Tag Archives: Dry Vibrant-tamp Cast Stone


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.








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


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


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



> 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



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





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.




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.