AAS stone panels are used on this project in various applications, as an exterior veneer rain-screen, at the entry and base of the facade, as the surround stone on all balconies, as a banding at the penthouse tower area, and extensively at the garden and pool areas. This project is an excellent example of using matching masonry materials, GFRC and cast stone.
When the structural shell of this building was completed in 2008, AAS provided cast stone wall panels for the first two floors of the parking garages. However, the building went into receivership soon after construction started, and was then purchased by a new owner in 2012. After a four years hiatus, a different general contractor was hired to complete the project along with a number of new suppliers. The architects for the project continued to emphasize the importance of the original design vision particularly of the stone panels on the balconies and on every floor of the tower. The AAS team recommended using GFRC panels for this to take advantage of the lighter weight and ease of installation. The carefully controlled batch mix of the GFRC wall panels matched the color and finish of the cast stone used on the first two floors.
Stoneleigh Residential Tower | Matching Custom GFRC Panels on Balconies
Stoneleight Residential Tower | Dry Vibrant-tamp Cast Stone for Rain-screen, Veneer, Cladding at Lower Levels of the Residential Tower Elevation
The challenge for AAS team was to understand the requirements of the new installer, and to modify the stone panels accordingly. While the balcony areas on different floors appear the same visually, there was a large variation in the dimensions. The support cut-out further complicated the balconies because there were different railing suppliers with varying cut-out positons. AAS engineering team created a series of unique notch and block-outs in the panel molds in order to create custom panels for almost every balcony. The built-in, pre-engineered GFRC connections simplified the installation for the contractor significantly and allowed the project to be highly successful.
Project: Stoneleigh Residential Tower
Architect: Jeff Smith/Gromatzky Dupree & Associates
Jeffersonian Design using Custom Design Manufactured Stone | Old Parkland, Dallas, TX | Specially Designed Columns, Egg-n-Dart Rope Design, Large Dentils, Profile | Project Specific Custom Molds, Product Batch Mixing, Manufacturing, Sequencing, Delivery, Installation Support
The technology and design expertise to develop custom molds enable flexibility to fabricate stone panels with unparalleled range of complex shapes and design details.
VIDEO: Custom mold making for complex shapes, intricate design details, custom sizes:
PROJECT: SMU COMMONS
Custom molds made it possible to create large size custom stone panels with stringent tolerance requirements. Detailed engineering of anchoring connections played a key role to achieve monolithic stone look for the facade veneer of the building.
Project: SMU Commons Building Facade | Architectural Stone Cladding, Veneer | Cast Stone, Precast Concrete, GFRC
Project: SMU Commons | Architectural Stone Cladding, Veneer Design | Custom Mold Making | Design and Technology
Architectural Stone Cladding | Cast Stone, Precast, GFRC
On The Westbrook Building, cast stone was used in the overall design of the building to be reminiscent of the Art Deco structures located in many areas in Ft. Worth.
AAS Project: The Westbrook – Sundance Square West – Ft Worth, TX | Art Deco Design using Cast Stone | Custom Mold Design | Architect: Bennett Benner Pettit, Inc
Architectural Stone made the molds for the Art Deco designs from isometric sketches provided by the architect. In other words, the sketches provided three sides, all in dimensional proportion, but none were shown as a true shape with 90 degree corners.
The sketch was only a guide to making actual size molds. Artisan designers created molds for the Art Deco panels combining their design craftsmanship with extensive CAD drafting and also precision cutting using CNC machines.
The Westbrook Building at Sundance Square, Ft Worth, TX | Art Deco Design, Custom Design Elements using Cast Stone, GFRC | Architect: Bennett Benner Pettit, Inc
PROJECT: High-End Design Element Using Custom Mold – Rockwall County Court House
The architect for this project had vision for unique design elements on the exterior of the building. AAS team designed highly intricate mold to create it in cast stone. The precise tolerance and detailed coordination with the construction team helped create the desired look with smooth installation that completed on time.
Advanced Architectural Stone – AAS – Formerly Advanced Cast Stone | Rockwall County Courthouse | Cast Stone, Precast | Technology Allowed Complex Shapes and Desired Aesthetic Design | Brinkley Sargent Architects | DMG Masonry
This project consisted of 6 panels installed in the entry to the remodeled and enlarged football stadium at Texas Christian University. The panels were made using architectural percast and cast stone. The purpose of the panels and the project was to honor and recognize the original founders of the University dating to 1895.
Architect for the project, HKS Architects hired an artist to approve and render the murals. The AAS team transferred the original art work to a rubber mold for casting. The panels represent the cultural icon at the heart and soul of the Texas Christian University. It was critical that the panels can be seen within a few feet of viewer. AAS team used its experience and technology to refine every detail within the mold, so that panels accurately depict the original aesthetic appeal so critical to project’s success.
Trahan Architects had vision for emulating Cane river channels inside the Louisiana Sports Hall of Fame Museum. This required cast stone panels with complex shapes. Panels were also very large in size. The project execution also demanded stringent tolerance requirements in the mold, so the panels would fit in seamlessly for monolithic look.
Advanced Architectural Stone (AAS – Formerly ACS) Team Supports Contractors, Builders, Masons – construction of LA Sports Hall of Fame Museum
LA Sports Hall of Fame | Large Size Precision Molds for Design That Had Highly Stringent Tolerance Requirements
LA Sports Hall of Fame | Cast Stone Realized Cane River Channels | Trahan Architects | CASE STUDY >>
LA State Museum Sports Hall of Fame | Trahan Architects | Cast Stone Veneer Developed using Complex Shaped, Large Cast Stone Pieces Fitting within Stringent Tolerance Requirements | LEARN MORE About Design, Manufacturing Process…
This project required matching building exterior color with the terracotta stone that was used to clad the building exterior.
714 Main St | Cast Stone for Building Exterior | Quality Experience, Desired Colors and Finish | Cost Effective Solution
The design had the Roman Heads depiction on the outside which were authenticated and designed by artists. AAS team worked closely with the architect and artist to design and create the depictions in cast stone that matched the original rendering of the artist precisely.
AAS Custom Mold Making | Roman Head Design in Cast Stone for 714 Main Street Building, Dallas, TX | Cast Stone Cladding
AAS Project: 714 Main Street | Unique Technology, Craftsmanship to Replicate design of Roman Heads | Product used Architectural Cast Stone
AAS team helped create exterior fronts of the building that used cast stone and architectural precast extensively. The design used grape leaves build from the cast stone panels. The grape leaf design and integration was to connect with the historic name of the city and local culture.
The AAS project team used custom molds to create highly intricate grape leaf design elements that are accurate representation of the original design renderings.
AAS Cast Stone | Custom Mold Making | Grapevine Leaf Designed using Dry Cast System
Specialized Rubber Molds for Grape Leaf Design | Cast Stone Design for Grapevine Convention and Visitors Bureau
Grapevine Convention Center | High End Leaf Design – Exterior Cladding | Cast Stone | APA Award of Excellence | ArchiTexas | J & E Masonry
AAS Cast Stone Project | Specific Color Contrast Requirements from the Architect of the Project ArchiTexas | Grapevine Convention & Visitors Bureau
Gilbert Christian High School is located in city of Gilbert in the Scottsdale (AZ) area. The school exterior used extensive Architectural GFRC elements that were easy to integrate with the exterior thin brick veneer of the building. The column capitals have Corinthian style.
AAS Architectural GFRC Case Study | Gilbert Christian Case Study
AAS Architectural GFRC Case Study | Gilbert Christian High School | Custom Molds and Finish | Simplified Installation with Higher Elevations, Brick Veneer
This is a new development added to the school campus.
The entry way of the building has very high elevation breeze way. The cast stone and architectural precast panels required custom molds that enabled panels of such a big size that would fit together to create seamless effect in the breeze way.
TCU Worth Hills Cast Study | Large Size Custom Shape Cast Stone Panels for Architectural Design
AAS (Formerly ACS) | Project: Texas Christian University (TCU) Worth Hills Campus, Entry Gate | Cast Stone, Architectural Precast
Large Size Custom Stone Panels Fit in for Monolithic Stone Look | Fabricated Stone Veneer, Cladding Design
SMU Simmons Hall Construction | Precise engineering, Custom Manufacturing of Architectural Cast Stone for the Portico Columns
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
Portico Column from Inside | Columns inset in Radial Wall Installed Easily with Precise Custom Shaped Pieces and Careful Planning
The 40,000 sq. ft. building has large columns that are four-story high with diameter of 5-6 feet. The side of the building has cylindrical portico, the precise integration of the columns in the radius wall required a large number of unique cast stone pieces that fit seamlessly for intended design effect.