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.
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.
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.
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.
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
Advanced Architectural Stone (AAS) is doubling the production capacity to custom design and manufacture architectural precast stone and Glass Fiber Reinforced Concrete (GFRC).
AAS is planning this increase in production in two phases: phase one is an expansion to the Mesa Precast plant in Tempe (AZ), followed by second phase to augment manufacturing capabilities in its Ft. Worth (TX) plant.
Phase One: Tempe, AZ Plant (Mesa Precast)
AAS has used Mesa Precast plant in Tempe (Phoenix) for strategic manufacturing and design support for GFRC and architectural wet-precast products.
Mesa has expanded to a second facility adjacent to the current plant in Tempe. This has doubled the production space available for customer projects.
Staffing has been increased by 25% as well as an increased management team.
Mesa production planning and management systems have been enhanced and integrated with AAS enterprise production management systems.
AAS Expansion of Manufacturing Plants | Phase one – Mesa Precast, Tempe, Phoenix, AZ | New Production Space to the Left in this Image
Phase Two: Ft. Worth, TX Plant (formerly known as Advanced Cast Stone)
The Ft. Worth plant is the largest of AAS plants. With this phase of expansion, AAS is aiming to provide even stronger support and flexibility to customers nationwide.
The expansion is increasing production space by 25%.
New inventory control system is implemented to improve tracking and control all three types of stone panel products used in a customer project: cast stone, wet-precast, GFRC (Glass Fiber Reinforced Concrete).
Implemented new manufacturing line producing wet-pour cast stone.
AAS is also adding GFRC manufacturing capability to the plant in Ft. Worth, TX in this expansion phase.
Alex Campolo, CEO of AAS: “This expansion of our production capacity is a strategic investment that is going to not only enable us handle more complex customer projects efficiently, but also help cut down lead time for the delivery of products.”
“Our design, manufacturing system has been refined over time to work closely with customers on every phase of the project. The new inventory control system will further provide more precise control and traceability simplifying job site management. “, added Tim Michael, VP of Business Development.
Advanced Architectural Stone (AAS) Plant in Ft. Worth, TX | Formerly Advanced Cast Stone (ACS)
The AAS team uses a very well refined customer project management system to work closely with customers on every phase of project execution:
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:
How do you mitigate risk in a construction project?
How do you keep wastage to a minimum in the construction process?
How do you minimize delays?
Advanced Architectural Stone (AAS formerly ACS) has thoroughly developed support system to come up with effective answers to these questions.
The AAS customer support team spends time right from the the beginning of the project proactively guiding customers with project planning.
Architectural stone panels are manufactured to size using integrated design technology and precise, custom mold making.
The project team works out sequences to fit the products. The products are made and released according to the sequence. The AAS support team explains the installation sequence to customers with a lot of details. This simplifies it for the installers and masons.
Listen to more on it in this video…
Project Stories: Smooth Installation with Well Thought Out Sequencing, Delivery
Here are three example projects that AAS team has delivered with smooth execution.
Technology creates opportunities for automation and consistency. Advanced Architectural Stone (AAS) puts it to use for consistent product quality and consistency.
The completely automated and computerized batch plant eliminates the error and guess work while making sure raw materials quality and consistency is same through out a project. A number of gauging points, measurements feeding into the monitoring system enables consistent colors, finish, product strength for projects of any size.
Learn more about the AAS computerized batch plant in this video.
AAS is integral part of development of the Reagan Place, now known as Old Parkland. The team combined architectural precast, cast stone and GFRC in this project with seamless color matching. The new construction blended naturally in to the overall ambiance, culture and heritage of the site. The batch plant made it all look so uniform and consistently beautiful for this project.
AAS Project: Reagan Place, Old Parkland | AAS Computerized Batch Plant and Craftsmanship Delivered Consistency | See the CASE STUDY…