Tag Archives: GFRC panels

GFRC DESIGN PROCESS: CUSTOM FABRICATION, CONSTRUCTION SUPPORT

Fluted GFRC Columns - Architectural GFRC Manufacturing Process

Fluted GFRC Columns – Architectural GFRC Manufacturing Process

Custom molds for every segment of the column

Corrithian capitals seamlessly integrated with overall design

Close collaboration with the architect and contractor in design phase for seamless monolithic design accent of columns

Manufacturing technique that creates 3/4″ thick GFRC panles with very high strength to weight ratio

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Architectural GFRC Cornice Manufacturing Process - Video Clips

Architectural GFRC Cornice Manufacturing Process – Video Clips

Light weight, high strength to weight ratio of GFRC cornice panels simplify design, construction

Option with integrated steel frame for built-in installation support

Custom color matching, consistent finish using specialized materials technology, batch mixing, fabrication techniques

See manufacturing in works with a series of video clips >>

Design Feasibility Review | Products Design with Built-in Anchorage | Manufacturing Process | Construction Support

Design Feasibility Review | Products Design with Built-in Anchorage | Manufacturing Process | Construction Support

Project: SMU Delta Gamma Sorority House

Active consultation, collaboration with architect as well as contractor in design phase for confirmation of design details

AAS product design methodology translates CAD drawings into precise custom molds

Pre-engineered connections for seamless design, simpler construction, smooth installation process

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GFRC ART PANELS ON FACADES OF DICKIES ARENA, FORT WORTH, TX

GFRC Panel with Detailed Design, Design Mockup GFRC Panel Precisely Matching with Design Details Intricate Horse Head Design Developed in GFRC as per the Design Vision Custom Molds, Fabrication Technique for Large Size GFRC Panels Custom Molds, Fabrication Technique for Large Size GFRC Panels Mockup for GFRC Panels | Dickies Arena Case Study Custom Design GFRC Panels on Right Side of this Mockup Custom Design GFRC Panels on Right Side of this Mockup Mockup of GFRC Art Panels | Frame Design on Panels is Asymmetrical by Design GFRC Panels Installed at Ft Worth Arena

This blog post shows design assist process, as well as custom fabrication of the large size GFRC panels for the Dickies Arena project. The Arena is sited on the Will Roger’s Memorial Center campus in Ft. Worth, TX.

 

Custom GFRC Panels Design, Fabrication

 

The architects for the project aim to develop Art Deco design elements on facades of the arena to match with the 1930s era experience on the campus. The building facade design uses large size GFRC panels with intricate design details in them.

  • The AAS team developed series of custom molds to match the large size and intricate design details required for the project.
  • The mockups are created to confirm the shapes, details in the fabricated stone panels and color matching.
  • AAS works closely with architects and contractors to review details and confirm design feasibility.

 

AAS has capabilities now to manufacture GFRC products in its Ft. Worth plant as well.

Art, Engineering, Design Craftsmanship, Technology for Custom Mold with Specific Design Pattern

Art, Engineering, Design Craftsmanship, Technology for Custom Mold with Specific Design Pattern

Refining Specific Details in the Mold using the Personalized Design Touch after CNC Machining

Refining Specific Details in the Mold using the Personalized Design Touch after CNC Machining

Custom Designed Mold to Match Specific GFRC Panel Size and Shape with Stringent Tolerance requirements

Custom Designed Mold to Match Specific GFRC Panel Size and Shape with Stringent Tolerance requirements

GFRC Art Panels for Art Deco Design Accent at Dickies Arena, Fort Worth

GFRC Art Panels for Art Deco Design Accent at Dickies Arena, Fort Worth

 

Image below shows exterior elevation on the west side with GFRC panels integrated with the brick veneer.

 

Fort Worth Arena Partial Elevation - West Side | GFRC Panels Integrated in Exterior Veneer of the Building Along with Brick Veneer

Fort Worth Arena Partial Elevation – West Side | GFRC Panels Integrated in Exterior Veneer of the Building Along with Brick Veneer

 

CLICK HERE TO SEE HIGHER RESOLUTION IMAGE (OPENS IN NEW TAB/WINDOW) >>

 

DOWNLOAD .PDF FILE FOR DESIGN DETAILS >>



SMU COMMONS: EXTERIOR VENEER, CLADDING, HARDSCAPE DESIGN USING STONE PANELS


Advanced Architectural Stone (AAS) has extensive track record for manufacturing cast stone, architectural precast and GFRC for cladding, exterior veneer, and almost any other architectural design.

These pictures are of a number of buildings at the Southern Methodist University (SMU) campus. You are viewing a new dining hall and housing complex call the SMU Commons; the vision was to integrate these buildings with the overall identity of the campus. At the same time, the designers wanted to create a contemporary feel to the buildings to reflect the school’s cutting edge approach to education and its fun, nurturing, and exciting environment for students.

The AAS team proposed carrying out the design including the exterior cladding and stone veneers using two different products: cast stone and glass fiber reinforced concrete panels (GFRC).

 

Anita and Truman Arnolds Dining Commons, SMU | Unparalleled Design Freedom with Manufactured Stone | Cast Stone, GFRC Cladding, Veneer Design | TECHNOLOGY: CUSTOM MOLD MAKING >>

Unparalleled Design Freedom with Manufactured Stone | Cast Stone, GFRC Cladding, Veneer Design

 

Precision molds combining the use of the CNC technology and employee craftsmanship made it possible to create veneer wall panels that fit together seamlessly for look of monolithic stone. With computerized batch mixing as part of the integral manufacturing process, the stone panels, using both  cast stone and GFRC (Glass Fiber Reinforced Concrete), had the required structural properties, as well as matching color and finish.

The new buildings are huge success for the campus since they excite students, faculty and visitors.

 

Anita and Truman Arnolds Dining Commons, SMU | Cast stone, Architectural GFRC | Custom Molds, Customer Project Management Simplified Installation, Achieved Design with Precision

Cast stone, GFRC | Monolithic Stone Facade, Veneer Design, Stone Capping | Custom Molds, Customer Project Management Simplified Installation

 

PROJECT: SMU Commons | Architectural Stone Cladding

PROJECT: SMU Commons | Architectural Stone Cladding Developed Quality Experience

 

Stone Panels | Technology, Design Flexibility | GFRC, Cast Stone and Wet-percast Concrete Products Materials Combined for Uniform Aesthetic Accent

Stone Panels | Technology, Design Flexibility | GFRC, Cast Stone and Wet-percast Concrete Products Materials Combined for Uniform Aesthetic Accent


VENEER, FACADE DESIGN USING FABRICATED STONE PANELS: MORE PROJECT EXAMPLES, LEARN MORE >>

 

ARCHITECTURAL STONE CLADDING: SEE MORE PROJECT EXAMPLES, LEARN MORE >>

 

WALL COPING, PIER CAPS, HARDSCAPE >>


 

 

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.