Stone Applications for Lebanon High School: Design Assist, Construction Assist
Advanced Architectural Stone (AAS) has a very well developed methodology to support the design process with a detailed review of drawings. The team actively collaborates with the contractor and architect for the project to define connection details for hanging the stone pieces.
See in this case study for the Lebanon Trail High School, comprehensive CAD drawing details with connections for stone pieces used in a range of applications such as deep archways in the main entrance of the building, project-specific cornices for curved exterior wall, columns & pilasters, etc.
The manufacturing schedule for the stone pieces was synchronized with the different phases of the school building, further simplifying the construction planning process.
Lebanon High School
Products: Dry vibrant-tamp cast stone, GFRC
This is a new high school in the fastest growing city in the U.S. The school will accommodate 5,500 students. Massive entry arches and pediments with a continuous cornice band accent the blended brick exterior.
Manufacturing Process – Release Map
One of the challenging aspects of this project was a very aggressive schedule to manufacture and install the stone pieces.
Right after confirming the engineering connection details and design feasibility using CAD drawings, the AAS team worked closely with the contractor to understand the intended sequence to install the stone.
AAS developed a release map with a detailed schedule to manufacture and ship the stone pieces in coordinated batches. This simplified construction project planning, and also mitigated risk in the execution.
Entryway Elevation Archways: Detailed Engineering, Design Assist, Installation Support for Suspended Soffit
The main entrance of Lebanon High School has several deep archways. The AAS team suggested using dry vibrant-tamp cast stone for that. With the flexibility to mold both sides of the stone pieces and CNC machining capabilities to develop molds with precision, large stone pieces in the archways fit together with visual continuity and flow.
The radius soffit is suspended from steel for the arches. A large number of suspended pieces in the archways, each with specific design intent, required detailed engineering analysis and close coordination with the architect as well as the installer for the project.
The school signage was also implemented in cast stone panels using precisely engineered custom molds.
With a fully automated tracking system and settings plan, the installation team was able to identify and track every single stone piece to be installed for the high school.
Detailed project planning enabled the smooth execution of the project.
The settings-plan for the main entry elevation of the high school shows different stone pieces fitting together.
Connection details for different parts of archways are different. These drawings identify sections that were detailed in the engineering process.
The settings plan here shows custom stone pieces with embedded signage letters.
NOTE: While CAD drawings used here from the design phase show school name as FRISCO HIGH SCHOOL NUMBER NINE, later on in the construction phase, the school was renamed to LEBANON TRAIL HIGH SCHOOL.
The connection details varied for almost every soffit piece.
The AAS team worked closely with the design team to confirm design feasibility.
The installation team got detailed drawings along with training not only to identify and track different pieces but also to install them.
Engineering Connection Details for Interior Column Covers, Pilasters
The central area of the high school has large size columns and pilasters that span multiple floors. These highlight the experience and accentuate the design of the building interior.
The AAS team worked closely with the architect and contractor to provide a custom cladding cover veneers for the columns.
The design required a number of variants to the connection details to make them look uniform from different angles.
Different column conditions required detailed analysis and close collaboration with the design & installation teams to confirm connection details for the stone panel veneer for the columns.
Curved Exterior Elevation for the School Dining Hall – Design Assist, Construction Assist
The radial cornices for the curved dining hall exterior were achieved using custom molds precisely fabricated using CNC technology.
Arches on this curved exterior elevation are achieved using precisely fitting custom stone panels that don’t have any visually obstructing connection details. The cast stone pieces for the arches are set on imposed steel bands.
The CAD drawings below show engineering details that made this high-end aesthetic possible.
Lebanon High School Project Completed with Aggressive Schedule
The use of cast stone to accent this massive facility makes this building a showcase higher education facility.