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.
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.
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.
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.
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: