Tag Archives: Manufactured Stone

CLADDING FT WORTH ARENA: LARGE SIZES + CUSTOM SHAPES + PRECISION

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.

 

Pre-engineered anchoring connections simply installation Custom molds enabling precise matching of intricate cast stone pieces Cast stone protection, design accent Cast stone cladding for Ft Worth Arena building Large size cast stone pieces for banding, wall coping all around the Ft Worth Arena Large size complex shapes with stringent tolerance requirements Arena Tower from the side view at top of the building Onsite installation support, coordination, troubleshooting Cast stone pillasters, baluster design

 

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.

 

> FT WORTH ARENA CASE STUDY

 

CAST STONE RIBBONS INTEGRATED WITH BRICK VENEER AND GLASS

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.

 

Sundance Square Cassidy Building | Cast Stone Ribbons Integrated with Glass Sundance Square Cassidy Building | Custom Fabricated Cast Stone Pieces for Monolithic Design Sundance Cassidy Building | Timeless and yet Contemporary Design integrating Cast Stone Ribbons with Brick and Glass Exterior Sundance Square Cassidy Building | Large Cast Stone Pieces Coordinated with 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.

 


DESIGN OF 68-FEET TALL CAST STONE ENTRY: GOTHIC ARC, CATHEDRAL WINDOW TURRET

How do you achieve grand entry that is more than five stories high with complex design details that also look seamless/monolithic in design?

The AAS team custom fabricated cast stone pieces for the for the Fertitta Hall building project at the Marshall School of Business, University of Southern California (USC). The 68-feet tall stone veneer with multi-profiled entry way trim for the vaulted gothic arc, and also cathedral window turret is built using 955 cast stone pieces (970 cubic feet, 131,000 lb. of weight).

See in this video how the cast stone panels are engineered with thoroughly integrated installation support:

 


Jill and Frank Fertitta Hall, Marshall School of Business, USC | Cast Stone Grand Entry that is more than Five Stories High | Custom Engineering, Fabrication

Jill and Frank Fertitta Hall, Marshall School of Business, USC | Cast Stone Grand Entry that is more than Five Stories High | Custom Engineering, Fabrication


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

 

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


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 >>

 



ART AND SCIENCE OF STONE MANUFACTURING: DESIGN FREEDOM WITH CUSTOM PANELS


Concrete and stone products have enabled architectural design of buildings for hundreds of years.

The manufacturing technology combined with opportunity to develop fully integrated solutions for construction projects enable wide range of new design possibilities using architectural stone panels. The project specific focus leads to not only more flexibility and options in design, but also much simpler construction at lower cost.

Learn more with this video how the AAS team is able to start with project specifications, work through the design process, and develop products that create un-paralleled design freedom.


 

Advantages of manufactured architectural stone panels:

  • Combine different product materials for optimum value while maintaining seamless design aesthetic
  • Get consistent product characteristics throughout the project of any size and design complexity
  • Simplify construction and mitigate risk with pre-engineered, built-in installation support
  • Create highly complex shapes for wall panels with stringent tolerance requirements
  • Customize color to any control sample

 

AAS PRODUCTS OVERVIEW >>                     PROJECTS GALLERY >>

 


 

MANUFACTURED ARCHITECTURAL STONE: PRODUCT SPECIFICATIONS

PRODUCTS COMPARISON GUIDE

How do different manufactured cast stone products compare? How do you select? SEE COMPARISON GUIDE >>

VIDEO: INSTALLATION ASSISTANCE: STAGING, SEQUENCING, DELIVERY


How do you mitigate risk in a construction project?

How do you keep wastage to a minimum in the construction process?

How do you minimize delays?

Advanced Architectural Stone (AAS formerly ACS) has thoroughly developed support system to come up with effective answers to these questions.

  1. The AAS customer support team spends time right from the the beginning of the project proactively guiding customers with project planning.
  2. Architectural stone panels  are manufactured to size using integrated design technology and precise, custom mold making.
  3. The project team works out sequences to fit the products. The products are made and released according to the sequence. The AAS support team explains the installation sequence to customers with a lot of details. This simplifies it for the installers and masons.

Listen to more on it in this video…

 

Project Stories: Smooth Installation with Well Thought Out Sequencing, Delivery

 

Here are three example projects that AAS team has delivered with smooth execution.

 

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

USC Ronald Tutor Campus Center | Cast Stone, Architectural Precast, Architectura [...]

PROJECT: Gilbert Christian, AZ | Architectural Precast, Architecural GFRC | | Light Weight, Superior Aesthetics, Design Flexibility

PROJECT: Gilbert Christian, AZ | Architectural GFRC | Light Weight, Superior Aes [...]

PROJECT: Higher Education Complex | Cast Stone | Architect: PBK Architects | Mason Contractor: Tim Hughes, Dee Brown Inc

AAS PROJECT Snapshot: Higher Education Complex | Cast Stone, Architectural GFRC [...]

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 Arc [...]

PRODUCT MATERIALS: HOW DO THEY COMPARE? HOW DO YOU SELECT?


Advanced Architectural Stone (AAS) provide different product materials options for projects –

  1. Cast Stone
  2. Architectural Precast
  3. Architectural GFRC (Glass Fiber Reinforced Concrete)
  4. GFRG (Glass Fiber Reinforced Concrete)

 

How do these products compare? How do you select a product material? Please refer to the tables below.

 

Product Materials Comparison

Basis Cast Stones Architectural Precast Architectural GFRC
Definition High quality masonry building material simulating limestone. Masonry building material produced in larger sizes; can be visually comparable to cast stone with special finishing, but without special finishing more like concrete. Masonry product made with glass fiber for strength with a hollow back having appearance of cast stone or precast at the option of specifier.
Design Made from graded aggregates, white Portland Cement, additives and color pigments Consists of larger aggregates from 1″ to fine sands, additives and Portland cement. Mix design same as precast with the addition of glass fiber for strength and face material visually the same as cast stone or precast.
Production
Method
Usually produced by dry cast method with very little moisture; compacting mix densely into molds. Wet Method used; mix is poured into molds. Product sets up in mold overnight. The product has a hollowunderside; strength through glass fibers. A wet pour method.
Structural /
Non structural
This product is self supporting but is not structural. This product can be conventionally reinforced or pre-stressed to be structural. Product is not structural but is self supporting through attachments.
Weight 132 pounds per cubic foot 150 pounds per cubic foot Approximately 50% or less weight for same area covered than cast stone or precast.
Specification Defined under Masonry Division – Section 4720 of the uniform building code. Defined under Concrete Division – Specification 3450 of the uniform building codes. Defined under Concrete Division – Specification 3490 of the uniform building codes.
Speed of Manufacture Multiple pieces per day from mold; higher production output. Usually 1 piece per day per mold; limiting daily production output. Usually 1 piece per day; limiting daily production output.
Size Usually less than 4′ in length; depends on depth or cubic value. Can be larger pieces up to 20′ and can be structural. Sizes can approximate both cast stone & precast.
Cost Usually the most cost effective. More expensive due to finishing to create close visual to cast stone and daily production limitation. Most expensive to produce; higher cost offset by less installation costs.

PRODUCT CHARACTERISTICS

PRODUCT REINFORCED ANCHORAGE FINISH APPLICATION
Cast Stone (Dry) Yes Rebar Can have dowel holes; anchor slots, embedded hardware Fine grain texture simulates Limestone Architectural Trim, Facing, Ornamentation, columns
Architectural Precast Yes Various methods Cast in weld plates, Threaded inserts, Slots & Dowel holes Exposed Aggregate, Form liners, Sandblasted , Visual bug holes unless finished to look close to cast stone. Architectural panels, columns, Spandrels, Structural
GFRC Yes Glass Fiber Anchor bolts and steel frame attached to product at plant. Fine grain texture or precast finish Architectural, trim, facing, columns, spandrels; where lighter weight is helpful.
Limestone
Grade II
No Cut in dowel holes and slots Fine grain texture Architectural trim, Facing, Ornamentation; long lead time
Calcium Silicate No Cut in dowel holes and slots Smooth, Rocked, Press Hammered, Dressed Architectural veneer, facing, and standard sizes only.

PHYSICAL STANDARDS

PRODUCT ASTM PSI (MINIMUM) AIR CONTENT RANGE ABSORBTION (MAXIMUM) FREEZE-THAW (DURABILITY)
Cast Stone (Dry) ASTM C 1364 6,500 N/A 6% 5% Loss of mass or less @ 300 cycles
Cast Stone (Wet) 6,500 4% – 6% 6% 5% Loss of mass or less @ 300 cycles
Architectural Precast CSI 3450 5,000 4% – 6% 6% Not required
GFRC CSI 3490 1,200 (flexgard module of rupture) 8% – 10% Similar to Cast Stone / Precast Similar to Cast Stone / Precast
Limestone Grade II ASTM C 568 4,000 N/A 7.50% Not available
Calcium Silicate ASTM C 73-99A Grade: NW 3,500 SW 5,500 N/A NW 18% SW 15% Not available

AAS team is able to combine different product materials as well to meet the design, structural and installation needs. AAS has experience with creating seamless design effects and uniform design appeal while combining different product materials on a same project.

 

Product Info/Reference Links

 

  1. AAS Product Materials
  2. Cast Stone
  3. Architectural Precast
  4. Architectural GFRC (Glass Fiber Reinforced Concrete)
  5. GFRG (Glass Fiber Reinforced Gypsum)

 

AAS COMPUTERIZED BATCH PLANT: TECHNOLOGY, PRODUCT CONSISTENCY


Technology creates opportunities for automation and consistency. Advanced Architectural Stone (AAS) puts it to use for consistent product quality and consistency.

The completely automated and computerized batch plant eliminates the error and guess work while making sure raw materials quality and consistency is same through out a project. A number of gauging points, measurements feeding into the monitoring system enables consistent colors, finish, product strength for projects of any size.

Learn more about the AAS computerized batch plant in this video.

 

AAS Batch Plant in Works: LA Sports Hall of Fame Project

The 27,500 sq ft building embodies Trahan Architect’s vision of cane river channels. The project required large cast stone pieces each unique in its shape and complexity.
See AAS Case Study --- Cast Stone Realized Vision for LA Sports Hall of Fame Project

 

AAS Batch Plant, Craftsmanship in Works: Reagan Place, Old Parkland

 

AAS team has extensive experience in coming up with materials composition to match colors while combining different products such as cast stone, architectural precast, architectural GFRC as well as GFRG.

AAS is integral part of development of the Reagan Place, now known as Old Parkland. The team combined architectural precast, cast stone and GFRC in this project with seamless color matching. The new construction blended naturally in to the overall ambiance, culture and heritage of the site. The batch plant made it all look so uniform and consistently beautiful for this project.

AAS Project: Reagan Place, Old Parkland | AAS Computerized Batch Plant and Craftsmanship Delivered Consistency | Click on the image to see the CASE STUDY...

AAS Project: Reagan Place, Old Parkland | AAS Computerized Batch Plant and Craftsmanship Delivered Consistency | See the CASE STUDY…

Note: See AAS video tour of the plant…