AAS provides three different product materials for architectural stone applications:
- Dry vibrant-tamp cast stone
- Wet-pour architectural precast concrete
- 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.
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
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
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
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
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.
