Tag Archives: GFRC Columns

GFRC: LARGE SIZE COLUMN COVERS

The GFRC products have high structural strength thanks to fibers reinforcement integrated at the time of manufacturing. At the same time, the GFRC panels are only 3/4″ thick enabling much higher strength to weight ratio than any other manufactured stone products.

AAS is able to develop column covers that are more than four feet in diameter. Images below show halves of the column wraps that don’t require any structural support.

 

Four Feet Diameter GFRC Column Wraps

 

 

GFRC Column Covers – Inherent Strength of Glass Fiber Reinfoced Concrete

 

> LEARN MORE: ARCHITECTURAL COLUMNS

 

> LEARN MORE: ARCHITECTURAL GFRC (Glass Fiber Reinforced Concrete)

 

CUSTOM DESIGN COLUMNS: HIGHLIGHT OF THE SHOPPING CENTER

The architect had vision to add an elevator and clock tower to the Highland Park Village shopping center that has unified architectural style. Developing intricate design details in the stone and matching the color and finish so that the new building would connect to the surrounding area that had been in existence for over 80 years.

Highland Park - Ornate Architectural Design Integrating Specialized Colums, Highly Decorative Design Elements

Highland Park – Ornate Architectural Design Integrating Specialized Columns, Highly Decorative Design Elements

Clock tower connected with seventy five years old shopping center area | columns at the top accentuate the design accent and shopping mall experience

Clock tower connected with seventy five years old shopping center area | columns at the top accentuate the design accent and shopping mall experience

Highland Park High Design Custom Columns

Highland Park High Design Custom Columns

 

 

Rubber mold for column cap design

Rubber mold for column cap design

The AAS project team developed the drawings for the project from templates without requiring detailed architectural plans. The templates were compared to the existing product and adjustments were made to achieve the precisely matching three dimensional design. The system to capture and communicate in-depth details using CAD drawings assisted the design process confirming the project feasibility in early stages of the project. The integrity of the details was made possible using CNC technology to fabricate the required molds. For high intricate design details in the column caps at the top, rubber molds were used.

Design Details for the top of the clock tower at highland park village shopping center

Design Details for the top of the clock tower at highland park village shopping center

 

Shop Drawing - Clock Tower Design at Highland Park Shopping Center

Shop Drawing – Clock Tower Design at Highland Park Shopping Center

 

Shop Drawing - Details for Support, Anchorage, Installation Connections

Shop Drawing – Details for Support, Anchorage, Installation Connections

 


The AAS team confirmed and communicated installation details for each stone piece used in this tower design. Installers got detailed settings plan with identification of each stone piece.

The clock tower looks as if it were part of the original design of the shopping center. The architectural columns accentuate the overall experience of the shopping center.

Products used: Cast Stone, GFRC (Glass Fiber Reinforced Concrete)
Architect: Omni Planners Architects
General Contractor: W B Kibbler Construction
Masonry Contractor: Metro Masonry

 


> ARCHITECTURAL COLUMNS

 

 

CONCRETE STONE COLUMN COVERS, COLUMN CAPS

Manufactured stone products provide flexibility to create fully customizable column covers, column wraps that can match with the design vision.

 

Colin Library Project - Cast Stone Wall Caps. Columns, Banding, Cornices for Unifying Custom Design AccentCast Stone | Architectural Precast | Architectural GFRC | Columns, Balustrade System, Columns, Pier Caps, Architectural TrimArchitectural-Precast-Columns-options-for-sizes-color-and-finish-1000x600SMU Simmons Hall | Cast Stone, GFRC, Precast Concrete | Large Size Columns Designed using Custom Molds | DOWNLOAD AND LEARN MORE >>Unlimited Design Freedom with Manufactured Architectural Cast Stone, Precast Concrete, GFRC | Seamless Matching with Different Materials for Optimum Value EngineeringCustom Mold Making | Precision and Consistency in Stone Tolerances along with Custom Shapes for High End DesignGFRC Fulted Columns, Corinthian Capitals | SMU Delta Gamma Sorority HouseFluted GFRC Columns, Cornices using Precise Custom Molds and Cutting Edge Manufacturing CapabilitiesColor matching and consistency over the entire project is an advantage with manufactured cast stone | Large stone pieces exceeded stringent tolerance requirementsAdvanced Architectural Stone (AAS) |Technology - Custom Molds using CNC Machining, Consistent Product Quality using Computerized Batch PlantCast stone pieces for column secured using steel plates and anchorsArchitectural Stone Cladding | Wall Coping, Window Trims, ColumnsArchitectural Columns, Cladding for Portico | Project: SMU Simmons HallCustom Shaped Large Cast Stone Pieces Fitting Together without Additional Work at the Construction SiteAAS Project: SMU Simmons Hall | Architect: Perkins and Will | General Contractor: Vaughn Construction | Masonry Contractor: Wilks Masonry | Manufactured PRODUCTS: Architectural Cast Stone, GFRCSMU Caruth Hall Architectural Stone Cladding | Cast Stone and Wet-precast Products Combined for Desired Design Accent | Large Column Porches and Entries, Design of Eaves, Window Surround Trim | Modular Columns DesignBuilding Cladding and use of Ionic Columns | Product Used: Architectural Cast Stone | Laura Lee Blanton BuildingAAS Architectual GFRC Project | Gilbert Christian High School | GFRC Eave Moldings Wrap the Entire Roof Line of the Structure ...AAS Architectural GFRC - Material Technology, Precise Mixing for Required Strength and Looks

 

Three Product Material Options

 

Dry vibrant-tamp cast stone provides design flexibility to custom design column covers with complex design while also providing competitive structural properties.

Wet-pour precast concrete enable options to embed structural support for load bearing column applications.

Architectural GFRC (Glass Fiber Reinforced Concrete) column wraps are only ¾” thick and yet have high strength to weight ratio, simplifying structural support requirements for higher elevation applications.

 

Project Specific Support: Custom Fabrication

 

Advanced Architectural Stone (AAS) has extensive track record for integrating columns with overall design for cladding applications, exterior stone veneer or façade applications, cornices and bandings, architectural trim around building entry ways/windows/doors, wall coping, etc. As required, design can be realized while combining different product materials as well while maintaining uniform/seamless design aesthetic.

The AAS team is able to collaborate with design team using SHOP drawings to confirm design feasibility and developing pre-engineered anchoring conditions for easy installation of the columns.

AAS helps contractors with columns covers and wraps for both commercial as well as residential applications.

Customers have flexibility to match any color with the control sample.

When required, designers have option to select column designs from an extensive range of in house molds inventory. This can help with faster turnaround times for stone concrete columns designs.

Use the support request form to ask about in-house inventory of architectural column covers, column wraps.

 

FLUTED COLUMNS

The AAS team is able to design project specific columns to integrate with the overall theme of the designer.

 

See video clips to understand steps for manufacturing Fluted GFRC columns.

 

Fluted GFRC Columns - Architectural GFRC Manufacturing Process

Fluted GFRC Columns – Architectural GFRC Manufacturing Process

 

GFRC Fulted Columns, Corinthian Capitals | SMU Delta Gamma Sorority House

GFRC Fulted Columns, Corinthian Capitals | SMU Delta Gamma Sorority House

 

 

GFRC COUMNS, COLUMN COVERS: FLEXIBILITY, OPTIONS TO CUSTOMIZE DESIGN

Architectural GFRC (Glass Fiber Reinforced Concrete), also known as light weight concrete are ideal for columns at higher elevation because of their lighter weight. With column that is hollow inside. GFRC casting technology can also be used to develop column covers or column wraps that envelope other structural support elements.

 

PROJECT: SMU DELTA GAMMA

 

The sorority house building at SMU used ornate GFRC cladding for the building elevation design. The designers aimed to blend the new building seamlessly with other much older buildings in the campus.

Fluted, tapered GFRC columns with corinthian capitals played a key role in highlighting the design. The AAS team worked closely with architects and contractor to review, confirm design details at CAD drawing’s level. The team fabricated a number of custom molds and manufactured the columns with modular design.

 

VIDEO: MANUFACTURING CLIPS

 

Fluted GFRC Columns - Architectural GFRC Manufacturing Process

Fluted GFRC Columns – Architectural GFRC Manufacturing Process

 

SMU Delta Gamma | Architectural GFRC Cladding | , Fluted GFRC Columns with Corinthian Capitals

SMU Delta Gamma | Architectural GFRC Cladding, Fluted GFRC Columns with Corinthian Capitals

 

The AAS team engineered anchorage connections while designing and fabricating the columns and cornices used in this project. That simplified the installation, and also opened up options and flexibility in the design process.

 

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

 

PROJECT: GILBERT CHRISTIAN HIGH SCHOOL, GILBERT, AZ

 

AAS (Formerly ACS) | Gilbert Christian Highschool | Product: Architectural GFRC (Light Weight Concrete) | Architect: L. Smith - H & S International LLC. | Contractor: A. R. Mays

AAS (Formerly ACS) | Gilbert Christian Highschool | Product: Architectural GFRC (Light Weight Concrete) | Architect: L. Smith – H & S International LLC. | Contractor: A. R. Mays

 

 

GFRC COLUMNS AT HIGHER ELEVATION

 

USC Ronald Tutor Campus Center | AC Martin Partners Architects | R & R Masonry

USC Ronald Tutor Campus Center | AC Martin Partners Architects | R & R Masonry | SEE CASE STUDY …

 

AAS Formerly ACS | GFRC for Architectural Stone Elements at Higher Elevation | Lighter Weight, Ease Of Installation

GFRC Columns at Higher Elevation | High Strength to Weight Ratio Simplified Structural Support Requirements | Lighter Weight, Ease Of Installation

VIDEO: GFRC CONNECTIONS SIMPLIFY INSTALLATION, OPEN UP DESIGN OPTIONS

GFRC products have pre-engineered, built in connections that simplifies the onsite installation.

See in this video, examples of drawings and images of products being installed at the SMU Delta Gamma Sorority House project.

AAS has bandwidth and a well developed system to work closely with architects, contractors and masons for every project. Installation support details are designed with intent of not only realizing architect’s desired design vision, but also simple, easy installation.

As required, project team works with customers in selecting combination of products that would achieve design cost effectively.


GFRC PRODUCTS: SEE MANUFACTURING IN WORKS

 

Custom Design GFRC Cornices

GFRC cornices with pre-engineered connections for simple, easy installation: see the manufacturing process for GFRC cornices in this VIDEO BLOG POST >>

 

Architectural GFRC Cornice Manufacturing Process - Video Clips

Fluted Tapered GFRC Columns, Corinthian Capitals

Custom design fluted, tapered GFRC columns and corinthian capitals … VIDEO CLIPS show manufacturing process for creating different components of the modular design >>

 

Fluted GFRC Columns - Architectural GFRC Manufacturing Process


GFRC Project: Architectural Stone Cladding, Columns for 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

 


GFRC Project: High Elevation Entry Way Design for Dry Creek Elementary School

 

GFRC Panels for Dry Creek Elementary School - AAS - formerly ACS - Case Study V01

GFRC Panels for Dry Creek Elementary School – AAS – formerly ACS – LEARN MORE >>

 


GFRC Project: High Design Fully Integrated Cladding, Columns, Architectural Accent

 

AAS Architectural GFRC Case Study | Gilbert Christian Case Study

AAS Architectural GFRC Case Study | Gilbert Christian High School  | SEE MORE >>

 

FLUTED GFRC COLUMNS FOR SMU: VIDEO CLIPS WITH MANUFACTURING STEPS

The architectural design of the new Sorority House building at SMU uses fluted columns for a unique accent. AAS team worked with the architect and contractor to come up with an answer of using architectural GFRC product for this. See the manufacturing process in these video clips.


Step One: Designing and Creating Custom Molds

 

AAS used CNC technology and craftsmanship to design the fluted column using modular molds that would create different components of the column – the base, tapered column split over parts, and uniquely sculpted Corinthian capital.

See the molds in this video…

 

Molds are lined up in the plant to begin the GFRC casting process…

 

Step Two: GFRC Casting Process – Applying Face Mix and Spraying, Packing Back up Mix

 

See in these video clips application of the face mix and back up mix.

 

Smooth layer of face mix applied …
Back up mix is sprayed and packed …

 

 

 

Step Three: GFRC Casting Process – Thickening the Edges

 


 

GFRC (Glass Fiber reinforced concrete) has a three forth of an inch thick wall with hollow space in the middle. So, it is much lighter in weight. GFRC is also called light weight concrete.

With fibers in the cast mix, GFRC still provides very good strength to weight ratio. This simplifies the structural and installation requirements.

See products comparison guide to compare the three manufactured stone products – architectural dry cast stone, architectural wet precast and GFRC.