Tag Archives: Stone Veneer

CREATIVITY, PRECISE DESIGN MATCHING FOR SUNDANCE PALACE THEATER

2017 APA Design Craftsmanship Award - Sundance East - Palace Block GFRC Keystone, Banding, Architectural Trim with Fish Pattern, Cornice with Denteel Pattern Retail, Entertainment Building Design Accent using Cast Stone, GFRC Intricate Fish Pattern, Key Stone Matched Exactly with Architects Renderings | GFRC product material Hand Carving in Clay on Top of Custom Design Wooden Piece to Match Architects Rendering for Keystone Creative Hand Design Touch in Clay to Develop Rubber Mold Exactly Matching with Original Design Renderings

The AAS team worked closely with the architect and contractor to realize elevation design for the Sundance Palace Theater  in Fort Worth, TX.

Preserving the original theme of the theater building while carrying out this renovation project was the key to success. The stone pieces for this are custom manufactured using cast stone and GFRC.

The stone panels for the fish design pattern on the jamb and arch used not only the AAS technology, but also the design craftsmanship and experience of the AAS team.

AAS developed the large protruding decorative keystone in architectural GFRC product material. The original design piece was hand carved. AAS artist developed the matching replica of the keystone using clay. Once it was approved by the architects, the team used that to develop rubber mold for the piece. This mold was used in turn to fabricate the keystone with intricate design details in GFRC.

The precise matching of stone pieces for the massive cornice and dentil design at the top of the theater elevation achieved monolithic stone look.

 

Project Name:
Sundance East – Palace Block

Architect:
David M Schwarz Architects, Inc.

General Contractor:
Dennet Construction

Products:
Cast Stone, Architectural GFRC

Award: APA Design Craftsmanship Award

Cornice work and banding, particularly decorative and protruded banding, are a particular specialty for Architectural Products. The ability of Advanced Architectural Stone (AAS) to produce massively projecting elements with light weight shapes allows architects not only to achieve unattainable results in other materials, but also to achieve the form at a practical and economical cost.

 

> PROJECTS GALLERY: INTEGRATED CORNICE AND BANDING DESIGNS

COMPLEX GEOMETRY, BIM COORDINATION FOR LA SPORTS HALL OF FAME

The Louisiana State Museum and Sports Hall of Fame building houses the cultural heritage of memorabilia contributed by diverse cultures shaping the state of Louisiana and the Gulf South.

To celebrate the region’s history and location, Trahan Architects envisioned passages inside the museum to emulate fluid shapes of the braided corridors of the Cane River channels, leading the visitor through a meandering path of galleries. The AAS team manufactured large size stone panels with complex shapes to achieve architect’s vision.

 

 

Complex Geometry: Never before had stone been used as veneer with such complex geometry and size. The AAS team used BIM (Building Information Modeling) to coordinate between the design and manufacturing. This BIM effort was headed by CASE, Inc. in New York.

Smooth Finish: The AAS team verified the geometry of molds used to cast the stone, and delivered unique shaped, large pieces with stringent tolerance requirements. The stone pieces fit like a glove to achieve the fluid shapes of the museum corridors with a smooth monolithic finish.

Large Size Stone Pieces: The biggest panel used in the building was about 18’ x 12’; it weighed 9,600 lbs. The AAS team molded both the front and back sides of every panel, so that the stone pieces would fit in the narrow wall space available. The vibrant-tamp cast stone panels weighed much less compared to wet-pour cast stone products of similar size. The AAS team designed every panel with the required thickness and attachments needed for precise installation.

17,000+ PRECISELY MANUFACTURED CUSTOM STONE PIECES: CLADDING, VENEER DESIGN

The Market Square residential tower is clad in the Leuders limestone and much darker color AAS cast stone.

 

  • Project specific custom molds were designed to manufacture 17,000+ cast stone pieces for custom design of building cladding, and veneer design that seamlessly integrated pilasters.
  • Detailed planning with manufacturing schedule, settings plan and sequencing, coordination with the construction team.
  • Product: Custom fabricated vibrant-tamp cast stone. LEARN MORE >>

 

Project: Houston Market Square | Custom Dark Color Cast Stone for Veneer, Cladding | Design Accent at the Top of Building

PROJECT: Houston Market Square | Custom Dark Color Manufactured Stone Highlighting the Leuders Limestone Exterior >>

 


 

PROJECTS GALLERY: CLADDING DESIGN >>

CASE STUDY: HOUSTON MARKET SQUARE TOWER >>

 


FABRICATED STONE PANELS: FIVE ADVANTAGES FOR VENEER, FACADE DESIGN


ONE: With precise control over size, shape and tolerances, AAS is able to manufacture stone panels with unparalleled range of design options. The veneer design can be customized to match any kind of geometry. When required, the veneer and façade designs can have monolithic stone look as well.


TWO: AAS is able to fabricate panels using three different types of stone products:

  1. Dry vibrant-tamp cast stone panels that allows for complex shapes and geometries
  2. Wet-pour architectural precast concrete stone products that can be structural as well
  3. GFRC panels that provide design flexibility, as well as high strength to weight ratio for higher elevation applications.

AAS team is able to suggest right combination of products for a project while maintaining seamless look and feel.


THREE: The panels can integrate seamlessly with brick veneer, glass, steel or any other aesthetic or structural elements. AAS is able to single source all three kinds of stone panels with detailed support and training for design assist, construction planning, onsite installation.


FOUR: Get any custom color of choice with a control sample. AAS has a very sophisticated color lab and fully automated batch plant to ensure precise, consistent color for project of any size.


FIVE: Seamless design aesthetic with other cladding applications on a building such as window surrounds, entry way surrounds, architectural columns, wall coping, etc.


PROJECT EXAMPLES:

LA Sports Hall of Fame

AAS Case Studies - Enable Customers Design Process - Support Installation - image - LA Sports Hall of Fame
Project Specific Focus, Manufacturing

Higher Education Complex

Manufactured Stone Veneer with Monolithic Stone Design Accent | Project: Higher Education Complex
Manufactured Stone Veneer with Monolithic Stone Design Accent | Project: Higher Education Complex

UCF ROTC

Fabricated Stone Veneer, 3D Framing of Sculpture | Project: UCF, ROTC Building
Fabricated Stone Veneer, 3D Framing of Sculpture | Project: UCF, ROTC Building

SMU Caruth Hall

Vibrant-tamp Cast Stone, Wet-pour Architectural Precast for Integrated Veneer Design
Vibrant-tamp Cast Stone, Wet-pour Architectural Precast for Integrated Veneer Design

Houston Market Square Tower

Dark Color Cast Stone Veneer | Custom Molds with Precision Enabled Monolithic Stone Look
Dark Color Cast Stone Veneer | Custom Molds with Precision Enabled Monolithic Stone Look

TCU Worth Hills

AAS Case Study | TCU Worth Hills | Large Size Custom Shape Cast Stone Panels for Architectural Design
AAS Case Study | TCU Worth Hills | Large Size Custom Shape Cast Stone Panels for Architectural Design

UCF ROTC: 3D Framing using Stone Veneer

AAS Project : ROTC Classroom at University of Central Florida | Architectural Stone Created Design of 3-Dimensional Frame for the Unique Sculpture
AAS Project : ROTC Classroom at University of Central Florida | Architectural Stone Created Design of 3-Dimensional Frame for the Unique Sculpture

Cook Children's Hospital

Cooks Children's Hospital | Cast Stone Uniformity and Consistency Helped Create Effect of a Monolithic Structure | Matched Native Limestone of Surrounding Buildings
Cooks Children's Hospital | Cast Stone Uniformity and Consistency Helped Create Effect of a Monolithic Structure | Matched Native Limestone of Surrounding Buildings

FABRICATED STONE CLADDING, VENEER DESIGN FOR SMU COMMONS

SMU Commons is newly developed residential hall. The designers wanted the new buildings to blend will the overall campus, and yet give it a contemporary feeling for the buildings that are equipped with cutting edge technology. The AAS team worked closely with the customer to custom design and fabricate the stone panels used in the buildings for unifying design accent.

The building designs combined architectural stone cladding, as well monolithic stone veneer for the intended aesthetic vision.


Cladding Design

All the halls in SMU Commons have wall copings, architectural trim, stone panel entry way designs, wainscots that unified the design accent. With computerized batch plant to precisely control the admixture for the manufactured stone panels, the custom color and structural properties of the stone panels were consistently uniform.

The buildings have integrated cornice and banding designs with look of monolithic stone.

The cladding application design used both cast stone, as well as GFRC (Glass Fiber Reinforced Concrete).

 

 

 


Veneer Design

The stone veneer design in the project has effect of monolithic stone customized to maximize the views. It is designed to integrate with the glass. Close working relationship with the contractor and designer for the project was a key to confirm design feasibility. The AAS team developed custom molds to fabricate every stone piece to precise shape with stringent tolerance requirements. The stone panels color precisely with cladding panels used throughout the SMU Commons buildings.

 

 

 


Pilaster Design

 

The exterior elevation design has seamlessly integrated pilasters using precisely developed custom molds that matched stringent tolerance requirements.

The ability of the AAS team to work closely assisting with the design feasibility early in the project mitigated risk in the project execution.

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 >>


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 >>


 

 

3-D FRAMING USING MANUFACTURED VENEER PANELS AT ROTC BUILDING, UCF


The new ROTC building at University of Central Florida highlights a 13-sided sculpture honoring our country and soldiers throughout the history.

The AAS team created framed views of the sculpture using architectural cast stone panels. The sculpture is housed in a one and half feet thick rotunda made from custom design dry-cast stone, and GFRC concrete panels. The rotunda is three stories high with 30 feet in diameter. There are three large radius openings in it with a complex series of step backs that create framed views of the sculpture from different directions.

This three-dimensional frame accentuates and emphasizes the unique sculpture symbolizing the spirit and storied tradition of the ROTC.

 

AAS Project : ROTC Classroom at University of Central Florida | Architectural Stone Created Design of 3-Dimensional Frame for the Unique Sculpture

AAS Project : ROTC Classroom at University of Central Florida | Architectural Stone Created Design of 3-Dimensional Frame for the Unique Sculpture


Color and texture consistency of architectural stone was achieved through a computer driven batch design.

The  CNC technology was utilized to design custom molds for the GFRC, cast stone wall panel pieces. Every one of the manufactured stone wall panels matched extremely stringent tolerance requirements. With all stone panels seamlessly fitting together, the entrance facade achieved desired look of a monolithic piece of stone.

 

University of Central Florida ROTC Classroom II Building | Architectural Stone Design Created Monolithic Look | Stone Veneer

University of Central Florida ROTC Classroom II Building | Architectural Stone Design Created Monolithic Look for the building facade | Stone Veneer


Exterior Veneer using Manufactured Stone Panels

 

The front entry and exterior of the building has architectural stone veneer that played a key role in harmonizing the new building with the rest of the school campus.

The facade veneer combined three different types of stone veneer panels – thin lightweight GFRC (Glass Fiber Reinforced Concrete) panels at the higher elevation, vibrant-tamp architectural dry cast stone for the framing and cladding design elements, as well as wet-precast architectural concrete where stronger structural support was required.

 

AAS Formerly ACS | Architectural Stone Veneer, Cladding Harmonized new ROTC Building with campus of University of Central Florida (UCF)

AAS Formerly ACS | Architectural Stone Veneer, Cladding Harmonized new ROTC Building with campus of University of Central Florida (UCF)


Project Name: University of Central Florida Classroom Building II ROTC

Architect: Schenkel Shultz, Architecture/Interior Design

General Contractor: Clancy & Theys Construction

Products Used: GFRCArchitectural Cast Stone, as well as Architectural Precast Concrete

 


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

 

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