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3-D FRAMING USING MANUFACTURED VENEER PANELS AT ROTC BUILDING, UCF

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The new ROTC building at University of Central Florida highlights a 13-sided sculpture honoring our country and soldiers throughout the history.

The AAS team created framed views of the sculpture using architectural cast stone panels. The sculpture is housed in a one and half feet thick rotunda made from custom design dry-cast stone, and GFRC concrete panels. The rotunda is three stories high with 30 feet in diameter. There are three large radius openings in it with a complex series of step backs that create framed views of the sculpture from different directions.

This three-dimensional frame accentuates and emphasizes the unique sculpture symbolizing the spirit and storied tradition of the ROTC.

 

AAS Project : ROTC Classroom at University of Central Florida | Architectural Stone Created Design of 3-Dimensional Frame for the Unique Sculpture

AAS Project : ROTC Classroom at University of Central Florida | Architectural Stone Created Design of 3-Dimensional Frame for the Unique Sculpture

Color and texture consistency of architectural stone was achieved through a computer driven batch design.

The  CNC technology was utilized to design custom molds for the GFRC, cast stone wall panel pieces. Every one of the manufactured stone wall panels matched extremely stringent tolerance requirements. With all stone panels seamlessly fitting together, the entrance facade achieved desired look of a monolithic piece of stone.

 

University of Central Florida ROTC Classroom II Building | Architectural Stone Design Created Monolithic Look | Stone Veneer

University of Central Florida ROTC Classroom II Building | Architectural Stone Design Created Monolithic Look for the building facade | Stone Veneer

Exterior Veneer using Manufactured Stone Panels

 

The front entry and exterior of the building has architectural stone veneer that played a key role in harmonizing the new building with the rest of the school campus.

The facade veneer combined three different types of stone veneer panels – thin lightweight GFRC (Glass Fiber Reinforced Concrete) panels at the higher elevation, vibrant-tamp architectural dry cast stone for the framing and cladding design elements, as well as wet-precast architectural concrete where stronger structural support was required.

 

AAS Formerly ACS | Architectural Stone Veneer, Cladding Harmonized new ROTC Building with campus of University of Central Florida (UCF)

AAS Formerly ACS | Architectural Stone Veneer, Cladding Harmonized new ROTC Building with campus of University of Central Florida (UCF)

Project Name: University of Central Florida Classroom Building II ROTC

Architect: Schenkel Shultz, Architecture/Interior Design

General Contractor: Clancy & Theys Construction

Products Used: GFRC, Architectural Cast Stone, as well as Architectural Precast Concrete

 

VENEER, FACADE DESIGN USING FABRICATED STONE PANELS: MORE PROJECT EXAMPLES, LEARN MORE >>

 

ARCHITECTURAL STONE CLADDING: SEE MORE PROJECT EXAMPLES, LEARN MORE >>

 

FLUTED GFRC COLUMNS FOR SMU: VIDEO CLIPS WITH MANUFACTURING STEPS

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The architectural design of the new Sorority House building at SMU uses fluted columns for a unique accent. AAS team worked with the architect and contractor to come up with an answer of using architectural GFRC product for this. See the manufacturing process in these video clips.

Step One: Designing and Creating Custom Molds

 

AAS used CNC technology and craftsmanship to design the fluted column using modular molds that would create different components of the column – the base, tapered column split over parts, and uniquely sculpted Corinthian capital.

See the molds in this video…

 

Molds are lined up in the plant to begin the GFRC casting process…

 

Step Two: GFRC Casting Process – Applying Face Mix and Spraying, Packing Back up Mix

 

See in these video clips application of the face mix and back up mix.

 

Smooth layer of face mix applied …
Back up mix is sprayed and packed …

 

 

 

Step Three: GFRC Casting Process – Thickening the Edges

 

 

GFRC (Glass Fiber reinforced concrete) has a three forth of an inch thick wall with hollow space in the middle. So, it is much lighter in weight. GFRC is also called light weight concrete.

With fibers in the cast mix, GFRC still provides very good strength to weight ratio. This simplifies the structural and installation requirements.

See products comparison guide to compare the three manufactured stone products – architectural dry cast stone, architectural wet precast and GFRC.

 

 

 

TRT HOLDINGS – PRECISE ENGINEERING AND CRAFTSMANSHIP FOR DESIGN

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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 | 2014 APA Award of Excellence

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.
  • Manufacturing was carried out using company’s computer-driven batch plant and computer driven liquid color system.  The automated systems provide the quality control to assure consistency of color and texture.

 

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

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

Architect: HKS, Inc

General Contractor:  Brasfield & Gorrie

Products: Architectural Cast Stone, Architectural GFRC, Precast Concrete

Applications: Architectural Stone Cladding, Veneer Design, Custom Columns

 

NORTH SIDE HIGH SCHOOL: CAST STONE MATCHES ART DECO DESIGN TRADITION

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The Culinary Arts Building is a 48,000 square foot building for an additional phase of the North Side High School campus. The school district’s vision was to stay consistent with the traditional Art Deco styling of the school campus. The project consisted of larger than average size architectural cast stone wall panels and architectural wet-precast concrete pieces in order to illustrate the Art Deco designs.

 

North Side-High School | Culinary Arts Building | Custom Finish Coordination with architect for size alterations

North Side-High School | Culinary Arts Building | Custom Finish Coordination with architect for size alterations | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors

AAS team replicated the original art deco design using cast stone.  There were no architectural plans detailing the elaborate Art Deco style precast designs as used on earlier buildings.  Advanced Architectural Stone sent artisan mold designers to the project site to trace the designs in order to make molds.  Once all designs were drawn, the employees returned to the job site to measure the various depths of each design for exact replication.

Advanced Architectural Stone (AAS Formerly ACS) | Art Deco Design style design using Cast Stone, Architectural Precast | North Side High School | Closeup of Entry | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors

Advanced Architectural Stone (AAS Formerly ACS) | Art Deco Design style design using Cast Stone, Architectural Precast | North Side High School | Closeup of Entry | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors

The design craftsmanship of AAS team and technology to create custom decorative stone delivered for the project.

There were 576 pieces of architectural cast stone and architectural precast concrete on the project with detailed design at the roof coping, on panel-lintels above windows, and period fluted pilasters around the structure.

 

Advanced Architectural Stone (AAS Formerly ACS) | Art Deco Design style design using Cast Stone, Architectural Precast | North Side High School | Close up Window Header | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors

Advanced Architectural Stone (AAS Formerly ACS) | Art Deco Design style design using Cast Stone, Architectural Precast | North Side High School | Close up Window Header | Architect: Corgan Associates | Contractor: Steele-Freeman, Inc. Contractors

 

Project Name: North Side High School, Culinary Arts Building

Location: 2211 McKinley Avenue, Fort Worth, TX 76164

Architect: Corgan Associates, Inc

General Contractor: Steele-Freeman, Inc. Contractors

 

ARCHITECTURAL GFRC FOR BUILDING VENEERS: INSTALLATION VIDEO

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The Architectural GFRC panels are only 3/4 of an inch thick making them easy to ship, handle and integrate.

This opens up new design options for building veneer applications.

 

Project Story: GFRC veneer at Gilbert Snooze Restaurant

 

Gilbert Snooze is located in the city of Gilbert in Phoenix, AZ area. The designers and planning team have created feel of an old country style industrial township in this area.

AAS team used Mesa Precast plant for supporting design of veneer for Gilbert Snooze. The team created color samples and worked with owner in matching the veneer with the wood and steel elevation of the restaurant. See videos of thin GFRC wall panels being placed in position and installed for this veneer.

 

See in this video, the panels being placed at higher elevation. Light weight of GFRC makes it easy to handle…
GFRC panels are installed in place by mason very easily. See a panel being installed in this video…

 

 

AAS Plant: Mesa Precast in Tempe, AZ | Architectural GFRC Panels Veneer Adding Accent to Wood and Steel Elevation - Gilbert Snooze Restaurant, AZ

AAS Plant: Mesa Precast in Tempe, AZ | Architectural GFRC Panels | Veneer using Thin Wall Panels Add Accent to Wood and Steel Elevation – Gilbert Snooze Restaurant, AZ

 

AAS Mesa Precast Plant | Custom Architectural GFRC Panels for Building Veneer - Gilbert Snooze Restaurant, Gilbert, Phoenix, AZ

AAS Mesa Precast Plant | Custom Architectural GFRC Panels for Building Veneer – Gilbert Snooze Restaurant, Gilbert, Phoenix, AZ

 

GFRC Veneers at Gilbert Christian High School

Gilbert Christian High School has a brick veneer enveloping the building.

The wainscots, window trims and entry way trim installed very easily.

 

AAS Architectural GFRC Integrates Well with Brick Veneer | It Requires Less Depth Compared to Other Materials such Cast Stone or Precast Concrete

AAS Architectural GFRC Integrates Well with Brick Veneer | It Requires Less Depth Compared to Other Materials such Cast Stone or Precast Concrete

AAS Architectural GFRC Wainscots and Entry Way Trim at Higher Elevation

AAS Architectural GFRC Wainscots and Entry Way Trim at Higher Elevation

 

AAS Formerly ACS Project: Gilbert Christian High School | Light Weight Architectural GFRC with Customized Colors, Finish, Simpler Higher Elevation Construction, Installation | See Case Study ...

AAS Formerly ACS Project: Gilbert Christian High School | Thin GFRC Panels Attached to the Structure Gives it Feeling of a Uiiform Structural Element | Light Weight Architectural GFRC with Customized Colors, Finish, Simpler Higher Elevation Construction, Installation | See Case Study …

 

 

ARCHITECTURAL GFRC CORNICES FOR SMU: SEE MANUFACTURING IN WORKS

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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.

 

 

LEARN MORE ABOUT PRE-ENGINEERED, BUILT IN CONNECTIONS WITH AAS GFRC PANELS, CUSTOM DESIGN >>

 

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.

 

 

 

 

VIDEO: INSTALLATION ASSISTANCE: STAGING, SEQUENCING, DELIVERY

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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.

  1. The AAS customer support team spends time right from the the beginning of the project proactively guiding customers with project planning.
  2. Architectural stone panels  are manufactured to size using integrated design technology and precise, custom mold making.
  3. 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.

 

USC - Ronald Tutor Center
USC Ronald Tutor Campus Center | AC Martin Partners Architects | R & R Masonry

USC Ronald Tutor Campus Center | Cast Stone, Architectural Precast, Architectura [...]

Gilbert Christian School
PROJECT: Gilbert Christian, AZ | Architectural Precast, Architecural GFRC | | Light Weight, Superior Aesthetics, Design Flexibility

PROJECT: Gilbert Christian, AZ | Architectural GFRC | Light Weight, Superior Aes [...]

Higher Education Complex
PROJECT: Higher Education Complex | Cast Stone | Architect: PBK Architects | Mason Contractor: Tim Hughes, Dee Brown Inc

AAS PROJECT Snapshot: Higher Education Complex | Cast Stone, Architectural GFRC [...]

SMU Simmons Hall
SMU Simmons Hall Construction | Precise engineering, Custom Manufacturing of Architectural Cast Stone for the Portico Columns

SMU Simmons Hall Construction | Precise engineering, Custom Manufacturing of Architectural Cast Stone for the Portico Columns

PRODUCT MATERIALS: HOW DO THEY COMPARE? HOW DO YOU SELECT?

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Advanced Architectural Stone (AAS) provide different product materials options for projects –

  1. Cast Stone
  2. Architectural Precast
  3. Architectural GFRC (Glass Fiber Reinforced Concrete)
  4. GFRG (Glass Fiber Reinforced Concrete)

 

How do these products compare? How do you select a product material? Please refer to the tables below.

 

PRODUCT MATERIALS COMPARISON

Basis Cast Stone Architectural Precast Architectural GFRC
Definition High quality masonry building material simulating limestone. Masonry building material produced in larger sizes; can be visually comparable to cast stone with special finishing, but without special finishing more like concrete. Masonry product made with glass fiber for strength with a hollow back having appearance of cast stone or precast at the option of the specifier.
Design Made from graded aggregates, white Portland Cement, additives and color pigments Consists of larger aggregates from 1″ to fine sands, additives and Portland cement. Mix design same as precast with the addition of glass fiber for strength and face material visually the same as cast stone or precast.
Production
Method		 Usually produced by dry cast method with very little moisture; compacting mix densely into molds. Wet Method used; mix is poured into molds. Product sets up in mold overnight. The product has a hollowunderside; strength through glass fibers. A wet pour method.
Structural /
Non structural		 This product is self supporting but is not structural. This product can be conventionally reinforced or pre-stressed to be structural. Product is not structural but is self supporting through attachments.
Weight 132 pounds per cubic foot 150 pounds per cubic foot Approximately 50% or less weight for same area covered than cast stone or precast.
Specification Defined under Masonry Division – Section 4720 of the uniform building code. Defined under Concrete Division – Specification 3450 of the uniform building codes. Defined under Concrete Division – Specification 3490 of the uniform building codes.
Speed of Manufacture Multiple pieces per day from mold; higher production output. Usually 1 piece per day per mold; limiting daily production output. Usually 1 piece per day; limiting daily production output.
Size Usually less than 4′ in length; depends on depth or cubic value. Can be larger pieces up to 20′ and can be structural. Sizes can approximate both cast stone & precast.
Cost Usually the most cost effective. More expensive due to finishing to create close visual to cast stone and daily production limitation. Most expensive to produce; higher cost offset by less installation costs.

PRODUCT CHARACTERISTICS

PRODUCT REINFORCED ANCHORAGE FINISH APPLICATION
Cast Stone (Dry) Yes Rebar Can have dowel holes; anchor slots, embedded hardware Fine grain texture simulates Limestone Architectural Trim, Facing, Ornamentation, columns
Architectural Precast Yes Various methods Cast in weld plates, Threaded inserts, Slots & Dowel holes Exposed Aggregate, Form liners, Sandblasted , Visual bug holes unless finished to look close to cast stone. Architectural panels, columns, Spandrels, Structural
GFRC Yes Glass Fiber Anchor bolts and steel frame attached to product at plant. Fine grain texture or precast finish Architectural, trim, facing, columns, spandrels; where lighter weight is helpful.
Limestone
Grade II		 No Cut in dowel holes and slots Fine grain texture Architectural trim, Facing, Ornamentation; long lead time
Calcium Silicate No Cut in dowel holes and slots Smooth, Rocked, Press Hammered, Dressed Architectural veneer, facing, and standard sizes only.

PHYSICAL STANDARDS

PRODUCT ASTM PSI (MINIMUM) AIR CONTENT RANGE ABSORBTION (MAXIMUM) FREEZE-THAW (DURABILITY)
Cast Stone (Dry) ASTM C 1364 6,500 N/A 6% 5% Loss of mass or less @ 300 cycles
Cast Stone (Wet) 6,500 4% – 6% 6% 5% Loss of mass or less @ 300 cycles
Architectural Precast CSI 3450 5,000 4% – 6% 6% Not required
GFRC CSI 3490 1,200 (flexgard module of rupture) 8% – 10% Similar to Cast Stone / Precast Similar to Cast Stone / Precast
Limestone Grade II ASTM C 568 4,000 N/A 7.50% Not available
Calcium Silicate ASTM C 73-99A Grade: NW 3,500 SW 5,500 N/A NW 18% SW 15% Not available

AAS team is able to combine different product materials as well to meet the design, structural and installation needs. AAS has experience with creating seamless design effects and uniform design appeal while combining different product materials on a same project.

 

Product Info/Reference Links

 

  1. AAS Product Materials
  2. Cast Stone
  3. Architectural Precast
  4. Architectural GFRC (Glass Fiber Reinforced Concrete)
  5. GFRG (Glass Fiber Reinforced Gypsum)

 

VIDEO: COLOR LAB, QUALITY CONTROL FOR ARCHITECTURAL STONE PRODUCTS

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How do you create high-end design and aesthetics using architectural stone?

The key to this is ability to manufacture the stone products using variety of product materials such as cast stone, architectural GFRC, architectural precast as well as GFRG. These products can create looks of natural lime stone or any other desired color as well as finish. With technology and manufacturing abilities, these products can be consistently accurate and reliable in aesthetics as well structural properties.

Custom mold making that create stone panels of any complex shape with stringent tolerance requirements makes it possible to realize virtually any exterior or interior architectural design vision.

 

How can you be sure of quality and consistency of architectural stone products?

  1. AAS has computerized batch plant that is able to monitor consistency and quality of raw materials throughout the project life cycle.
  2. AAS has a sophisticated internal color lab. AAS team uses computerized density system for regular color sampling, material consistency, strength and moisture absorption testing.
  3. AAS has experienced quality control supervisors. They are trained to spot defects.

 

Watch this video to see AAS lab and quality control in action.

 

 

> PROJECTS GALLERY: MATCH ANY CUSTOM COLOR WITH A CONTROL SAMPLE

 

> HOW DO YOU GET THE COLOR YOU NEED FOR YOUR PROJECT?

 

 

VIDEO: DEDICATED PROJECT FOCUS TEAMS FOR SMOOTH EXECUTION

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AAS sales team members are experienced project coordinators.

AAS has been able to complex a wide range of complex projects, and deliver consistently good quality of products because it is able to dedicate and align team members and manufacturing resources for customer projects.

AAS project team is able to answer questions, track and manage project design as well as follow through on molding, manufacturing schedule, products sequencing and delivery. With technology support, and dedicated bandwidth, customer project leads are able to track and monitor progress of every project.

Learn more in this video.

 

Project Stories: Dedicated Support for Execution – From Design to Installation

 

Click on any of the three images below to learn more about that project.

 

Cook Children's Hospital
Cooks Children's Hospital | Monolithic Structure using Cast Stone and Architectural Precast | Seamless Addition of the Building to Existing Hospital Complex

Cooks Children’s Hospital | Monolithic Structure using Cast Stone and Architectural Precast | Seamless Addition of the Building to Existing Hospital Complex

SMU Caruth Hall: Cladding, Veneer
SMU 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

SMU 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

Old Park Land: Reagan Place
Reagan Place, Old Park Land | Cladding using Architectural Cast Stone, Precast Concrete, GFRC Products

Reagan Place, Old Park Land | Cladding using Architectural Cast Stone, Precast Concrete, GFRC Products