Tag Archives: balusters

BALUSTERS MANUFACTURED IN ONE PIECE: GFRC

Balusters are used for design accent with commercial as well as residential buildings for centuries.

AAS GFRC manufacturing technique is able to cast balusters in one piece without any seams. This enables superior design aesthetic while also simplifying the installation of the balusters at the construction site.

The fabrication method uses mold for each side or half of the baluster. The inside of the molds is sprayed with a thin layer of the GFRC mix for the desired finish.

Mold for for casting balusters

Mold for for casting balusters

Spraying outer layer of GFRC mix for desired look and finish of balusters

Spraying outer layer of GFRC mix for desired look and finish of balusters

Inspection, hand packing using brush for uniform surface finish quality

Inspection, hand packing using brush for uniform surface finish quality

Inspection, hand packing using brush for uniform surface finish quality

Inspection, hand packing using brush for uniform surface finish quality


After that the two mold pieces are held together to fill in the GFRC admixture inside. The center of the cylindrical space has 2” wide PVC, so that way the finished GFRC baluster has hollow core in the middle.

GFRC balusters cast in one piece

GFRC balusters cast in one piece


In a typical installation, threaded rod is passed through the hollow core in the middle. The rod is attached to the steel channel for securing balusters in place. The AAS team is able to custom design the handrail for the balustrade system so that it has groove from inside to conceal the steel channel inside.

The AAS team is able to make project specific molds as required for the custom size and shape of the balusters.

AAS is able to match color of any control sample provided by the customers.

The AAS team is able to guide customers with selection of the product material, as well as the most appropriate installation details that would achieve the desired design intent.

Balustrade System, Columns, Cladding Design for Harold Clark Simmons Hall, SMU

Balustrade System, Columns, Cladding Design for Harold Clark Simmons Hall, SMU

 

> LEARN MORE ABOUT DESIGN OF BALUSTERS, BALUSTRADE SYSTEM DESIGN

MODULAR COLUMNS: CUSTOM DESIGN FLEXIBILITY, FREEDOM

AAS project team works with architects, contractors and building owners in design and manufacturing of modular columns in variety of shapes and styles. AAS has a lot of experience with very large size columns as required for a project.

 

Manufactured vibrant-tamp cast stone pieces | Sequencing of products delivery, detailed palletization and labeling, settings drawings simplified installation | AAS Project: SMU Simmons Hall

Manufactured Vibrant-tamp Cast Stone Pieces | Column Design Integrated with overall Building Elevation Design at SMU Simmons Hall | Sequencing of Products Delivery, Detailed Palletization and Labeling, Settings Drawings Simplified Installation

 

Cast stone pieces for column secured using steel plates and anchors

Cast Stone Pieces for Column Secured using Steel Plates and Anchors

 

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, Balusters Designed using Custom Molds | DOWNLOAD AND LEARN MORE >>

 

SMU Caruth Hall Architectural Stone Cladding | Cast Stone and Wet-precast Products Combined for Desired Design Accent | Large Column Porches and Entries, Design of Eaves, Window Surround Trim | Modular Columns Design

SMU Caruth Hall Architectural Stone Cladding | Cast Stone and Wet-precast Products Combined for Desired Design Accent | Large Column Porches and Entries, Design of Eaves, Window Surround Trim, Modular Columns Design

 

PROJECT: Collin Library | Architectural Cast Stone Columns

PROJECT: Collin Library | Architectural Cast Stone Columns

 

AAS | Cast Stone, Precast, GFRC | Seamlessly Integrated Custom Columns for Reagan Place, Dallas, TX | Combine Panels with Matching Color, Finish | Good Fulton & Ferrel Architects

CUCTOM MOLDS ENABLE COMPLEX SHAPES, INTRICATE DESIGNS, MONOLITHIC VENEERS

Jeffersonian Design using Custom Design Manufactured Stone | Old Parkland, Dallas, TX | Specially Designed Columns, Egg-n-Dart Rope Design, Large Dentils, Profile | Project Specific Custom Molds, Product Batch Mixing, Manufacturing, Sequencing, Delivery, Installation Support

Jeffersonian Design using Custom Design Manufactured Stone | Old Parkland, Dallas, TX | Specially Designed Columns, Egg-n-Dart Rope Design, Large Dentils, Profile | Project Specific Custom Molds, Product Batch Mixing, Manufacturing, Sequencing, Delivery, Installation Support


The technology and design expertise to develop custom molds enable flexibility to fabricate stone panels with an unparalleled range of complex shapes and design details.

 

VIDEO: Custom mold making for complex shapes, intricate design details, custom sizes:

 

 

 


 

PROJECT: SMU COMMONS

 

Custom molds made it possible to create large size custom stone panels with stringent tolerance requirements. Detailed engineering of anchoring connections played a crucial role in achieving a monolithic stone look for the facade veneer of the building.

 

Architectural Stone Cladding, Veneer Design using Custom Designed Stone - Mold Making Technology, Design Craftsmanship - cast stone, precast, GFRC

Project: SMU Commons Building Facade | Architectural Stone Cladding, Veneer | Cast Stone, Precast Concrete, GFRC

 

Project: SMU Commons | Architectural Stone Cladding, Veneer Design | Custom Mold Making | Design and Technology

Project: SMU Commons | Architectural Stone Cladding, Veneer Design | Custom Mold Making | Design and Technology

 

Architectural Stone Cladding | Cast Stone, Precast, GFRC

Architectural Stone Cladding | Cast Stone, Precast, GFRC

 


 

PROJECT: High-end columns for clock tower – Highland Park shopping center

 

Columns with intricate design details at the top of the tower developed a signature highlight for the shopping center experience.

Clock tower connected with seventy five years old shopping center area | columns at the top accentuate the design accent and shopping mall experience

Clock tower connected with seventy-five years old shopping center area | columns at the top accentuate the design accent and shopping mall experience

 

Highland Park High Design Custom Columns

Highland Park High Design Custom Columns

 

The design combined cast stone and GFRC (Glass Fiber Reinforced Concrete) product materials.

 

LEARN MORE >>


 

PROJECT: The Westbrook Building, Sundance Square, Ft. Worth, TX: Art Deco Panels

 

On The Westbrook Building, the cast stone was used in the overall design of the building to be reminiscent of the Art Deco structures located in many areas in Ft. Worth.

AAS Project: The Westbrook - Sundance Square West - Ft Worth, TX | Art Deco Design using Cast Stone | Custom Mold Design | Architect: Bennett Benner Pettit, Inc

AAS Project: The Westbrook – Sundance Square West – Ft Worth, TX | Art Deco Design using Cast Stone | Custom Mold Design | Architect: Bennett Benner Pettit, Inc

 

Architectural Stone made the molds for the Art Deco designs from isometric sketches provided by the architect.  In other words, the descriptions provided three sides, all in dimensional proportion, but none were shown as an actual shape with 90-degree corners.

The sketch was only a guide to making actual size molds.  Artisan designers created molds for the Art Deco panels combining their design craftsmanship with extensive CAD drafting and also precision cutting using CNC machines.

 

The Westbrook Building at Sundance Square, Ft Worth, TX | Art Deco Design, Custom Design Elements using Cast Stone, GFRC

The Westbrook Building at Sundance Square, Ft Worth, TX | Art Deco Design, Custom Design Elements using Cast Stone, GFRC | Architect: Bennett Benner Pettit, Inc

 

PROJECT CASE STUDY >>


 

PROJECT: High-End Design Element Using Custom Mold – Rockwall County Court House

 

The architect for this project had a vision for unique design elements on the exterior of the building. AAS team designed a highly intricate mold to create it in cast stone. The precise tolerance and detailed coordination with the construction team helped create the desired look with a smooth installation that completed on time.

 

Advanced Architectural Stone - AAS - Formerly Advanced Cast Stone | Rockwall County Courthouse | Cast Stone, Precast | Technology Allowed Complex Shapes and Desired Aesthetic Design | Brinkley Sargent Architects | DMG Masonry

Advanced Architectural Stone – AAS – Formerly Advanced Cast Stone | Rockwall County Courthouse | Cast Stone, Precast | Technology Allowed Complex Shapes and Desired Aesthetic Design | Brinkley Sargent Architects | DMG Masonry

 

 

PROJECT: Texas Christian University (TCU) Relief Panels

 

This project consisted of 6 panels installed in the entry to the remodeled and enlarged football stadium at Texas Christian University. The panels were made using architectural precast and cast stone. The purpose of the panels and the project was to honor the founders of the University dating to 1895.

The architect for the project, HKS Architects, hired an artist to approve and render the murals. The AAS team transferred the original artwork to a rubber mold for casting. The panels represent the cultural icon at the heart and soul of Texas Christian University. It was critical that the panels could be seen within a few feet of the viewer. AAS team used its experience and technology to refine every detail within the mold so that panels accurately depict the original aesthetic appeal so critical to the project’s success.

The project won the 2014 APA (Architectural Precast Association) Craftsmanship Award.

Following is a composite image showing example panels.

AAS 2014 APA Award | TCU Relief Panels | Finish and Precision for Design Appeal | HKS Architects | General Contractor: Austin Commercial

AAS 2014 APA Award | TCU Relief Panels | Finish and Precision for Design Appeal | HKS Architects | General Contractor: Austin Commercial

 

AAS 2014 APA Award | TCU Relief Panels | Forming using Precise Molds, Design Experience | HKS Architects | General Contractor: Austin Commercial

AAS 2014 APA Award | TCU Relief Panels | Forming using Precise Molds, Design Experience | HKS Architects | General Contractor: Austin Commercial


 

PROJECT: LA Sports Hall of Fame – Complex Shaped Panels – LA Sports Hall of Fame

 

Trahan Architects had a vision for emulating Cane river channels inside the Louisiana Sports Hall of Fame Museum. This required cast stone panels with complex shapes. The stone pieces were also huge. The project execution also demanded stringent tolerance requirements in the mold so that the stone would fit in seamlessly for a consistent look.

 

Advanced Architectural Stone (AAS - Formerly ACS) Team Supports Contractors, Builders, Masons - construction of LA Sports Hall of Fame Museum

Advanced Architectural Stone (AAS – Formerly ACS) Team Supports Contractors, Builders, Masons – construction of LA Sports Hall of Fame Museum

 

LA Sports Hall of Fame | Large Size Precision Molds for Design That Had Highly Stringent Tolerance Requirements

LA Sports Hall of Fame | Large Size Precision Molds for Design That Had Highly Stringent Tolerance Requirements

 

LA State Museum and Sports Hall of Fame | Cast Stone Realized Cane River Channels | Large Complex U-Shaped Stone Pieces | BIM Modelling | Trahan Architects | CASE STUDY ...

LA Sports Hall of Fame | Cast Stone Realized Cane River Channels | Trahan Architects | CASE STUDY >>

 

LA State Museum Sports Hall of Fame | Trahan Architects | Cast Stone Veneer Developed using Complex Shaped, Large Cast Stone Pieces Fitting within Stringent Tolerance Requirements | LEARN MORE About Design, Manufacturing Process...

LA State Museum Sports Hall of Fame | Trahan Architects | Cast Stone Veneer Developed using Complex Shaped, Large Cast Stone Pieces Fitting within Stringent Tolerance Requirements | LEARN MORE About Design, Manufacturing Process…

 

PROJECT CASE STUDY: LA SPORTS HALL OF FAME >>


 

PROJECT: 714 Main Street – Authentic High Design Roman Heads using Custom Molds

 

The requirement was that the AAS stone would match the pre-existing terracotta stone.

 

714 Main St | Cast Stone for Building Exterior | Quality Experience, Desired Colors and Finish | Cost Effective Solution

714 Main St | Cast Stone for Building Exterior | Quality Experience, Desired Colors and Finish | Cost Effective Solution

 

The design had the Roman Heads depiction on the outside, which were authenticated and designed by artists. AAS team worked closely with the architect and artist to design and create the representations in cast stone that matched the original rendering of the artist precisely.

 

AAS Custom Mold Making | Roman Head Design in Cast Stone for 714 Main Street Building, Dallas, TX | Cast Stone Cladding

AAS Custom Mold Making | Roman Head Design in Cast Stone for 714 Main Street Building, Dallas, TX | Cast Stone Cladding

 

AAS Project: 714 Main Street | Unique Technology, Craftsmanship to Replicate design of Roman Heads | Product used Architectural Cast Stone

AAS Project: 714 Main Street | Unique Technology, Craftsmanship to Replicate design of Roman Heads | Product used Architectural Cast Stone

 

>See more on this project


 

PROJECT: Grapevine Convention and Visitors Bureau

 

AAS team helped create exterior fronts of the building that used cast stone and architectural precast extensively. The design used grape leaves build from the cast stone panels. The integration of the grape leaf design connects with the historical name of the city, and the local culture.

The AAS project team used custom molds to create highly intricate grape leaf design elements that are an accurate representation of the original design renderings.

 

AAS Cast Stone | Custom Mold Making | Grapevine Leaf Designed using Dry Cast System

AAS Cast Stone | Custom Mold Making | Grapevine Leaf Designed using Dry Cast System

 

Specialized Rubber Molds for Grape Leaf Design | Cast Stone Design for Grapevine Convention and Visitors Bureau

Specialized Rubber Molds for Grape Leaf Design | Cast Stone Design for Grapevine Convention and Visitors Bureau

 

Grapevine Convention Center and Visitors Bureau - High End Leaf Design - Manufactured stone cladding

Grapevine Convention Center | High-End Leaf Design – Exterior Cladding | Cast Stone | APA Award of Excellence | ArchiTexas | J & E Masonry

 

AAS Cast Stone Project | Specific Color Contrast Requirements from the Architect of the Project ArchiTexas | Grapevine Convention & Visitors Bureau

AAS Cast Stone Project | Specific Color Contrast Requirements from the Architect of the Project ArchiTexas | Grapevine Convention & Visitors Bureau

 

> LEARN MORE: Creative Art Design Process for the Grapevine Leaf Design Elements

> See more on Grapevine Convention Center and Visitors Bureau Project.


 

PROJECT: Gilbert Christian High School – Custom Molds for Architectural GFRC

 

Gilbert Christian High School is located in the city of Gilbert in the Scottsdale (AZ) area. The school exterior used extensive Architectural GFRC elements that were easy to integrate with the exterior thin brick veneer of the building. The column capitals have Corinthian style.

 

AAS Architectural GFRC Case Study | Gilbert Christian Case Study

AAS Architectural GFRC Case Study | Gilbert Christian Case Study

 

AAS Architectural GFRC Case Study | Gilbert Christian High School | Custom Molds and Finish | Simplified Installation with Higher Elevations, Brick Veneer

AAS Architectural GFRC Case Study | Gilbert Christian High School | Custom Molds and Finish | Simplified Installation with Higher Elevations, Brick Veneer

 

See more about the Gilbert Christian High School project in the case study.


 

PROJECT: Texas Christian University (TCU) Worth Hills – Large Sized Molds for Curved Panels

 

This is a new development added to the school campus.

The entryway of the building has a very high elevation breezeway. The cast stone and architectural precast panels required custom molds that enabled panels of such a big size that would fit together to create a seamless effect in the breezeway.

 

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

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

 

AAS Project - TCU - color matching - custom molds for Large Complex Curves - Download case study

AAS (Formerly ACS) | Project: Texas Christian University (TCU) Worth Hills Campus, Entry Gate | Cast Stone, Architectural Precast

 


 

PROJECT: SMU Simmons Hall Project: Precise molds, Construction Support, Coordination

 

Large Size Custom Stone Panels Fit in for Monolithic Stone Look | Fabricated Stone Veneer, Cladding Design

Large Size Custom Stone Panels Fit in for Monolithic Stone Look | Fabricated Stone Veneer, Cladding Design

 

The AAS team tapped into its extensive experience with the design of elaborate balustrade systems as well for this project. The dimensions and shape of balusters had specific requirements; custom molds were developed for this as well.

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