SMU Simmons Hall: Design, Manufacturing, Project Coordination – 2016 CSI Award, 2017 Golden Trowel Award

SMU Simmons Hall Cast Stone, GFRC, Precast Concrete | 2016 CSI Awards for Manufacturing Excellence, Design Excellence

AAS Project: SMU Simmons Hall | Cast Stone, GFRC, Precast Concrete | 2016 CSI Awards for Manufacturing Excellence, Design Excellence | DOWNLOAD AND LEARN MORE >>


The HAROLD CLARK SIMMONS HALL is a classic building on the campus of Southern Methodist University (SMU) in Dallas, Texas. It is an academic building with classroom and student labs for various departments.

The structure is approximately 40,000 square feet.

The architectural stone cladding and design accent kept the building consistent with the adjacent buildings on the campus.

The project won 2016 awards from the CSI (Cast Stone Institute) in the categories of Design Excellence, and also Manufacturing Excellence.

The project won 2017 Golden Trowel Award in category of educational buildings.

 

DOWNLOAD PROJECT INFO >>

 

AAS Project: SMU Simmons Hall | Architect: Perkins and Will | General Contractor: Vaughn Construction | Masonry Contractor: Wilks Masonry | Manufactured PRODUCTS: Architectural Cast Stone, GFRC

AAS Project: SMU Simmons Hall | Architect: Perkins and Will | General Contractor: Vaughn Construction | Masonry Contractor: Wilks Masonry | Manufactured PRODUCTS: Architectural Cast Stone, GFRC | Architectural Stone Cladding, Large Size Custom Columns, Cornices, Trim, Wall Coping

Oversize Cast Stone Columns

 

Oversize cast stone columns are the focal point of this structure. The columns have height of all four floors of the building. Each column has diameter of five to six feet.

AAS team developed custom molds using detailed CAD drawings. The molds were precisely cut using CNC machining capabilities. The process used not only the AAS technology, but also the design craftsmanship of the project team members.

Computerized batch plant provided consistency in color and the structural properties of the manufactured stone.

Large Custom Shape Cast Stone Pieces | Precise Design Using CAD Drawings and Custom Molds Cut using CNC Machining

Large Custom Shape Cast Stone Pieces | Precise Design Using CAD Drawings and Custom Molds Cut using CNC Machining

Custom Shaped Large Cast Stone Pieces Fitting Together without Additional Work at the Construction Site

Custom Shaped Large Cast Stone Pieces Fitting Together without Additional Work at the Construction Site

Color matching and consistency over the entire project is an advantage with manufactured cast stone | Large stone pieces exceeded stringent tolerance requirements

Color matching and consistency over the entire project is an advantage with manufactured cast stone | Large stone pieces exceeded stringent tolerance requirements

Advanced Architectural Stone (AAS) |Technology - Custom Molds using CNC Machining, Consistent Product Quality using Computerized Batch Plant

Advanced Architectural Stone (AAS) |Technology – Custom Molds using CNC Machining, Consistent Product Quality using Computerized Batch Plant

SMU Simmons Hall | Cast Stone, GFRC, Precast Concrete | Large Size Columns Designed using Custom Molds | DOWNLOAD AND LEARN MORE >>

SMU Simmons Hall | Cast Stone, GFRC, Precast Concrete | Large Size Columns Designed using Custom Molds | DOWNLOAD AND LEARN MORE >>

 

Architectural Stone at Higher Elevation

 

Architectural stone cladding design for SMU Simmons Hall has manufactured stone at higher elevation as well.

Vibrant-tamp dry cast stone is much lighter in weight compared to wet cast stone. That is an advantage with the AAS technology and manufacturing techniques.

AAS project team is able to work closely with customers for value engineering where GFRC (Glass Fiber Reinforced Concrete) can be effectively used for applications like this. AAS is able to match the color and finish while combining wet-cast stone, dry-cast stone and also GFRC stone.

Manufactured Architectural Stone for Higher Elevation | Cast Stone and GFRC (Glass Fiber Reinforced Concrete)

Manufactured Architectural Stone for Higher Elevation | Cast Stone and GFRC (Glass Fiber Reinforced Concrete)

Wall coping at higher elevation | AAS has experience developing it in GFRC as well with matching color and design effects

Wall Coping at Higher Elevation | AAS has Experience Developing it in GFRC as well with Matching Color and Design Effects

Detailed Engineering, Precise Manufacturing, Construction Support, Project Coordination

 

The side entry columns required detailed engineering and production planning. These columns were inset into a radius wall, meaning that the columns were not symmetrical—a unique design and manufacturing challenge. Each piece required custom curvature on the inside and tapered cylindrical shaping on the outside.

The cylindrical base of the columns and the pieces attached from both sides have a custom shape that allowed the cast stone pieces to be installed in place, without carving or retrofitting.

AAS provided a detailed layout or setting plan that showed how all the pieces joined together for the construction.

The manufacturing and delivery schedule planned delivery releases in sync with onsite construction milestones. AAS has a very well thought out system of labeling every pallet; that simplifies the installation of the cast stone pieces.

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 Stone Cladding | Wall Coping, Window Trims, Columns

Portico with Architectural Stone Adds Unique Aesthetic Appeal to the Simmons Hall Building

Cast Stone for Portico Columns and Circular Wall, Window Surrounds, Wall Coping at the Top Level

Architectural Columns, Cornice on the Portico Combined with Window Trims and Wall Coping at the Top Enhance and Unify Design Accent on the Side Elevation


Troubleshooting, Conforming to As Built Conditions

 

The entry porticoes had assemblies that tied into the cornice on the main building. Because the structural steel was slightly off, the transition cornice on the portico didn’t align properly with the main building cornice.

Transition Cornice Piece Designed to Tie in With Main Building Cornice

Transition Cornice Piece Designed to Tie in With Main Building Cornice

Installers Trying to Fit the Corner Piece with the Main Cornice | manufactured architectural stone

Installers Trying to Fit the Corner Piece with the Main Cornice

As Built Condition Deviated from Design | Transition Cornice Piece Wouldn't Fit with the Main Cornice

As Built Condition Didn’t Match with the Design | Transition Cornice Piece didn’t Fit

The AAS project manager worked closely with the mason and developed full scale templates. The project team then coordinated this with the CAD department and the form shop to ensure the pieces were made according to onsite field conditions.

The improvised cast stone piece was designed and manufactured with four days of turn around.


  • SMU Simmons Hall Cast Stone, GFRC, Precast Concrete | 2016 CSI Awards for Manufacturing Excellence, Design Excellence
    SMU Simmons Hall Cast Stone, GFRC, Precast Concrete | 2016 CSI Awards for Manufacturing Excellence, Design Excellence
  • Architectural Stone Cladding | Portico on the side of the SMU Simmons Hall | Custom Columns, Architectural Trim, Wall Coping, Cornices
    Architectural Stone Cladding | Portico on the side of the SMU Simmons Hall | Custom Columns, Architectural Trim, Wall Coping, Cornices
  • Tapered Architectural Cast Stone Columns | Height of Four Floors, Diameter of 5-6 feet
    Tapered Architectural Cast Stone Columns | Height of Four Floors, Diameter of 5-6 feet
  • Large Custom Shape Cast Stone Pieces | Precise Design Using CAD Drawings and Custom Molds Cut using CNC Machining
    Large Custom Shape Cast Stone Pieces | Precise Design Using CAD Drawings and Custom Molds Cut using CNC Machining
  • Custom Shaped Large Cast Stone Pieces Fitting Together without Additional Work at the Construction Site
    Custom Shaped Large Cast Stone Pieces Fitting Together without any Adjustments Required by Masons at the Construction Site
  • 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
  • AAS Project: SMU Simmons Hall | Portico on one side of Building - Structure set up to install Manufactured Architectural Cast Stone
    AAS Project: SMU Simmons Hall | Portico on one side of Building - Structure set up to install Manufactured Architectural Cast Stone
  • Steel structure for installation of cast stone
    Steel Structure for Installation of Dry-cast Architectural Cast Stone
  • Installation of Dry-cast Architectural Cast Stone at Higher Elevation - Structural Support during Installation
    Cylindrical Cast Stone Pieces to be Attached to the Steel Plates Running through Full Height of the Columns
  • Cast Stone Pieces Installed for Base of the Architectural Columns | Advanced Architectural Stone (AAS) - Formerly Advanced Cast Stone (ACS)
    Cast Stone Pieces Installed for Base of the Architectural Columns | Advanced Architectural Stone (AAS) - Formerly Advanced Cast Stone (ACS)
  • Architectural Columns, Cladding for Portico | Project: SMU Simmons Hall
    Architectural Columns Split over Radial Wall | CNC Machining Eliminates Variances between Stone Pieces Saving Installation Time
  • Architectural Stone Cladding | Wall Coping, Window Trims, Columns
    Architectural Stone Cladding | Wall Coping, Window Trims, Columns
  • Cast Stone for Portico Columns and Circular Wall, Window Surrounds, Wall Coping at the Top Level
    Cast Stone for Portico Columns and Circular Wall, Window Surrounds, Wall Coping at the Top Level
  • Building Signage at Higher Elevation using Cast Stone | AAS Has Experience in Developing Applications Like this in GFRC as Well
    Building Signage at Higher Elevation using Cast Stone | AAS Has Experience in Developing Applications Like this in GFRC as Well
  • Cast stone pieces for column secured using steel plates and anchors
    Cast Stone Pieces for Column Secured using Steel Plates and Anchors
  • SMU Simmons Hall | Cast Stone, GFRC, Precast Concrete | Large Size Columns Designed using Custom Molds | DOWNLOAD AND LEARN MORE >>
    SMU Simmons Hall | Cast Stone, GFRC, Precast Concrete | Large Size Columns Designed using Custom Molds | DOWNLOAD AND LEARN MORE >>
  • Cornice design using manufactured architectural cast stone pieces | casting (dry or wet) with precision allows complex stone pieces to fit with required accuracy and precision
    Cornice Design using Manufactured Architectural Cast stone | Casting (dry or wet) with Precision Allows Complex Stone Pieces to Fit Seamlessly
  • Detailed Engineering, Custom Mold Making Technology Enabled Cast Stone Columns that are Four Stories High | Diameter of Columns: 5-6 feet
    Detailed Engineering, Custom Mold Making Technology Enabled Cast Stone Columns that are Four Stories High | Diameter of Columns: 5-6 feet
  • SMU Simmons Hall | Products: Dry-cast Stone, Wet-precast Concrete, GFRC | 2016 CSI Awards for Manufacturing Excellence, Design Excellence
    SMU Simmons Hall | Products: Dry-cast Stone, Wet-precast Concrete, GFRC | 2016 CSI Awards for Manufacturing Excellence, Design Excellence
  • Wall coping at higher elevation | AAS has experience developing it in GFRC as well with matching color and design effects
    Wall Coping at High Elevation | AAS Develops this in GFRC (Glass Fiber Reinforced Concrete) as well with Matching Color and Design Effects
  • Southern Methodist University (SMU) Simmons Hall | Architectural Stone for Design Accent, Matching with Other Buildings in the Campus
    Southern Methodist University (SMU) Simmons Hall | Architectural Stone for Design Accent, Matching with Other Buildings in the Campus
  • Advanced Architectural Stone (AAS) |Technology - Custom Molds using CNC Machining, Consistent Product Quality using Computerized Batch Plant
    Advanced Architectural Stone (AAS) |Technology - Custom Molds using CNC Machining, Consistent Product Quality using Computerized Batch Plant
  • Architectural cast stone balustrade system, wall coping | Front elevation cladding at SMU Simmons Hall
    Architectural cast stone balustrade system, wall coping | Front elevation cladding at SMU Simmons Hall
  • Manufactured vibrant-tamp cast stone pieces | Sequencing of products delivery, detailed palletization and labeling, settings drawings simplified installation | AAS Project: SMU Simmons Hall
    Manufactured Vibrant-tamp Cast Stone Pieces | Sequencing of Products Delivery, Detailed Palletization and Labeling, Settings Drawings Simplified Installation
  • Color matching and consistency over the entire project is an advantage with manufactured cast stone | Large stone pieces exceeded stringent tolerance requirements
    Color Matching and Consistency Over the Entire Project is an Advantage with Manufactured Cast Stone | Large Stone Pieces Exceeded Stringent Tolerance Requirements
  • Manufactured Architectural Stone for Higher Elevation | Cast Stone and GFRC (Glass Fiber Reinforced Concrete)
    Manufactured Architectural Stone for Higher Elevation | Cast Stone and GFRC (Glass Fiber Reinforced Concrete)

Project: Southern Methodist University (SMU) Simmons Hall

Architect: Perkins and Will

General Contractor: Vaughn Construction

Masonry Contractor: Wilks Masonry

Product: Architectural Cast Stone

 

DOWNLOAD PROJECT INFO >>

 

SMU Simmons Hall | Custom Molds, Manufacturing, Construction Support | 2016 CSI Award

SMU Simmons Hall | Custom Molds, Manufacturing, Construction Support | 2016 CSI Awards … DOWNLOAD AND LEARN MORE >>