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BALUSTERS MANUFACTURED IN ONE PIECE: GFRC

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Balusters are used for design accent with commercial as well as residential buildings for centuries.

AAS GFRC manufacturing technique is able to cast balusters in one piece without any seams. This enables superior design aesthetic while also simplifying the installation of the balusters at the construction site.

The fabrication method uses mold for each side or half of the baluster. The inside of the molds is sprayed with a thin layer of the GFRC mix for the desired finish.

Mold for for casting balusters

Mold for for casting balusters

Spraying outer layer of GFRC mix for desired look and finish of balusters

Spraying outer layer of GFRC mix for desired look and finish of balusters

Inspection, hand packing using brush for uniform surface finish quality

Inspection, hand packing using brush for uniform surface finish quality

Inspection, hand packing using brush for uniform surface finish quality

Inspection, hand packing using brush for uniform surface finish quality

After that the two mold pieces are held together to fill in the GFRC admixture inside. The center of the cylindrical space has 2” wide PVC, so that way the finished GFRC baluster has hollow core in the middle.

GFRC balusters cast in one piece

GFRC balusters cast in one piece

In a typical installation, threaded rod is passed through the hollow core in the middle. The rod is attached to the steel channel for securing balusters in place. The AAS team is able to custom design the handrail for the balustrade system so that it has groove from inside to conceal the steel channel inside.

The AAS team is able to make project specific molds as required for the custom size and shape of the balusters.

AAS is able to match color of any control sample provided by the customers.

The AAS team is able to guide customers with selection of the product material, as well as the most appropriate installation details that would achieve the desired design intent.

Balustrade System, Columns, Cladding Design for Harold Clark Simmons Hall, SMU

Balustrade System, Columns, Cladding Design for Harold Clark Simmons Hall, SMU

 

> LEARN MORE ABOUT DESIGN OF BALUSTERS, BALUSTRADE SYSTEM DESIGN

CONCRETE: UNPARALLELED DESIGN FLEXIBILITY, OPTIONS

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Concrete has captured the imagination of designers for thousands of years offering options and flexibility to mold it in different shapes and surface finishes.

The architectural GFRC (Glass Fiber Reinforced Concrete), also known as lightweight concrete, is able to extend the range of possibilities that can be realized using concrete. The AAS fabrication methodology empowers designers to customize product shape, color, finish, as well as attachment connections to achieve the design intent. GFRC is much simpler to install than other cast stone products or limestone.

GFRC - Glass Fiber Reinforced Concrete - Design options, flexibility

GFRC – Design options, flexibility

DESIGN FREEDOM, FLEXIBILITY

 

  • Applications: wall units, window wall units, mullions, spandrels, column covers or wraps, cornices & banding, trim, soffits, sunscreens, custom cladding, veneer, or facade design, coping, interior features, etc.
  • Designers have the flexibility to achieve deep reveals, complex shapes, short radius curves, wide sweeping arcs, as well as sharp angels.
  • With a face mix, a GFRC panel is indistinguishable in exterior appearance from traditional precast or cast stone. The AAS team has the track record to use GFRC in place of limestone for high-end design aesthetic at fraction of the cost.
  • A wide range of surface finishes can be achieved by using exposed aggregate faces such as acid wash, sandblasting, integral color, white cement, and texture.

> LEARN MORE

GFRC - Structural, Engineering, Installation Advantages

Structural & Installation Advantages

LIGHTWEIGHT, HIGH STRENGTH TO WEIGHT RATIO

 

  • The low weight of GFRC panels decreases superimposed loads on the building’s structural framing and foundation.
  • The GFRC panels are ideal for use on buildings where heavier cladding systems would increase the size of required framing members.
  • For rehabilitation or retrofit projects, the use of GFRC panels for re-cladding minimizes the load added to the existing structure.
  • The lightweight of the GFRC panels allows the contractor to quickly and efficiently erect panels even in hard to reach areas, using smaller, less expensive equipment.

> LEARN MORE

GFRC - Project Specific Manufacturing, Support

Project Specific Fabrication, Support

PROJECT-SPECIFIC MANUFACTURING

 

> LEARN MORE ABOUT MANUFACTURING PROCESS

GFRC Design Process Case Study - SMU Delta Gamma Sorority House Project

GFRC Design Process Case Study

GFRC PROJECT EXAMPLE – DESIGN PROCESS CASE STUDY

 

  • See examples of the project-specific design of GFRC products.
  • See videos of the GFRC manufacturing process.
  • Collaboration with customers for design-assist, as well as construction-assist.

> LEARN MORE

Architectural GFRC | Pre-engineered, Built-in Connections | Installation Support | Installation of GFRC Products at SMU Delta Gamma Sorority House

Architectural GFRC | Pre-engineered, Built-in Connections | Installation Support | Installation of GFRC Products at SMU Delta Gamma Sorority House

 

 

 

> LEARN MORE: ARCHITECTURAL GFRC

ARCHITECTURAL DETAILING OF GFRC

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The AAS team is able to provide design assist to the architect and contractor for a project. The in-house engineering support team develops detailed attachment connections that will achieve the design objectives.

The shop drawings will provide the architect and installer an opportunity to review the attachment and make the final detailing.

 

General Rules for attachment

 

  • GFRC pieces up to about 4 feet x 6 feet can often be produced without an additional structural back-up. The manufacturer will add a stiffener-rib to the product back side for added support. A stiffener usually runs the height of the piece every 24 to 30 inches of the product and has very concentrated glass fiber to cement mix. The product can be attached via a veneer tie and strap, kerf and clip, or similar attachment to the structure of the building.
  • Larger pieces or pieces where a stiffener-rib is not appropriate are generally hung with a metal stud back-up. The metal stud system is designed and attached to GFRC piece by the manufacturer as part of the cost of the GFRC on the project. Metal stud back-up is very similar to metal stud framing on most commercial projects, but designed with more precision. The metal stud back-up is usually attached with a grade #2 bolt to the structure of the building. There are occasions where the metal stud framing is welded to the structure. Again the specifications on the welding should follow AWS (American Welding Society) standards.
  • Very large pieces (larger than 8 feet x 20 feet) will have tube steel back-up. The process is much the same as with metal studs discussed above. This back-up will be engineered by AAS.

 

Installation

 

  1.  AAS is able to provide type of connection that is preferred by customer. GFRC provides flexibility with selection of the connection type.
  2. Once the connections are selected, the AAS manufacturing and design process is able to pre-engineer the connections support in the products.
  3. GFRC is much simpler and less expensive to install compared to other much heavier stone products. GFRC installation doesn’t require extensive support structure and heavy construction equipment at the project site.
  4. AAS GFRC products provide flexibility to select right application of caulk or sealants making it easier for masonry contractors not only in their installation process, but also with long term reliability of the installed projects.

 

> LEARN MORE: ARCHITECTURAL GFRC

CUSTOM DESIGN COLUMNS: HIGHLIGHT OF THE SHOPPING CENTER

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The architect had vision to add an elevator and clock tower to the Highland Park Village shopping center that has unified architectural style. Developing intricate design details in the stone and matching the color and finish so that the new building would connect to the surrounding area that had been in existence for over 80 years.

Highland Park - Ornate Architectural Design Integrating Specialized Colums, Highly Decorative Design Elements

Highland Park – Ornate Architectural Design Integrating Specialized Columns, Highly Decorative Design Elements

Clock tower connected with seventy five years old shopping center area | columns at the top accentuate the design accent and shopping mall experience

Clock tower connected with seventy five years old shopping center area | columns at the top accentuate the design accent and shopping mall experience

Highland Park High Design Custom Columns

Highland Park High Design Custom Columns

 

 

Rubber mold for column cap design

Rubber mold for column cap design

The AAS project team developed the drawings for the project from templates without requiring detailed architectural plans. The templates were compared to the existing product and adjustments were made to achieve the precisely matching three dimensional design. The system to capture and communicate in-depth details using CAD drawings assisted the design process confirming the project feasibility in early stages of the project. The integrity of the details was made possible using CNC technology to fabricate the required molds. For high intricate design details in the column caps at the top, rubber molds were used.

Design Details for the top of the clock tower at highland park village shopping center

Design Details for the top of the clock tower at highland park village shopping center

 

Shop Drawing - Clock Tower Design at Highland Park Shopping Center

Shop Drawing – Clock Tower Design at Highland Park Shopping Center

 

Shop Drawing - Details for Support, Anchorage, Installation Connections

Shop Drawing – Details for Support, Anchorage, Installation Connections

 

The AAS team confirmed and communicated installation details for each stone piece used in this tower design. Installers got detailed settings plan with identification of each stone piece.

The clock tower looks as if it were part of the original design of the shopping center. The architectural columns accentuate the overall experience of the shopping center.

Products used: Cast Stone, GFRC (Glass Fiber Reinforced Concrete)
Architect: Omni Planners Architects
General Contractor: W B Kibbler Construction
Masonry Contractor: Metro Masonry

 

> ARCHITECTURAL COLUMNS

 

 

CONCRETE STONE COLUMN COVERS, COLUMN CAPS

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Manufactured stone products provide flexibility to create fully customizable column covers, column wraps that can match with the design vision.

 

Colin Library Project - Cast Stone Wall Caps. Columns, Banding, Cornices for Unifying Custom Design AccentCast Stone | Architectural Precast | Architectural GFRC | Columns, Balustrade System, Columns, Pier Caps, Architectural TrimArchitectural-Precast-Columns-options-for-sizes-color-and-finish-1000x600SMU Simmons Hall | Cast Stone, GFRC, Precast Concrete | Large Size Columns Designed using Custom Molds | DOWNLOAD AND LEARN MORE >>Unlimited Design Freedom with Manufactured Architectural Cast Stone, Precast Concrete, GFRC | Seamless Matching with Different Materials for Optimum Value EngineeringCustom Mold Making | Precision and Consistency in Stone Tolerances along with Custom Shapes for High End DesignGFRC Fulted Columns, Corinthian Capitals | SMU Delta Gamma Sorority HouseFluted GFRC Columns, Cornices using Precise Custom Molds and Cutting Edge Manufacturing CapabilitiesColor matching and consistency over the entire project is an advantage with manufactured cast stone | Large stone pieces exceeded stringent tolerance requirementsAdvanced Architectural Stone (AAS) |Technology - Custom Molds using CNC Machining, Consistent Product Quality using Computerized Batch PlantCast stone pieces for column secured using steel plates and anchorsArchitectural Stone Cladding | Wall Coping, Window Trims, ColumnsArchitectural Columns, Cladding for Portico | Project: SMU Simmons HallCustom Shaped Large Cast Stone Pieces Fitting Together without Additional Work at the Construction SiteAAS Project: SMU Simmons Hall | Architect: Perkins and Will | General Contractor: Vaughn Construction | Masonry Contractor: Wilks Masonry | Manufactured PRODUCTS: Architectural Cast Stone, GFRCSMU Caruth Hall Architectural Stone Cladding | Cast Stone and Wet-precast Products Combined for Desired Design Accent | Large Column Porches and Entries, Design of Eaves, Window Surround Trim | Modular Columns DesignBuilding Cladding and use of Ionic Columns | Product Used: Architectural Cast Stone | Laura Lee Blanton BuildingAAS Architectual GFRC Project | Gilbert Christian High School | GFRC Eave Moldings Wrap the Entire Roof Line of the Structure ...AAS Architectural GFRC - Material Technology, Precise Mixing for Required Strength and Looks

 

Three Product Material Options

 

Dry vibrant-tamp cast stone provides design flexibility to custom design column covers with complex design while also providing competitive structural properties.

Wet-pour precast concrete enable options to embed structural support for load bearing column applications.

Architectural GFRC (Glass Fiber Reinforced Concrete) column wraps are only ¾” thick and yet have high strength to weight ratio, simplifying structural support requirements for higher elevation applications.

 

Project Specific Support: Custom Fabrication

 

Advanced Architectural Stone (AAS) has extensive track record for integrating columns with overall design for cladding applications, exterior stone veneer or façade applications, cornices and bandings, architectural trim around building entry ways/windows/doors, wall coping, etc. As required, design can be realized while combining different product materials as well while maintaining uniform/seamless design aesthetic.

The AAS team is able to collaborate with design team using SHOP drawings to confirm design feasibility and developing pre-engineered anchoring conditions for easy installation of the columns.

AAS helps contractors with columns covers and wraps for both commercial as well as residential applications.

Customers have flexibility to match any color with the control sample.

When required, designers have option to select column designs from an extensive range of in house molds inventory. This can help with faster turnaround times for stone concrete columns designs.

Use the support request form to ask about in-house inventory of architectural column covers, column wraps.

 

CLADDING FT WORTH ARENA: LARGE SIZES + CUSTOM SHAPES + PRECISION

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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.

 

> FT WORTH ARENA CASE STUDY

 

PRECAST CONCRETE: PRECISION ENGINEERING FOR CIRCULAR STAIR TREADS

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The Ft. Worth Arena has circular stairs leading to the entry level as shown in the image below. The AAS team custom fabricated the stone pieces using wet-pour architectural precast concrete to realize the design vision of concentric circular pattern.

 

Ft Worth Arena Project | Concentric Circles of Stair Treads Achieved using Wet-pour Architectural Precast Concrete

Ft Worth Arena Project | Concentric Circles of Stair Treads Achieved using Wet-pour Architectural Precast Concrete

 

Precision Engineering, Design Assist, Construction Assist

 

  • The AAS team developed custom molds for unique radial shape of the stone pieces required for stair treads at every step/level.
  • The molds design included the circular grooves required on each stone piece.
  • The shape, size and tolerance for each stone piece was confirmed in the design phase using CAD drawings.
  • The project team provided detailed settings plan that identified position of every stone piece.

 

Ft Worth Arena | Wet-pour Architectural Precast Concrete Stone for Circular Stair Tread DesignProject Specific Fabrication of Stone Panels | Product: Wet-pour Precast ConcreteGrooves in the Stone Pieces to Match Overall Pattern of Circular Stair Tread Designed using Precast Concrete StoneDesign Freedom, Flexibility with Custom Manufacturing of Architectural Stone | Precast Concrete Pieces Fitting Flawlessly to Realize Design VisionPrecise Custom Molds with Stringent Tolerance Requirements Confirmed using CAD Drawings | Project Specific Manufacturing for High-end Design, Smooth Project ExecutionAAS Project Planning, Collaboration Matched Manufacturing Schedule with Building Construction Milestones

 

The in-house color lab developed batch mixes to coordinate color of the precast concrete panels with the dry vibrant-tamp cast stone, and GFRC panels used on the exterior façade & surrounding support buildings of the arena.

Detailed engineering enabled stair treads design to dissolve with the overall end user experience.

 

> WET-POUR ARCHITECTURAL PRECAST CONCRETE

 

> FT WORTH ARENA CASE STUDY

 

 

CAST STONE RIBBONS INTEGRATED WITH BRICK VENEER AND GLASS

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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.

 

Sundance Square Cassidy Building | Cast Stone Ribbons Integrated with GlassSundance Square Cassidy Building | Custom Fabricated Cast Stone Pieces for Monolithic DesignSundance Cassidy Building | Timeless and yet Contemporary Design integrating Cast Stone Ribbons with Brick and Glass ExteriorSundance Square Cassidy Building | Large Cast Stone Pieces Coordinated with 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.

 

> PROJECT SPECIFIC CUSTOM PRODUCTS

> PROJECT EXECUTION: DESIGN SUPPORT

HARDSCAPE – COPING STONES & STONE CAPS, WALL COPING

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Custom manufactured coping stones and caps can be integral to a unifying hardscape design theme while also providing vital protection from rainfall penetration.

The AAS team is able to match the color and finish of the wall coping seamlessly with other manufactured stone design elements of a building such as stone cladding and veneer design, building elevation design, door and window trims, banding, cornices, etc.

Customers are able to:

  • Select and combine from three different products – dry vibrant-tamp cast stone, architectural wet-pour precast concrete, or GFRC (Glass Fiber Reinforced Concrete)
  • Customize stone products for curved walls, complex shapes, ramped walls, stepped walls, etc.
  • Match any color with control sample.

Cast Stone Caps, Signage

Old Park Land Exterior Hardscape | Wall Coping, Signage, Column Capitals | Designed Contrast with Brick Work

Old Park Land Exterior Hardscape | Wall Coping, Signage, Column Capitals | Designed Contrast with Brick Work

Unifying Design Accent

Texas State University (TSU) Wall Coping Matching with Cast Stone Signage as well as Natural Limestone Work, Building Cladding

Texas State University (TSU) Wall Coping Matching with Cast Stone Signage as well as Natural Limestone Work, Building Cladding

Custom Wall Cap Design

Cast Stone Wall Coping, Custom Signage

Cast Stone Wall Coping, Custom Signage

San Antonio Zoo | Custom Curved Wall Coping, Stone Cap for Hardscape Design

San Antonio Zoo | Custom Curved Wall Coping, Stone Cap for Hardscape Design

WALL COPING, PIER CAPS, HARDSCAPE >>

VIDEO: MAJESTIC SPIRES, DETAILED ARCHES, STONE CLADDING FOR ST. FRANCIS CHURCH

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The American Gothic style design for the St. Francis Xavier Catholic Church in Stillwater, Oklahoma required very detailed arches, window ornamentation, and large spires that weighed over 7,000 lb:

 

The custom cladding design combined three different product materials:

  1. Wet-pour precast concrete was used for large size stone pieces used in the spires.
  2. Detailed design work on arches, banding, cornices was realized using dry vibrant-tamp cast stone panels.
  3. Cornices, coping and design accent panels at higher elevation were developed using GFRC (Glass Fiber Reinforced Concrete).

Color and finish matched seamlessly among the three product materials developing high-end design accent to the multi blended brick veneer.

 

> LEARN MORE: PROJECT CASE STUDY – ST. FRANCIS XAVIER CHURCH

 

> COMBINE STONE PANELS FOR OPTIMUM DESIGN: CASE STUDY

 

> AAS PROJECT EXECUTION: DESIGN SUPPORT