Author Archives: Admin

FABRICATED STONE PANELS: FIVE ADVANTAGES FOR VENEER, FACADE DESIGN


ONE: With precise control over size, shape and tolerances, AAS is able to manufacture stone panels with unparalleled range of design options. The veneer design can be customized to match any kind of geometry. When required, the veneer and façade designs can have monolithic stone look as well.


TWO: AAS is able to fabricate panels using three different types of stone products:

  1. Dry vibrant-tamp cast stone panels that allows for complex shapes and geometries
  2. Wet-pour architectural precast concrete stone products that can be structural as well
  3. GFRC panels that provide design flexibility, as well as high strength to weight ratio for higher elevation applications.

AAS team is able to suggest right combination of products for a project while maintaining seamless look and feel.


THREE: The panels can integrate seamlessly with brick veneer, glass, steel or any other aesthetic or structural elements. AAS is able to single source all three kinds of stone panels with detailed support and training for design assist, construction planning, onsite installation.


FOUR: Get any custom color of choice with a control sample. AAS has a very sophisticated color lab and fully automated batch plant to ensure precise, consistent color for project of any size.


FIVE: Seamless design aesthetic with other cladding applications on a building such as window surrounds, entry way surrounds, architectural columns, wall coping, etc.


PROJECT EXAMPLES:

LA Sports Hall of Fame

AAS Case Studies - Enable Customers Design Process - Support Installation - image - LA Sports Hall of Fame
Project Specific Focus, Manufacturing

Higher Education Complex

Manufactured Stone Veneer with Monolithic Stone Design Accent | Project: Higher Education Complex
Manufactured Stone Veneer with Monolithic Stone Design Accent | Project: Higher Education Complex

UCF ROTC

Fabricated Stone Veneer, 3D Framing of Sculpture | Project: UCF, ROTC Building
Fabricated Stone Veneer, 3D Framing of Sculpture | Project: UCF, ROTC Building

SMU Caruth Hall

Vibrant-tamp Cast Stone, Wet-pour Architectural Precast for Integrated Veneer Design
Vibrant-tamp Cast Stone, Wet-pour Architectural Precast for Integrated Veneer Design

Houston Market Square Tower

Dark Color Cast Stone Veneer | Custom Molds with Precision Enabled Monolithic Stone Look
Dark Color Cast Stone Veneer | Custom Molds with Precision Enabled Monolithic Stone Look

TCU Worth Hills

AAS Case Study | TCU Worth Hills | Large Size Custom Shape Cast Stone Panels for Architectural Design
AAS Case Study | TCU Worth Hills | Large Size Custom Shape Cast Stone Panels for Architectural Design

UCF ROTC: 3D Framing using Stone Veneer

AAS Project : ROTC Classroom at University of Central Florida | Architectural Stone Created Design of 3-Dimensional Frame for the Unique Sculpture
AAS Project : ROTC Classroom at University of Central Florida | Architectural Stone Created Design of 3-Dimensional Frame for the Unique Sculpture

Cook Children's Hospital

Cooks Children's Hospital | Cast Stone Uniformity and Consistency Helped Create Effect of a Monolithic Structure | Matched Native Limestone of Surrounding Buildings
Cooks Children's Hospital | Cast Stone Uniformity and Consistency Helped Create Effect of a Monolithic Structure | Matched Native Limestone of Surrounding Buildings

FABRICATED STONE CLADDING, VENEER DESIGN FOR SMU COMMONS

SMU Commons is newly developed residential hall. The designers wanted the new buildings to blend will the overall campus, and yet give it a contemporary feeling for the buildings that are equipped with cutting edge technology. The AAS team worked closely with the customer to custom design and fabricate the stone panels used in the buildings for unifying design accent.

The building designs combined architectural stone cladding, as well monolithic stone veneer for the intended aesthetic vision.


Cladding Design

All the halls in SMU Commons have wall copings, architectural trim, stone panel entry way designs, wainscots that unified the design accent. With computerized batch plant to precisely control the admixture for the manufactured stone panels, the custom color and structural properties of the stone panels were consistently uniform.

The buildings have integrated cornice and banding designs with look of monolithic stone.

The cladding application design used both cast stone, as well as GFRC (Glass Fiber Reinforced Concrete).

 

PROJECT: SMU Commons | Architectural Stone CladdingFabricated Stone Panels Cladding: Cast Stone, GFRC PanelsFabricated Stone Panels Cladding: Cast Stone, GFRC Panels

 

 


Veneer Design

The stone veneer design in the project has effect of monolithic stone customized to maximize the views. It is designed to integrate with the glass. Close working relationship with the contractor and designer for the project was a key to confirm design feasibility. The AAS team developed custom molds to fabricate every stone piece to precise shape with stringent tolerance requirements. The stone panels color precisely with cladding panels used throughout the SMU Commons buildings.

 

Anita and Truman Arnolds Dining Commons, SMU | Cast stone, Architectural GFRC | Custom Molds, Customer Project Management Simplified Installation, Achieved Design with PrecisionProject: SMU Commons | Architectural Stone Cladding, Veneer Design | Custom Mold Making | Design and Technology

 

 


Pilaster Design

 

The exterior elevation design has seamlessly integrated pilasters using precisely developed custom molds that matched stringent tolerance requirements.

The ability of the AAS team to work closely assisting with the design feasibility early in the project mitigated risk in the project execution.

ART AND SCIENCE OF ARCHITECTURAL STONE CLADDING

Custom design, fabrication of stone panels with unlimited options to customize shapes and sizes enable unparalleled design freedom for cladding applications.

Advanced Architectural Stone (AAS) has a well-developed system to:

  • Review, revise design details while working closely with architects and contractors.
  • Pre-engineer connection & structural support systems in the stone products fabrication process. This simplifies the installation.
  • Precisely control and confirm stringent tolerance requirements.
  • Combine stone products with seamless design effect.
  • Match any color with a control sample.

PROJECT EXAMPLES:

Sundance Square

AAS Computerized Color Lab, Testing - project image - Sundance Square East - Commercial Building - retail shops, offices

Architectural Stone Cladding | Products: Cast Stone, GFRC

Cook Children's Hospital

AAS Architectural Precast Concrete Products - Large Sizes, Custom Finishes - project - cook children's hospital - large sizes, custom shapes

Fabricated Stone Panels for Exterior Cladding | Large Sizes | Custom Shapes

Grapevine Convention Center

AAS Manufactured Architectural Stone - Custom Shapes, High End Design, Products Materials options - cast stone, architectural gfrc, precast, gfrg

Technology | Craftsmanship | Customer Focus

Old Parkland Business Park

Combine Products with Seamless Look, Design Aesthetic | Opens up Design Options, Saves Cost, Simplifies Construction

Combine Products with Seamless Look, Design Aesthetic | Opens up Design Options, Saves Cost, Simplifies Construction | Wall Coping, Cornices and Banding, Unifying Design Accent using Stone Cladding

USC Fertitta Hall

USC Fertitta Hall - North Entry Arch

Jill and Frank Fertitta Hall, USC Marshall School of Business | North Entry Arch

SMU: Delta Gamma Sorority House

GFRC-Connections-Installation-Fluted-Columns-Corinthian-Capitals-SMU-Delta-Gamma-Sorority-House

GFRC Connections, Pre-engineered, Built-in Installation Support | Fluted Columns Corinthian Capitals SMU Delta Gamma Sorority House

ACU Wellness Center

ACU Wellness Center

ACU Wellness Center | Cast Stone Matched Colors of the Brick Exterior for Desired Design Appeal

GFRC DESIGN PROCESS: CUSTOM FABRICATION, CONSTRUCTION SUPPORT

Fluted GFRC Columns - Architectural GFRC Manufacturing Process

Fluted GFRC Columns – Architectural GFRC Manufacturing Process

Custom molds for every segment of the column

Corrithian capitals seamlessly integrated with overall design

Close collaboration with the architect and contractor in design phase for seamless monolithic design accent of columns

Manufacturing technique that creates 3/4″ thick GFRC panles with very high strength to weight ratio

Learn More >>

Architectural GFRC Cornice Manufacturing Process - Video Clips

Architectural GFRC Cornice Manufacturing Process – Video Clips

Light weight, high strength to weight ratio of GFRC cornice panels simplify design, construction

Option with integrated steel frame for built-in installation support

Custom color matching, consistent finish using specialized materials technology, batch mixing, fabrication techniques

See manufacturing in works with a series of video clips >>

Design Feasibility Review | Products Design with Built-in Anchorage | Manufacturing Process | Construction Support

Design Feasibility Review | Products Design with Built-in Anchorage | Manufacturing Process | Construction Support

Project: SMU Delta Gamma Sorority House

Active consultation, collaboration with architect as well as contractor in design phase for confirmation of design details

AAS product design methodology translates CAD drawings into precise custom molds

Pre-engineered connections for seamless design, simpler construction, smooth installation process

Learn More >>

FABRICATION COORDINATION, SEQUENCING SIMPLIFY CONSTRUCTION PLANNING

The AAS team works very closely with customers to simplify the onsite construction process. The team is able to guide customers with the planning different phases of the stone installation.   For large size projects, AAS is able to schedule manufacturing of the stone products to match with the onsite installation schedule.

AAS provides detailed settings plan with ability to identify and track individual stone pieces. The AAS project team is able to deliver the stone panels in different batches leading to much simpler construction site management.

See in this video, details of sequencing, staging, batch fabrication and palletization of stone products used in the Jill and Frank Fertitta Hall project at the Marshall School of Business, USC:

 


 

DESIGN OF 68-FEET TALL CAST STONE ENTRY: GOTHIC ARC, CATHEDRAL WINDOW TURRET

How do you achieve grand entry that is more than five stories high with complex design details that also look seamless/monolithic in design?

The AAS team custom fabricated cast stone pieces for the for the Fertitta Hall building project at the Marshall School of Business, University of Southern California (USC). The 68-feet tall stone veneer with multi-profiled entry way trim for the vaulted gothic arc, and also cathedral window turret is built using 955 cast stone pieces (970 cubic feet, 131,000 lb. of weight).

See in this video how the cast stone panels are engineered with thoroughly integrated installation support:

 


Jill and Frank Fertitta Hall, Marshall School of Business, USC | Cast Stone Grand Entry that is more than Five Stories High | Custom Engineering, Fabrication

Jill and Frank Fertitta Hall, Marshall School of Business, USC | Cast Stone Grand Entry that is more than Five Stories High | Custom Engineering, Fabrication


VENEER, FACADE DESIGN USING FABRICATED STONE PANELS: MORE PROJECT EXAMPLES, LEARN MORE >>

 

ARCHITECTURAL STONE CLADDING: SEE MORE PROJECT EXAMPLES, LEARN MORE >>


CAST STONE FOR DICKIES ARENA SUPPORT BUILDING

The Phase One of the Dickies Arena project is for outside support building to the arena access. This part of the building uses extensive custom fabricated cast stone (dry, vibrant-tamp).

 

The cast stone in this building matches with the architectural wet-precast and GFRC (glass fiber reinforced concrete) stone products used in other parts of the arena.

 

See this video with more details on this phase of the project:


 

 



 

GFRC ART PANELS ON FACADES OF DICKIES ARENA, FORT WORTH, TX

This blog post shows design assist process, as well as custom fabrication of the large size GFRC panels for the Dickies Arena project. The Arena is sited on the Will Roger’s Memorial Center campus in Ft. Worth, TX.

 

Custom GFRC Panels Design, Fabrication

 

The architects for the project aim to develop Art Deco design elements on facades of the arena to match with the 1930s era experience on the campus. The building facade design uses large size GFRC panels with intricate design details in them.

  • The AAS team developed series of custom molds to match the large size and intricate design details required for the project.
  • The mockups are created to confirm the shapes, details in the fabricated stone panels and color matching.
  • AAS works closely with architects and contractors to review details and confirm design feasibility.

 

AAS has capabilities now to manufacture GFRC products in its Ft. Worth plant as well.

Art, Engineering, Design Craftsmanship, Technology for Custom Mold with Specific Design Pattern

Art, Engineering, Design Craftsmanship, Technology for Custom Mold with Specific Design Pattern

Refining Specific Details in the Mold using the Personalized Design Touch after CNC Machining

Refining Specific Details in the Mold using the Personalized Design Touch after CNC Machining

Custom Designed Mold to Match Specific GFRC Panel Size and Shape with Stringent Tolerance requirements

Custom Designed Mold to Match Specific GFRC Panel Size and Shape with Stringent Tolerance requirements

GFRC Art Panels for Art Deco Design Accent at Dickies Arena, Fort Worth

GFRC Art Panels for Art Deco Design Accent at Dickies Arena, Fort Worth

 

Image below shows exterior elevation on the west side with GFRC panels integrated with the brick veneer.

 

Fort Worth Arena Partial Elevation - West Side | GFRC Panels Integrated in Exterior Veneer of the Building Along with Brick Veneer

Fort Worth Arena Partial Elevation – West Side | GFRC Panels Integrated in Exterior Veneer of the Building Along with Brick Veneer

 

CLICK HERE TO SEE HIGHER RESOLUTION IMAGE (OPENS IN NEW TAB/WINDOW) >>

 

DOWNLOAD .PDF FILE FOR DESIGN DETAILS >>



KERF SLOT WITH STRAP ANCHORS: TECHNIQUE FOR INSTALLATION

This video shows details of a very commonly used technique for anchoring cast stone (dry-vibrant tamp), architectural wet-pour precast, or GFRC (Glass Fiber Reinforced Concrete) panels.

The AAS design and engineering process includes details for installation anchorage to confirm the final design aesthetic in the initial review, design assist process. With detailed drawings and coordination with masons and contractor, installation completes very smoothly.



 

The seamless integration of manufactured architectural stone panels makes it much simpler to design exterior cladding, and veneer applications with monolithic design accent.

 

 

AAS PROJECT EXECUTION: DESIGN SUPPORT: LEARN MORE >>

 

GFRC CONNECTIONS: MUCH SIMPLER INSTALLATION, INTEGRATION WITH BRICK WALL


GFRC (Glass Fiber Reinforced Concrete) is much simpler to install because of its light weight and pre-engineered connections for anchorage with substrate.

See in this video details of GFRC connections, and how different stone pieces are custom designed and anchored for installation.

The AAS design team provides settings plan that clearly shows how different stone panels install together for overall design aesthetic.


 

 

The seamless integration of manufactured architectural stone panels makes it much simpler to design exterior cladding, and veneer applications with monolithic design accent.

 

This project also show how cast stone and GFRC can be combined with seamless color matching  opening up opportunities for simplified construction, value engineering, and at the same time unparalleled design freedom.