Stone Applications for Lebanon High School: Design Assist, Construction Assist

Advanced Architectural Stone (AAS) has a very well developed methodology to support design process with detailed review of drawings. The team actively collaborates with the contractor and architect for the project to define connection details for hanging the stone pieces.

See in this case study for the Lebanon Trail High School, comprehensive CAD drawing details with connections for stone pieces used in a range of applications such as deep arch ways in the main entry of the building, project specific cornices for curved exterior wall, columns & pilasters, etc.

The manufacturing schedule for the stone pieces was synchronized with the different phases of the school building, further simplifying the construction planning process.

Project: Lebanon High School, Frisco, TX | Skinner Masonry | Stantec Architects | Product Applications: Dry Vibrant-tamp Cast Stone, GFRCProject: Lebanon High School, Frisco, TX | Skinner Masonry | Stantec Architects | Product Applications: Dry Vibrant-tamp Cast Stone, GFRCProject: Lebanon High School, Frisco, TX | Skinner Masonry | Stantec Architects | Product Applications: Dry Vibrant-tamp Cast Stone, GFRC

Project:
Lebanon High School

Location:
Frisco, TX

Masonry Contractor:
Skinner Masonry

Architect:
Stantec Architects

Products: Dry vibrant-tamp cast stone, GFRC


This is a new high school in the fastest growing city in the U.S. The school will accommodate 5,500 students. Massive entry arches and pediments with a continuous cornice band accent the blended brick exterior.


Manufacturing Process – Release Map


Release Map - All TogetherRelease Map - Backside - LeftRelease Map - Backside - RightRelease Map - Front Entry Side of the Building

One of the challenging aspects with this project was very aggressive schedule to manufacture and install the stone pieces.

Right after confirming the engineering connection details and design feasibility using CAD drawings, the AAS team worked closely with the contractor to understand the intended sequence to install the stone.

AAS developed release map with detailed schedule to manufacture and ship the stone pieces in coordinated batches. This simplified construction project planning, and also mitigated risk in the execution.

Entryway Elevation Archways: Detailed Engineering, Design Assist, Installation Support for Suspended Soffit

 

Lebanon High School | Archways with Suspended Soffit

Lebanon High School Main Entry Elevation Design | Archways with Suspended Soffit

The main entrance of the Lebanon High School has a number deep archways. The AAS team suggested using dry vibrant-tamp cast stone for that. With flexibility to mold both sides of the stone pieces and CNC machining capabilities to develop molds with precision, large stone pieces in the archways fit together with visual continuity and flow.


The radius soffit is suspended from steel for the archways. The large number of suspended pieces in the archways, each with specific design intent, required detailed engineering analysis and close coordination with the architect as well as the installer for the project.


The school signage was also implemented in cast stone panels using precisely engineered custom molds.


With comprehensive RFID system and settings plan, the installation team was able to identify and track every single stone piece to be installed for the high school.

Detailed project planning enabled smooth execution of the project.

Lebanon Trail High School - Front Entry Settings PlanLebanon High School Main Entry - Overview DrawingLebanon Highschool - Deep Archways Achieved using Suspended SoffitLebanon Highschool - Deep Archways Achieved using Suspended Soffit

Settings plan for the main entry elevation of the high school shows different stone pieces fitting together.

Connection details for different parts of archways are different. These drawings identify sections that were detailed in the engineering process.


The settings plan here shows custom stone pieces with embedded signage letters.

NOTE: While CAD drawings used here from the design phase show school name as FRISCO HIGH SCHOOL NUMBER NINE, later on in the construction phase, school was renamed to LEBANON TRAIL HIGH SCHOOL.

Section 4.116 - Connection Details for Suspended Soffit of Archway

Section 4.116 – Connection Details for Suspended Soffit of Archway

Section 4.115 - Connection Details for Suspended Soffit of Archway

Section 4.115 – Connection Details for Suspended Soffit of Archway

Section 4.114 - Connection Details for Suspended Soffit of Archway

Section 4.114 – Connection Details for Suspended Soffit of Archway

Section 4.113 - Connection Details for Suspended Soffit of Archway

Section 4.113 – Connection Details for Suspended Soffit of Archway

The connection details varied for almost every soffit piece.

The AAS team worked closely with the design team to confirm design feasibility.

The installation team got detailed drawings along with training not only to identify and track different pieces, but also to install them.

Section 4.104 - Connection Details for Suspended Soffit of Archway

Section 4.104 – Connection Details for Suspended Soffit of Archway

Lebanon High School Main Entry - Settings Plan - Backview

Lebanon High School Main Entry – Settings Plan – Backview

Engineering Connection Details for Interior Column Covers, Pilasters

Lebanon Trail High School, Frisco, TX - Manufactured Stone Cladding Covers for Interior Columns, Pilasters

Lebanon Trail High School, Frisco, TX | Manufactured Stone Cladding Covers for Interior Columns, Pilasters

The central area of the high school has large size columns and pilasters that span multiple floors. These highlight the experience and accentuate design of the building interior.

The AAS team worked closely with the architect and contractor to provide a custom cladding cover veneers for the columns.

The design required a number of variants to the connection details to make them look uniform from different angles.

Interior Elevation - SW Corridor

Interior Elevation – SW Corridor

 

 

Interior Elevation - NE Corridor

Interior Elevation – NE Corridor

Connection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster CladdingConnection Details for Pilaster Cladding

Different column conditions required detailed analysis and close collaboration with the design & installation teams to confirm connection details for the stone panel veneer for the columns.

Curved Exterior Elevation for the School Dining Hall – Design Assist, Construction Assist

 

The radial cornices for the curved dining hall exterior were achieved using custom molds precisely fabricated using CNC technology.

Arches on this curved exterior elevation are achieved using precisely fitting custom stone panels that don’t have any visually obstructing connection details. The cast stone pieces for the arches are set on imposed steel bands.

Advanced Architectural Stone - Concrete - Design Flexibility, Options

Advanced Architectural Stone – Concrete – Design Flexibility, Options


The CAD drawings below show engineering details that made this high-end aesthetic possible.

Curved Dining Area – Overview of Exterior Design – CAD Drawing Section


Dining Hall Exterior Elevation – Curved Cornice and Banding – Arches – CAD Drawing Section


Curved Dining Hall Entry – Elevation Drawing 2.2606-7

Curved Dining Hall Entry – Elevation Drawing 2.2602

Lebanon High School Project Completed with Aggressive Schedule

 

Lebanon High School Project - Construction with Aggressive Timeline

Lebanon High School Project – Construction with Aggressive Timeline

Imposed Steel Archway to Attach Cast Stone

Imposed Steel Archway to Attach Cast Stone

Manufactured Stone panels for coping, cornices, veneer and banding applications

Manufactured Stone panels for coping, cornices, veneer and banding applications

The use of cast stone to accent this massive facility makes this building a showcase higher education facility.

 

Lebanon High School - Cast Stone Accentuates this Massive Educational Facility

Lebanon High School – Cast Stone Accentuates this Massive Educational Facility