Cook Children’s Hospital: Cost-effective Cladding using Stone Panels
This project consisted of a new building adjacent to the existing regional children’s hospital built approximately 25 years earlier. The new building more than doubled the size of the hospital. The expansion was over 250,000 square feet.
The cladding design combined three different types of architectural stone – cast stone panels, precast concrete structural elements, and GFRC (Glass Fiber Reinforced Concrete) panels at the higher elevation.
Cost savings achieved by using manufactured stone made is feasible to complete the project within budget.
Architectural Stone Cladding for Monolithic Design Aesthetic
This project was originally scoped to match existing buildings on the campus. So, the new building was specified to use native limestone. However, when bids for the exterior cost of the hospital were analyzed, the cost of limestone cladding was approximately $4 million in excess of the available budget. The project was placed on hold.
Advanced Architectural Stone (AAS) proposed formulating a batch design for its architectural cast stone, wet precast and Architectural GFRC that coordinated with the existing limestone on the original structure. This lowered the cost while still matching desired design look of limestone.
As the general contractor said, the manufactured stone with the matching aesthetic made it possible to complete the project cost effectively. Without that the project couldn’t be completed within the required budget.
Project Scale and Quality Control
This was a large project with 25,000 square feet of construction. The consistent look throughout the exterior of such a large building was key to the success.This required consistent color and surface of the manufactured stone panels for the entire duration of the project that lasted for more than a year.
AAS team designed a specific batch mix of raw materials for each of three product panels – dry vibrant-tamp cast stone, architectural precast and Glass Fiber Reinforced Concrete panels. The computerized batch plant and close supervision by the quality control staff made it possible to maintain the consistency while also regularly adjusting to the climatic factors.
The design of the building was done in 3-D BIM modeling with the express purpose of environmental considerations and total integration of all components of the building.
The building has become an integral part of the hospital campus. The design blends the hospital well in the part of Fort Worth, TX that has a number of hospitals and healthcare buildings.
Project Name: Cooks Children’s Hospital
Location: Fort Worth, Texas
Architect: David M Schwarz Architectural Service and FKP Architects
General Contractor: Linbeck
Masonry Contractor: Dee Brown Masonry
Award: 2012 Golden Trowel Award