Tag Archives: GFRC Manufacturing

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 >>

 



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.