SMU Simmons Hall: Design, Manufacturing, Project Coordination
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 the 2017 Golden Trowel Award in the 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 | Architectural Stone Cladding, Large Size Custom Columns, Cornices, Trim, Wall Coping
Large Size Cast Stone Columns
The key feature of this structure is the oversize cast stone columns. Each column in the front elevation of the building has the height of all four floors of the building. The diameter for these columns is five to six feet.
AAS team designed custom molds using detailed CAD drawings and then precisely cut them using CNC machining capabilities. The process used not only the AAS technology but also the design craftsmanship of the project team members.
The 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
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
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 | Balusters, Balustrade System Design | DOWNLOAD AND LEARN MORE >>
Balustrade System Design
The AAS team designed an elaborate balustrade system that blended seamlessly with the rest of the architectural stone cladding application. AAS custom-fabricated stone for the entire project using a dry vibrant-tamped casting process.
Architectural Stone at Higher Elevation
Architectural stone cladding design for SMU Simmons Hall has manufactured stone at a 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 can work closely with customers for value engineering, combining GFRC (Glass Fiber Reinforced Concrete) panels for applications like this. AAS can 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)
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 challenges. Each piece required custom curvature on the inside and tapered cylindrical shaping on the outside.
Project-specific custom fabrication: The cylindrical base of the columns and the pieces attached from both sides have a custom shape, allowing the installers to hang the cast stone 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
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
Portico with Architectural Stone Adds Unique Aesthetic Appeal to the Simmons Hall Building
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
Installers Trying to Fit the Corner Piece 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 that the pieces matched onsite field conditions.
The AAS team designed and fabricated the improvised cast stone with four days of turn around.
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
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SMU Simmons Hall | Custom Molds, Manufacturing, Construction Support | 2016 CSI Awards … DOWNLOAD AND LEARN MORE >>
