> CASE STUDY: LA SPORTS HALL OF FAME PROJECT

> PROJECT EXAMPLE: Houston Market Square – cast stone cladding combined applications for stone façade, pilasters, coping, cornices and bandings.

 

Project: Houston Market Square | Custom Dark Color Cast Stone for Veneer, Cladding | Design Accent at the Top of Building

Project: Houston Market Square | Custom Dark Color Cast Stone for Veneer, Cladding | Design Accent at the Top of Building

 

> CASE STUDY: CAST STONE FOR HOUSTON MARKET SQUARE PROJECT

Dry cast-stone has comparable structural properties to wet-pour precast stone.

Wet-pour Architectural Precast

 

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.

> PROJECT EXAMPLE: Circular stair treads for Ft. Worth Arena

 

Ft Worth Arena | Wet-pour Architectural Precast Concrete Stone for Circular Stair Tread Design

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.

 

> Design flexibility, freedom with GFRC: LEARN MORE

 

> GFRC Design Case Study: SMU Delta Gamma Sorority House

 

SMU Delta Gamma Sorority House | Architectural GFRC Columns, Cladding for Desired Building Elevation Aesthetic

SMU Delta Gamma Sorority House | Architectural GFRC Columns, Cladding for Desired Building Elevation Aesthetic

Customers have options to combine any of the three product materials with seamless matching of color and finish.

 

> CASE STUDY: Project Examples where Different Product Materials Are Combined for Design Objectives

 

> St. Francis Xavier Church: High-end Design Combined cast stone, wet-pour concrete stone and GFRC (Glass Fiber Reinforced Concrete) panels

 

> Refer to the products comparison guide to learn more about product properties.

 

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.

 

CLADDING FT WORTH ARENA: LARGE SIZES + CUSTOM SHAPES + PRECISION

The new Ft. Worth Arena design has used exterior stone cladding all around the building. The AAS team custom fabricated cast stone for this application.

 

Pre-engineered anchoring connections simply installationCustom molds enabling precise matching of intricate cast stone piecesCast stone protection, design accentCast stone cladding for Ft Worth Arena buildingLarge size cast stone pieces for banding, wall coping all around the Ft Worth ArenaLarge size complex shapes with stringent tolerance requirementsArena Tower from the side view at top of the buildingOnsite installation support, coordination, troubleshootingCast stone pillasters, baluster design

 

The AAS team confirmed design feasibility working closely with the architect and contractor  using CAD drawings. AAS leveraged manufacturing flexibility to mold both sides of the stone pieces using the dry vibrant-tamp casting process for the stone panels. Custom molds were developed using the CNC technology. With each custom designed stone panel matching stringent tolerance requirement, the bandings, cornices, wall coping, pilasters, balusters and large size architectural trim match the complex angles and wide range of shapes precisely.

The cast stone matched color with wet-pour precast concrete used on stair trades and also large size GFRC panels.

With detailed planning and close coordination with customer, the manufacturing schedule matched with the construction milestones for smooth execution of this massive cladding application for the arena.

AAS worked closely with the installers for onsite troubleshooting.

 

> FT WORTH ARENA CASE STUDY

 

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 GlassSundance Square Cassidy Building | Custom Fabricated Cast Stone Pieces for Monolithic DesignSundance Cassidy Building | Timeless and yet Contemporary Design integrating Cast Stone Ribbons with Brick and Glass ExteriorSundance 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.

 


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: