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.

 

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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

Large Size 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 | Balustrade System Design

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 | Balusters, Balustrade System Design | DOWNLOAD AND LEARN MORE >>

 

Balustrade System Design

 

The AAS team designed elaborate balustrade system that blended seamlessly with the rest of the architectural stone cladding application. The system was built using dry vibrant-tamped cast stone.

 

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


Installing Cornices at High 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 ExcellenceArchitectural Stone Cladding | Portico on the side of the SMU Simmons Hall | Custom Columns, Architectural Trim, Wall Coping, CornicesTapered Architectural Cast Stone Columns | Height of Four Floors, Diameter of 5-6 feetLarge Custom Shape Cast Stone Pieces | Precise Design Using CAD Drawings and Custom Molds Cut using CNC MachiningCustom Shaped Large Cast Stone Pieces Fitting Together without Additional Work at the Construction SiteInstallation of Portico Columns | Cast Stone Pieces Planned in Sequence of Releases and Clear Labeling Simplified Onsite ConstructionAAS Project: SMU Simmons Hall | Portico on one side of Building - Structure set up to install Manufactured Architectural Cast StoneSteel structure for installation of cast stoneInstallation of Dry-cast Architectural Cast Stone at Higher Elevation - Structural Support during InstallationCast 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 HallArchitectural Stone Cladding | Wall Coping, Window Trims, ColumnsCast Stone for Portico Columns and Circular Wall, Window Surrounds, Wall Coping at the Top LevelBuilding Signage at Higher Elevation using Cast Stone | AAS Has Experience in Developing Applications Like this in GFRC as WellCast stone pieces for column secured using steel plates and anchorsSMU 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 precisionDetailed Engineering, Custom Mold Making Technology Enabled Cast Stone Columns that are Four Stories High | Diameter of Columns: 5-6 feetSMU Simmons Hall | Products: Dry-cast Stone, Wet-precast Concrete, GFRC | 2016 CSI Awards for Manufacturing Excellence, Design ExcellenceWall coping at higher elevation | AAS has experience developing it in GFRC as well with matching color and design effectsSouthern Methodist University (SMU) Simmons Hall | Architectural Stone for Design Accent, Matching with Other Buildings in the CampusAdvanced Architectural Stone (AAS) |Technology - Custom Molds using CNC Machining, Consistent Product Quality using Computerized Batch PlantArchitectural cast stone balustrade system, wall coping | Front elevation cladding at SMU Simmons HallManufactured vibrant-tamp cast stone pieces | Sequencing of products delivery, detailed palletization and labeling, settings drawings simplified installation | AAS Project: SMU Simmons HallColor matching and consistency over the entire project is an advantage with manufactured cast stone | Large stone pieces exceeded stringent tolerance requirementsManufactured Architectural Stone for Higher Elevation | Cast Stone and GFRC (Glass Fiber Reinforced Concrete)

Project:
HAROLD CLARK SIMMONS HALL, Southern Methodist University (SMU)

 

Architect:
Perkins and Will

 

General Contractor:
Vaughn Construction

 

Masonry Contractor:
Wilks Masonry

 

Product:
Architectural Cast Stone

 

 

> DOWNLOAD PROJECT INFO (.PDF)


 

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 >>