Tag Archives: Cast Stone

CREATIVE GRAPEVINE DESIGN IN ARCHITECTURAL STONE

The design intent with the renovation of the Grapevine Convention Center project was to preserve the cultural heritage of the historic town on the buildings’  exterior. The interior spaces serve as the modern-day city administration offices.

The architect determined to incorporate grapevines into the design elements of the series of buildings. When the project started, the architect had not decided on the material to use for the grapevine pattern. After numerous meetings with our company, the architect settled on cast stone as the material to use to convey the historical beginnings of the community. Cast stone copings, pier caps, and water tables all were produced with a grapevine design.

All that the assignment for the grape leaf design was only a simple 2-dimensional drawing. In order to make the design, Advanced Cast Stone worked with its commercial artist to form a design that was suitable in size and relief. Rubber molds were finally made to capture the creativity of the artwork.

 

Grapevine Rubber Mold for Singular Cast Stone PieceLeaf Design Stone Pieces Fit Together at Different AngelsGrapevine Leaf Design Connected with the Historical Roots of the City

 

While molds were difficult since the amount of detail desired for the grape leaf is very subjective, its use on the various surface areas of the building further complicated mold production. The design was used on several areas of the structure, such as a typical long flat wall, on radius arches, and at curved sections in the turret areas. At each area of the building, the grape design needed to align with windows, mullions, and other elements of the building. This required careful adjustments to the mold and the pieces of stone to provide overall alignment with the other components of the building.

 

Grapevine Rubber Mold for Cast Stone Band Around the BuildingGrapevine Leaf Design on Curved SurfaceContinuous Leaf Design on Cast Stone BandCustom Mold Making, Project Specific Manufacturing Realized Architect's Design Vision

 

> LEARN MORE: CREATIVE STONE ART

 

HOW DO I SELECT RIGHT PRODUCT(S) FOR MY PROJECT?

AAS provides three different product materials for architectural stone applications:

  1. Dry vibrant-tamp cast stone
  2. Wet-pour architectural precast concrete
  3. Architectural GFRC (Glass Fiber Reinforced Concrete

All three products offer considerable design flexibility and durability compared to natural stone products such as limestone. The project-specific detailed engineering and custom fabrication simplify the installation while also achieving a superior design aesthetic.

  • While cast stone and architectural precast use different casting techniques, the two products have similar structural properties. AAS has a track record for developing custom stone design, using either of the two products or combining the two products as required to achieve the intended design objective for a project cost-effectively.
  • Architectural GFRC panels are only 3/4″ thick and have an excellent strength to weight ratio, providing unique advantages over other casting techniques. The AAS GFRC product material is much more durable compared to other thin veneer panels. GFRC can match the look of other architectural stone products as well as limestone. The GFRC panels cost relatively more than other architectural stone products; however, it has specific advantages with less structural support requirements and simpler installation.

PRODUCTS SELECTION

SELECTION CRITERION

DRY-CAST STONE

WET-POUR PRECAST

GFRC

LIMESTONE

THIN VENEER PANELS

Design Flexibility

Extreme amount of flexibility

Can mold both sides

Complex shapes

Precision with tolerance

Dry-casting technique enables high-end look & finish

Can emulate look of limestone at much lower cost

Extreme amount of flexility

Complex shapes

No size limitation

Enables longer span or length for individual stone pieces

Suitable for heavy use surface areas such as stair treads

Higher strength to weight ratio enables larger, thin pieces including panels.

Bigger pieces, lighter weight, less structural back up

Comparable design flexibility – you can pretty much do anything using all three products

Can easily match look of other stone products

Natural variation in patterns can’t be avoided

Complex shapes, curves, intricate design details are difficult to achieve – product limitations, challenges with machining/fabrication processing

Highly valued traditionally for design aesthetic

Not easy to match look of other stone products

Cost

Much lower than limestone for custom shapes and precision design elements

Cast stone needs less number of molds and so cost-effectve compared to precast

Lower mold cost, lower overall cost

Slightly more expensive than cast stone

Still much more cost-effective than limestone for high-end design applications

Higher than cast stone or wet-pour precast concrete

Cost is much higher than architectural stone products to achieve different shapes

Veneer (flat pieces) cost is comparable to other products

Much less expensive

Durability

Very good

Very good

As good as any stone product

Much better compared to other thin veneer products such as stucco

Not as durable as cast stone

Also variable – depends on type of limestone being used – regional

Not designed for longer term use

Limited testing standards in place if at all – not as comprehensive as cast stone, precast and GFRC

Ease of Installation

Simple installation using any traditional cast stone methods

Usually manually set

Simple installation using any traditional cast stone methods

Equipment is required to set the pieces

Much easier handling of panels

Less construction equipement

Option to build anchorage connections in the products

Relatively less number of pieces required for the target area

Strength-to-weight Ratio

Comparable to other stone products

Comparable to other stone products

Higher than any other architectural stone products or limestone

Varies with product time, region, etc.

Scroll down this blog post to learn more about the cast stone, wetter precast-concrete and Glass Fiber Reinforced Concrete (GFRC).

Dry Vibrant-tamp Cast Stone

 

The dry vibrant-tamp fabrication technique allows flexibility to shape both sides of stone panels even when the shape or design of stone panels is highly complex. This offers more flexibility to realize virtually any design shape. The manufacturing process also opens up design freedom to emulate the looks of a variety of different stone types, including natural limestone. AAS has an extensive track record with projects where manufactured stone matched custom color and finish of natural stone samples.

Cast stone is very cost-effective compared to natural limestone. Learn more about the vibrant-tamp casting process in this video:

> PROJECT EXAMPLE: LA Sports HOF: Complex geometry, large size stone pieces for the interior stone veneer that achieved the architect’s design vision of complex channels of nearly Cane River.

 

LA Sports Hall of Fame | Cast Stone | Architect: Trahan Architects | Masonry Contractor: Masonry Arts | SEE CASE STUDY ...

AAS Advantage: Track Record & Experience | Design Freedom for Designers | Support System for Contractors, Masons

 

> CASE STUDY: LA SPORTS HALL OF FAME PROJECT

> PROJECT EXAMPLE: Houston Market Square – cast stone cladding combined applications for stone façade, pilasters, coping, cornices and bandings – custom color emulating Lueders limestone.

 

Project: Houston Market Square | Custom Dark Color Cast Stone for Veneer, Cladding | Design Accent at the Top of Building

Project: Houston Market Square | Custom Dark Color Cast Stone for Veneer, Cladding | Design Accent at the Top of Building

 

> CASE STUDY: CAST STONE FOR HOUSTON MARKET SQUARE PROJECT

Dry cast-stone has comparable structural properties to wet-pour precast stone.

Wet-pour Architectural Precast Concrete Stone

 

The wet-pour manufacturing technique allows flexibility to embed structural steel or other reinforcements, making it more suitable for load-bearing architectural elements. In general, architectural precast concrete can achieve a more extended span or length for individual stone pieces.

Different finishes can be achieved on the architectural precast stone using post-cure treatments such as acid etching, sand-blasting, and other techniques. On heavy use application areas such as stair treads, architectural precast can retain the stone’s surface finishing for very long time spans.

 

> PROJECT EXAMPLE: Circular stair treads for Ft. Worth Arena

 

Ft Worth Arena | Wet-pour Architectural Precast Concrete Stone for Circular Stair Tread Design

Ft Worth Arena | Wet-pour Architectural Precast Concrete Stone for Circular Stair Tread Design

 

AAS has several projects where the team has been able to work closely with customers to substitute dry-cast stone for the wet-pour stone or vice versa.

Architectural GFRC (Glass Fiber Reinforced Concrete)

 

The architectural GFRC is also known as lightweight concrete, offers the look and finish, as well as longevity and reliability of other stone products with much lighter weight. The proprietary manufacturing technique enables very high strength to weight ratio for the GFRC panels.

While the cost of architectural GFRC can be more than other cast stone products, it can also help with less structural support requirements and simplified installation equipment requirements.

 

> Design flexibility, freedom with GFRC: LEARN MORE

 

> GFRC Design Case Study: SMU Delta Gamma Sorority House

 

SMU Delta Gamma Sorority House | Architectural GFRC Columns, Cladding for Desired Building Elevation Aesthetic

SMU Delta Gamma Sorority House | Architectural GFRC Columns, Cladding for Desired Building Elevation Aesthetic

 

> ARCHITECTURAL GFRC: PRODUCT HOME

COMBINING DIFFERENT PRODUCTS FOR A SPECIFIC PROJECT

 

Customers have options to combine any of the three product materials with seamless matching of color and finish.

> CASE STUDY: Project Examples where Different Product Materials Are Combined for Design Objectives

 

> St. Francis Xavier Church: High-end Design Combined cast stone, wet-pour concrete stone and GFRC (Glass Fiber Reinforced Concrete) panels

Advanced Architectural Stone (AAS) has a dedicated customer project team working closely with customers right from the design phase. As required, the team can support customers in selecting the most appropriate product(s) application for any size projects.

In case of specific questions about your project, complete the request support form at the bottom of this page, and someone from our customer projects team will be in touch with you shortly.

 

 

CLADDING FT WORTH ARENA: LARGE SIZES + CUSTOM SHAPES + PRECISION

The new Ft. Worth Arena design has used exterior stone cladding all around the building. The AAS team custom fabricated cast stone for this application.

 

Pre-engineered anchoring connections simply installationCustom molds enabling precise matching of intricate cast stone piecesCast stone protection, design accentCast stone cladding for Ft Worth Arena buildingLarge size cast stone pieces for banding, wall coping all around the Ft Worth ArenaLarge size complex shapes with stringent tolerance requirementsArena Tower from the side view at top of the buildingOnsite installation support, coordination, troubleshootingCast stone pillasters, baluster design

 

The AAS team confirmed design feasibility working closely with the architect and contractor  using CAD drawings. AAS leveraged manufacturing flexibility to mold both sides of the stone pieces using the dry vibrant-tamp casting process for the stone panels. Custom molds were developed using the CNC technology. With each custom designed stone panel matching stringent tolerance requirement, the bandings, cornices, wall coping, pilasters, balusters and large size architectural trim match the complex angles and wide range of shapes precisely.

The cast stone matched color with wet-pour precast concrete used on stair trades and also large size GFRC panels.

With detailed planning and close coordination with customer, the manufacturing schedule matched with the construction milestones for smooth execution of this massive cladding application for the arena.

AAS worked closely with the installers for onsite troubleshooting.

 

> FT WORTH ARENA CASE STUDY

 

CAST STONE RIBBONS INTEGRATED WITH BRICK VENEER AND GLASS

Project Name: The Cassidy Building
Location: The Sundance Square, downtown Fort Worth, Texas
Product: Dry Vibrant-tamp Cast Stone

Architect: Bennett Benner Pettit Architects
General Contractor: Beck Group
Masonry Contractor: DMG Masonry

The architect for the project, Bennett Benner Pettit Architects had design vision to incorporate horizontal ribbons in the repeating pattern seamlessly integrated with contours of the building façade consisting of brick veneer and glass.

 

Sundance Square Cassidy Building | Cast Stone Ribbons Integrated with GlassSundance Square Cassidy Building | Custom Fabricated Cast Stone Pieces for Monolithic DesignSundance Cassidy Building | Timeless and yet Contemporary Design integrating Cast Stone Ribbons with Brick and Glass ExteriorSundance Square Cassidy Building | Large Cast Stone Pieces Coordinated with Glass

 

The AAS team custom fabricated cast stone panels that realized the ribbon design with precision. With the shape and tolerance of each stone piece confirmed using CAD drawings, the stone ribbons look monolithic on the building envelope. The anchorage support was pre-engineered in each stone panel simplifying the installation process.

The design of the 99,000 sq. ft. Cassidy Building feels timeless and yet contemporary at the same time.

 


TUSCAN COLUMNS

Tuscan columns are the columns used most frequently in the United States because they are also the simplest.  They are not carved and do not have scrolls.  They are columns that have a capital that is square with a circle under the square.  Think of the circle as being round crown molding.  There may be a ring under the circle, all of which would be considered the column capital.

AAS has an extensive range of molds to manufacture columns with a much shorter turn around time. The team is able to customize the column design for any diameter, length, as well as size of the capital.

  • Vibrant-tamp cast stone columns provide options for design with unparalleled flexibility and design freedom to integrate columns into facades, cladding designs, porticos, or other ornamental design elements.
  • Wet-pour architectural precast concrete columns are ideally suited for load bearing applications.
  • GFRC column covers are 3/4″ inch think. They provide very competitive strength to weight ratio and are suitable for higher elevation applications, or cladding design elements where they aren’t bearing the load by themselves.

AAS provides design assist, construction assist for the columns confirming design feasibility, and also simplifying the installation process.

 

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

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

 

 

PROJECT: TRT Holdings Headquarters | Case Stone | 2014 APA Award of Excellence

PROJECT: TRT Holdings Headquarters | Case Stone, Architectural Precast | 2014 APA Award of Excellence

 

Unlimited Design Freedom with Manufactured Architectural Cast Stone, Precast Concrete, GFRC | Seamless Matching with Different Materials for Optimum Value Engineering

Unlimited Design Freedom with Manufactured Architectural Cast Stone, Precast Concrete, GFRC | Seamless Matching with Different Materials for Optimum Value Engineering

IONIC COLUMNS, COLUMN COVERS/WRAPS

The Ionic columns are usually defined by the scrolls at each corner of the capital.  These scrolls are fairly large in proportion to the column itself and the scrolls are also known architecturally as volutes.

  • The AAS team is able to fabricate ionic columns using any of three different product materials: vibrant-tamp cast stone, wet-pour architectural precast, or GFRC (Glass Fiber Reinforced Concrete).
  • For really large size column designs, AAS is able to create modular design with different pieces fitting together at the time of installation with seamless monolithic stone look.
  • Customers have options to seamlessly integrate the columns with other cladding elements such as stone veneer, entry way elevation designs, balusters, cornices, wall coping, door and window surrounds …etc.
  • AAS offers a range of options to fabricate column covers or column wraps to envelope structural elements while seamlessly matching color with other stone products.

Designers are able to achieve any custom color for the columns with a control Sample.

 

Ionic Columns using Architectural Cast Stone | Laura Lee Blanton Building

Ionic Columns using Architectural Cast Stone | Laura Lee Blanton Building

 

Building Cladding and use of Ionic Columns | Product Used: Architectural Cast Stone | Laura Lee Blanton Building

Building Cladding and use of Ionic Columns | Product Used: Architectural Cast Stone | Laura Lee Blanton Building

 

AAS 2016 APA, CSI Awards for AAS Project Old Parkland | Cast Stone, GFRC | Custom Molds, Architectural Stone Cladding

AAS 2016 APA, CSI Awards for AAS Project Old Parkland | Cast Stone, GFRC | Custom Molds, Architectural Stone Cladding

ART AND SCIENCE OF STONE MANUFACTURING: DESIGN FREEDOM WITH CUSTOM PANELS


Concrete and stone products have enabled architectural design of buildings for hundreds of years.

The manufacturing technology combined with opportunity to develop fully integrated solutions for construction projects enable wide range of new design possibilities using architectural stone panels. The project specific focus leads to not only more flexibility and options in design, but also much simpler construction at lower cost.

Learn more with this video how the AAS team is able to start with project specifications, work through the design process, and develop products that create un-paralleled design freedom.


 

Advantages of manufactured architectural stone panels:

  • Combine different product materials for optimum value while maintaining seamless design aesthetic
  • Get consistent product characteristics throughout the project of any size and design complexity
  • Simplify construction and mitigate risk with pre-engineered, built-in installation support
  • Create highly complex shapes for wall panels with stringent tolerance requirements
  • Customize color to any control sample

 

AAS PRODUCTS OVERVIEW >>                     PROJECTS GALLERY >>

 


 

SMU COMMONS: EXTERIOR VENEER, CLADDING, HARDSCAPE DESIGN USING STONE PANELS


Advanced Architectural Stone (AAS) has extensive track record for manufacturing cast stone, architectural precast and GFRC for cladding, exterior veneer, and almost any other architectural design.

These pictures are of a number of buildings at the Southern Methodist University (SMU) campus. You are viewing a new dining hall and housing complex call the SMU Commons; the vision was to integrate these buildings with the overall identity of the campus. At the same time, the designers wanted to create a contemporary feel to the buildings to reflect the school’s cutting edge approach to education and its fun, nurturing, and exciting environment for students.

The AAS team proposed carrying out the design including the exterior cladding and stone veneers using two different products: cast stone and glass fiber reinforced concrete panels (GFRC).

 

Anita and Truman Arnolds Dining Commons, SMU | Unparalleled Design Freedom with Manufactured Stone | Cast Stone, GFRC Cladding, Veneer Design | TECHNOLOGY: CUSTOM MOLD MAKING >>

Unparalleled Design Freedom with Manufactured Stone | Cast Stone, GFRC Cladding, Veneer Design

 

Precision molds combining the use of the CNC technology and employee craftsmanship made it possible to create veneer wall panels that fit together seamlessly for look of monolithic stone. With computerized batch mixing as part of the integral manufacturing process, the stone panels, using both  cast stone and GFRC (Glass Fiber Reinforced Concrete), had the required structural properties, as well as matching color and finish.

The new buildings are huge success for the campus since they excite students, faculty and visitors.

 

Anita and Truman Arnolds Dining Commons, SMU | Cast stone, Architectural GFRC | Custom Molds, Customer Project Management Simplified Installation, Achieved Design with Precision

Cast stone, GFRC | Monolithic Stone Facade, Veneer Design, Stone Capping | Custom Molds, Customer Project Management Simplified Installation

 

PROJECT: SMU Commons | Architectural Stone Cladding

PROJECT: SMU Commons | Architectural Stone Cladding Developed Quality Experience

 

Stone Panels | Technology, Design Flexibility | GFRC, Cast Stone and Wet-percast Concrete Products Materials Combined for Uniform Aesthetic Accent

Stone Panels | Technology, Design Flexibility | GFRC, Cast Stone and Wet-percast Concrete Products Materials Combined for Uniform Aesthetic Accent


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

 

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

 

WALL COPING, PIER CAPS, HARDSCAPE >>


 

 

TRT HOLDINGS – PRECISE ENGINEERING AND CRAFTSMANSHIP FOR DESIGN


TRT Holdings Headquarters is a new 170,000 square ft, six-story Jeffersonian-style office building.  The project is one of several buildings located on the Old Parkland Campus at Dallas, Texas developed by Trammell Crow Holdings, one of the largest developers in the U.S.

  • The overriding design criterion of this building was to have the same style as all other buildings on the business campus.
  • Precast and cast stone was used exclusively as the material at all entries, the exterior connecting porches, hallways and veneer panels at the first floor of the building.
  • Pediments, lintels, sills, water tables, columns and roof coping comprised the remainder of the precast or cast stone on the project.
  • All entrances to the building have beautiful classical Tuscan columns. The Tuscan columns were repeated at a covered portico connecting the building to a restaurant as well.  The columns were connected with a deeply profiled trim. The precast portico runs a length of over 50 feet.

 

PROJECT: TRT Holdings Headquarters | Case Stone | 2014 APA Award of Excellence

PROJECT: TRT Holdings Headquarters | Case Stone, Architectural Precast | 2014 APA Award of Excellence

 

Process for Design

 

  • All pieces, of the same profile, were scaled to varying sizes due to different size windows, doors, entryways and breezeways around the structure.   Precise mold making ability of AAS enabled the required precision over wide range of sizes.
  • There were 7712 pieces of precast and cast stone on the project. The production was carried out using 153 different molds.  The mix design was the company’s standard formula with adjustment to a special color used throughout the campus.
  • Manufacturing was carried out using company’s computer-driven batch plant and computer driven liquid color system.  The automated systems provide the quality control to assure consistency of color and texture.

 

TRT Head Quarters | Cast Stone, Architectural Precast, Architectural GFRC | 2014 APA Award | Product Materials: Cast Stone, Architectural Precast, Architectural GFRC | Entries, exterior connecting porches, hallways, veneers, pediments, lintels, sills, water tables, columns and roof coping

TRT Head Quarters | Cast Stone, Architectural Precast, Architectural GFRC | 2014 APA Award | Product Materials: Cast Stone, Architectural Precast, Architectural GFRC | Entries, exterior connecting porches, hallways, veneers, pediments, lintels, sills, water tables, columns and roof coping

 


 

The owner of the Old Park Land campus, with all five of their architects visited AAS production facility throughout the project life cycle to make sure the color, texture, and scale of the precast and cast stone met the overall design intent of the campus.

 

Project Name: TRT Holdings Headquarters

Location: 4001 Maple Avenue @ the Old Parkland Campus, Dallas, Texas

Architect: HKS, Inc

General Contractor:  Brasfield & Gorrie

Products: Architectural Cast Stone, Architectural GFRC, Precast Concrete

Applications: Architectural Stone Cladding, Veneer Design, Custom Columns

 

NORTH SIDE HIGH SCHOOL: CAST STONE MATCHES ART DECO DESIGN TRADITION


The Culinary Arts Building is a 48,000 square foot building for an additional phase of the North Side High School campus. The school district’s vision was to stay consistent with the traditional Art Deco styling of the school campus. The project consisted of larger than average size architectural cast stone wall panels and architectural wet-precast concrete pieces in order to illustrate the Art Deco designs.

 

North Side-High School | Culinary Arts Building | Custom Finish Coordination with architect for size alterations

North Side-High School | Culinary Arts Building | Custom Finish Coordination with architect for size alterations | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors


AAS team replicated the original art deco design using cast stone.  There were no architectural plans detailing the elaborate Art Deco style precast designs as used on earlier buildings.  Advanced Architectural Stone sent artisan mold designers to the project site to trace the designs in order to make molds.  Once all designs were drawn, the employees returned to the job site to measure the various depths of each design for exact replication.

Advanced Architectural Stone (AAS Formerly ACS) | Art Deco Design style design using Cast Stone, Architectural Precast | North Side High School | Closeup of Entry | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors

Advanced Architectural Stone (AAS Formerly ACS) | Art Deco Design style design using Cast Stone, Architectural Precast | North Side High School | Closeup of Entry | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors


The design craftsmanship of AAS team and technology to create custom decorative stone delivered for the project.

There were 576 pieces of architectural cast stone and architectural precast concrete on the project with detailed design at the roof coping, on panel-lintels above windows, and period fluted pilasters around the structure.

 

Advanced Architectural Stone (AAS Formerly ACS) | Art Deco Design style design using Cast Stone, Architectural Precast | North Side High School | Close up Window Header | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors

Advanced Architectural Stone (AAS Formerly ACS) | Art Deco Design style design using Cast Stone, Architectural Precast | North Side High School | Close up Window Header | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors


 

Project Name: North Side High School, Culinary Arts Building

Location: 2211 McKinley Avenue, Fort Worth, TX 76164

Architect: Corgan Associates, Inc

General Contractor: Steele-Freeman, Inc. Contractors