The Advanced Architectural Stone (AAS) team helps clients achieve the design goals, mitigating risk in the construction process.
Design Assist: AAS uses a proven methodology to review CAD drawings with customers. As required, the team can guide customers detailing anchorage connections to hang the stone pieces. Customers can confirm the feasibility of the design early in the project lifecycle.
Construction Planning: AAS develops project-specific product releases that match with the construction milestones. Customers get a detailed settings-plan with the ability to track individual stone pieces.
Installation Support: Customers get a detailed CAD drawing for different sections, each showing specific installation details. AAS also supports customers with onsite troubleshooting during the installation phase.
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, 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.
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
What does it take to design and manufacture Architectural GFRC products?
What makes Architecture GFRC ideal for higher elevation applications?
See the manufacturing process and technology used for cornices of the new sorority house building at the Southern Methodist University (SMU) in step-by-step sequence of videos in this blog post. These video clips are captured at the Mesa Precast plant of Advanced Architectural Stone; this plant is located in Tempe, AZ.
Step One: Custom Molds
AAS team used the in house custom mold making technology and craftsmanship to create the required molds of specific shape for each GFRC panel used on this project. For the exterior cornices of the building, these molds are big in size as well. See more on it in their video.
Step Two: Spray Mix for GFRC
The Architectural GFRC (Glass Fiber Reinforced Concrete) products are manufactured by spraying specific mix. AAS has automated batch plant system to create the right mix with precise control over proportions and consistency.
See spray mix getting ready for the manufacturing in this video.
Step Three: Facing Mix
The first step in creating 3/4 ” thick GFRC panel is, applying the face mix. It doesn’t have any fibers in it. It helps create a smooth finish on the outside. In this project, the cornices are going to be acid etched, so the smooth surface is very helpful for creating that finish later on.
See facing mix being applied…
The face mix is brushed to make sure all surfaces are covered, and also there are no air bubbles…
Step Four: Applying Back up Mix
Next step in the manufacturing is applying back up mix that has fibers in it. This is applied over three layers typically with brushing and packing in every step to eliminate bubbles and gaps in the panels.
Material technology to create the right mix is one of core differentiators of the Advanced Architectural Stone.
Watch back up mix being compacted using brush and rollers in this video clip…
Step Five: GFRC Frame for Attaching Cornice to the Building During Installation
The idea with this GFRC cornice is to simplify installation with per-engineered steel installation frame attached to the GFRC skin, so that from outside it looks like a solid concrete piece…
While the frame is being integrated into the GFRC panel structure, edges are also thickened to make the product stronger and structurally more sound.
GFRC Cornice Ready for Surface Finishing and then for the Installation
The the manufactured Cornice piece realized with custom molds, right materials selection, and specific technology and expertise in creating an engineered piece precise in tolerance, ready to install.
While it looks like solid concrete from the outside, this Architectural GFRC cornice is so light in weight when compared to concrete or other cast products such as cast stone or architectural precast. This makes Architectural GFRC ideal for higher elevation applications.