Advanced Architectural Stone (AAS) opens up new design possibilities for architects, designers, contractors and masons. Manufacturing technology and design craftsmanship makes it possible to have consistent product quality for projects of any size. AAS has very well developed customer projects management support that simplifies onsite installation, construction.
Learn more in this webinar presentation from AAS CEO Eddie Lesok: VIDEO >>
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.
PROJECT: TRT Holdings Headquarters | Case Stone, Architectural Precast | 2014 APA Award of Excellence
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:Â Brasfield & Gorrie
Products: Architectural Cast Stone, Architectural GFRC, Precast Concrete
Applications: Architectural Stone Cladding, Veneer Design, Custom Columns
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 | 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
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
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
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.
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.
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.
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…
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…
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 >>
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.
Jeffersonian Design using Custom Design Manufactured Stone | Old Parkland, Dallas, TX | Specially Designed Columns, Egg-n-Dart Rope Design, Large Dentils, Profile | Project Specific Custom Molds, Product Batch Mixing, Manufacturing, Sequencing, Delivery, Installation Support
The technology and design expertise to develop custom molds enable flexibility to fabricate stone panels with an unparalleled range of complex shapes and design details.
VIDEO: Custom mold making for complex shapes, intricate design details, custom sizes:
Custom molds made it possible to create large size custom stone panels with stringent tolerance requirements. Detailed engineering of anchoring connections played a crucial role in achieving a monolithic stone look for the facade veneer of the building.
Project: SMU Commons Building Facade | Architectural Stone Cladding, Veneer | Cast Stone, Precast Concrete, GFRC
Project: SMU Commons | Architectural Stone Cladding, Veneer Design | Custom Mold Making | Design and Technology
Architectural Stone Cladding | Cast Stone, Precast, GFRC
Columns with intricate design details at the top of the tower developed a signature highlight for the shopping center 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
The design combined cast stone and GFRC (Glass Fiber Reinforced Concrete) product materials.
On The Westbrook Building, the cast stone was used in the overall design of the building to be reminiscent of the Art Deco structures located in many areas in Ft. Worth.
AAS Project: The Westbrook – Sundance Square West – Ft Worth, TX | Art Deco Design using Cast Stone | Custom Mold Design | Architect: Bennett Benner Pettit, Inc
Architectural Stone made the molds for the Art Deco designs from isometric sketches provided by the architect. In other words, the descriptions provided three sides, all in dimensional proportion, but none were shown as an actual shape with 90-degree corners.
The sketch was only a guide to making actual size molds. Â Artisan designers created molds for the Art Deco panels combining their design craftsmanship with extensive CAD drafting and also precision cutting using CNC machines.
The Westbrook Building at Sundance Square, Ft Worth, TX | Art Deco Design, Custom Design Elements using Cast Stone, GFRC | Architect: Bennett Benner Pettit, Inc
The architect for this project had a vision for unique design elements on the exterior of the building. AAS team designed a highly intricate mold to create it in cast stone. The precise tolerance and detailed coordination with the construction team helped create the desired look with a smooth installation that completed on time.
Advanced Architectural Stone – AAS – Formerly Advanced Cast Stone | Rockwall County Courthouse | Cast Stone, Precast | Technology Allowed Complex Shapes and Desired Aesthetic Design | Brinkley Sargent Architects | DMG Masonry
This project consisted of 6 panels installed in the entry to the remodeled and enlarged football stadium at Texas Christian University. The panels were made using architectural precast and cast stone. The purpose of the panels and the project was to honor the founders of the University dating to 1895.
The architect for the project, HKS Architects, hired an artist to approve and render the murals. The AAS team transferred the original artwork to a rubber mold for casting. The panels represent the cultural icon at the heart and soul of Texas Christian University. It was critical that the panels could be seen within a few feet of the viewer. AAS team used its experience and technology to refine every detail within the mold so that panels accurately depict the original aesthetic appeal so critical to the project’s success.
The project won the 2014 APA (Architectural Precast Association) Craftsmanship Award.
Following is a composite image showing example panels.
AAS 2014 APA Award | TCU Relief Panels | Finish and Precision for Design Appeal | HKS Architects | General Contractor: Austin Commercial
AAS 2014 APA Award | TCU Relief Panels | Forming using Precise Molds, Design Experience | HKS Architects | General Contractor: Austin Commercial
Trahan Architects had a vision for emulating Cane river channels inside the Louisiana Sports Hall of Fame Museum. This required cast stone panels with complex shapes. The stone pieces were also huge. The project execution also demanded stringent tolerance requirements in the mold so that the stone would fit in seamlessly for a consistent look.
Advanced Architectural Stone (AAS – Formerly ACS) Team Supports Contractors, Builders, Masons – construction of LA Sports Hall of Fame Museum
LA Sports Hall of Fame | Large Size Precision Molds for Design That Had Highly Stringent Tolerance Requirements
LA Sports Hall of Fame | Cast Stone Realized Cane River Channels | Trahan Architects | CASE STUDY >>
LA State Museum Sports Hall of Fame | Trahan Architects | Cast Stone Veneer Developed using Complex Shaped, Large Cast Stone Pieces Fitting within Stringent Tolerance Requirements | LEARN MORE About Design, Manufacturing Process…
PROJECT CASE STUDY: LA SPORTS HALL OF FAME >>
The requirement was that the AAS stone would match the pre-existing terracotta stone.
714 Main St | Cast Stone for Building Exterior | Quality Experience, Desired Colors and Finish | Cost Effective Solution
The design had the Roman Heads depiction on the outside, which were authenticated and designed by artists. AAS team worked closely with the architect and artist to design and create the representations in cast stone that matched the original rendering of the artist precisely.
AAS Custom Mold Making | Roman Head Design in Cast Stone for 714 Main Street Building, Dallas, TX | Cast Stone Cladding
AAS Project: 714 Main Street | Unique Technology, Craftsmanship to Replicate design of Roman Heads | Product used Architectural Cast Stone
AAS team helped create exterior fronts of the building that used cast stone and architectural precast extensively. The design used grape leaves build from the cast stone panels. The integration of the grape leaf design connects with the historical name of the city, and the local culture.
The AAS project team used custom molds to create highly intricate grape leaf design elements that are an accurate representation of the original design renderings.
AAS Cast Stone | Custom Mold Making | Grapevine Leaf Designed using Dry Cast System
Specialized Rubber Molds for Grape Leaf Design | Cast Stone Design for Grapevine Convention and Visitors Bureau
Grapevine Convention Center | High-End Leaf Design – Exterior Cladding | Cast Stone | APA Award of Excellence | ArchiTexas | J & E Masonry
AAS Cast Stone Project | Specific Color Contrast Requirements from the Architect of the Project ArchiTexas | Grapevine Convention & Visitors Bureau
> LEARN MORE: Creative Art Design Process for the Grapevine Leaf Design Elements
> See more on Grapevine Convention Center and Visitors Bureau Project.
Gilbert Christian High School is located in the city of Gilbert in the Scottsdale (AZ) area. The school exterior used extensive Architectural GFRC elements that were easy to integrate with the exterior thin brick veneer of the building. The column capitals have Corinthian style.
AAS Architectural GFRC Case Study | Gilbert Christian Case Study
AAS Architectural GFRC Case Study | Gilbert Christian High School | Custom Molds and Finish | Simplified Installation with Higher Elevations, Brick Veneer
See more about the Gilbert Christian High School project in the case study.
This is a new development added to the school campus.
The entryway of the building has a very high elevation breezeway. The cast stone and architectural precast panels required custom molds that enabled panels of such a big size that would fit together to create a seamless effect in the breezeway.
TCU Worth Hills Cast Study | Large Size Custom Shape Cast Stone Panels for Architectural Design
AAS (Formerly ACS) | Project: Texas Christian University (TCU) Worth Hills Campus, Entry Gate | Cast Stone, Architectural Precast
Large Size Custom Stone Panels Fit in for Monolithic Stone Look | Fabricated Stone Veneer, Cladding Design
The AAS team tapped into its extensive experience with the design of elaborate balustrade systems as well for this project. The dimensions and shape of balusters had specific requirements; custom molds were developed for this as well.
SMU Simmons Hall Construction | Precise engineering, Custom Manufacturing of Architectural Cast Stone for the Portico Columns
Accuracy in Design Details – Complex Curved Cast Stone Pieces Fit Together Seamlessly Without Carving or Retrofitting
Installation of Portico Columns | Cast Stone Pieces Planned in Sequence of Releases and Clear Labeling Simplified Onsite Construction
Portico Column from Inside | Columns inset in Radial Wall Installed Easily with Precise Custom Shaped Pieces and Careful Planning
Technology creates opportunities for automation and consistency. Advanced Architectural Stone (AAS) puts it to use for consistent product quality and consistency.
The completely automated and computerized batch plant eliminates the error and guess work while making sure raw materials quality and consistency is same through out a project. A number of gauging points, measurements feeding into the monitoring system enables consistent colors, finish, product strength for projects of any size.
Learn more about the AAS computerized batch plant in this video.
The 27,500 sq ft building embodies Trahan Architect’s vision of cane river channels. The project required large cast stone pieces each unique in its shape and complexity.
AAS team has extensive experience in coming up with materials composition to match colors while combining different products such as cast stone, architectural precast, architectural GFRC as well as GFRG.
AAS is integral part of development of the Reagan Place, now known as Old Parkland. The team combined architectural precast, cast stone and GFRC in this project with seamless color matching. The new construction blended naturally in to the overall ambiance, culture and heritage of the site. The batch plant made it all look so uniform and consistently beautiful for this project.
AAS Project: Reagan Place, Old Parkland | AAS Computerized Batch Plant and Craftsmanship Delivered Consistency | See the CASE STUDY…
Note: See AAS video tour of the plant…
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