Tag Archives: GFRC

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

TUSCAN COLUMNS

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Tuscan columns are the columns used most frequently in the United States because they are also the simplest.  They are not carved and do not have scrolls.  They are columns that have a capital that is square with a circle under the square.  Think of the circle as being round crown molding.  There may be a ring under the circle, all of which would be considered the column capital.

AAS has an extensive range of molds to manufacture columns with a much shorter turn around time. The team is able to customize the column design for any diameter, length, as well as size of the capital.

  • Vibrant-tamp cast stone columns provide options for design with unparalleled flexibility and design freedom to integrate columns into facades, cladding designs, porticos, or other ornamental design elements.
  • Wet-pour architectural precast concrete columns are ideally suited for load bearing applications.
  • GFRC column covers are 3/4″ inch think. They provide very competitive strength to weight ratio and are suitable for higher elevation applications, or cladding design elements where they aren’t bearing the load by themselves.

AAS provides design assist, construction assist for the columns confirming design feasibility, and also simplifying the installation process.

 

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

 

 

PROJECT: TRT Holdings Headquarters | Case Stone | 2014 APA Award of Excellence

PROJECT: TRT Holdings Headquarters | Case Stone, Architectural Precast | 2014 APA Award of Excellence

 

Unlimited Design Freedom with Manufactured Architectural Cast Stone, Precast Concrete, GFRC | Seamless Matching with Different Materials for Optimum Value Engineering

Unlimited Design Freedom with Manufactured Architectural Cast Stone, Precast Concrete, GFRC | Seamless Matching with Different Materials for Optimum Value Engineering

ARCHITECTURAL COLUMNS, COLUMN COVERS: LEARN MORE >>

IONIC COLUMNS, COLUMN COVERS/WRAPS

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The Ionic columns are usually defined by the scrolls at each corner of the capital.  These scrolls are fairly large in proportion to the column itself and the scrolls are also known architecturally as volutes.

  • The AAS team is able to fabricate ionic columns using any of three different product materials: vibrant-tamp cast stone, wet-pour architectural precast, or GFRC (Glass Fiber Reinforced Concrete).
  • For really large size column designs, AAS is able to create modular design with different pieces fitting together at the time of installation with seamless monolithic stone look.
  • Customers have options to seamlessly integrate the columns with other cladding elements such as stone veneer, entry way elevation designs, balusters, cornices, wall coping, door and window surrounds …etc.
  • AAS offers a range of options to fabricate column covers or column wraps to envelope structural elements while seamlessly matching color with other stone products.

Designers are able to achieve any custom color for the columns with a control Sample.

 

Ionic Columns using Architectural Cast Stone | Laura Lee Blanton Building

Ionic Columns using Architectural Cast Stone | Laura Lee Blanton Building

 

Building Cladding and use of Ionic Columns | Product Used: Architectural Cast Stone | Laura Lee Blanton Building

Building Cladding and use of Ionic Columns | Product Used: Architectural Cast Stone | Laura Lee Blanton Building

 

AAS 2016 APA, CSI Awards for AAS Project Old Parkland | Cast Stone, GFRC | Custom Molds, Architectural Stone Cladding

AAS 2016 APA, CSI Awards for AAS Project Old Parkland | Cast Stone, GFRC | Custom Molds, Architectural Stone Cladding

ARCHITECTURAL COLUMNS, COLUMN COVERS: LEARN MORE >>

GFRC ART PANELS ON FACADES OF DICKIES ARENA, FORT WORTH, TX

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GFRC Panel with Detailed Design, Design MockupGFRC Panel Precisely Matching with Design DetailsIntricate Horse Head Design Developed in GFRC as per the Design VisionCustom Molds, Fabrication Technique for Large Size GFRC PanelsCustom Molds, Fabrication Technique for Large Size GFRC PanelsMockup for GFRC Panels | Dickies Arena Case StudyCustom Design GFRC Panels on Right Side of this MockupCustom Design GFRC Panels on Right Side of this MockupMockup of GFRC Art Panels | Frame Design on Panels is Asymmetrical by DesignGFRC Panels Installed at Ft Worth Arena

This blog post shows design assist process, as well as custom fabrication of the large size GFRC panels for the Dickies Arena project. The Arena is sited on the Will Roger’s Memorial Center campus in Ft. Worth, TX.

 

Custom GFRC Panels Design, Fabrication

 

The architects for the project aim to develop Art Deco design elements on facades of the arena to match with the 1930s era experience on the campus. The building facade design uses large size GFRC panels with intricate design details in them.

  • The AAS team developed series of custom molds to match the large size and intricate design details required for the project.
  • The mockups are created to confirm the shapes, details in the fabricated stone panels and color matching.
  • AAS works closely with architects and contractors to review details and confirm design feasibility.

 

AAS has capabilities now to manufacture GFRC products in its Ft. Worth plant as well.

Art, Engineering, Design Craftsmanship, Technology for Custom Mold with Specific Design Pattern

Art, Engineering, Design Craftsmanship, Technology for Custom Mold with Specific Design Pattern

Refining Specific Details in the Mold using the Personalized Design Touch after CNC Machining

Refining Specific Details in the Mold using the Personalized Design Touch after CNC Machining

Custom Designed Mold to Match Specific GFRC Panel Size and Shape with Stringent Tolerance requirements

Custom Designed Mold to Match Specific GFRC Panel Size and Shape with Stringent Tolerance requirements

GFRC Art Panels for Art Deco Design Accent at Dickies Arena, Fort Worth

GFRC Art Panels for Art Deco Design Accent at Dickies Arena, Fort Worth

 

Image below shows exterior elevation on the west side with GFRC panels integrated with the brick veneer.

 

Fort Worth Arena Partial Elevation - West Side | GFRC Panels Integrated in Exterior Veneer of the Building Along with Brick Veneer

Fort Worth Arena Partial Elevation – West Side | GFRC Panels Integrated in Exterior Veneer of the Building Along with Brick Veneer

 

CLICK HERE TO SEE HIGHER RESOLUTION IMAGE (OPENS IN NEW TAB/WINDOW) >>

 

DOWNLOAD .PDF FILE FOR DESIGN DETAILS >>

GFRC CONNECTIONS: MUCH SIMPLER INSTALLATION, INTEGRATION WITH BRICK WALL

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GFRC (Glass Fiber Reinforced Concrete) is much simpler to install because of its light weight and pre-engineered connections for anchorage with substrate.

See in this video details of GFRC connections, and how different stone pieces are custom designed and anchored for installation.

The AAS design team provides settings plan that clearly shows how different stone panels install together for overall design aesthetic.

 

 

The seamless integration of manufactured architectural stone panels makes it much simpler to design exterior cladding, and veneer applications with monolithic design accent.

 

This project also show how cast stone and GFRC can be combined with seamless color matching  opening up opportunities for simplified construction, value engineering, and at the same time unparalleled design freedom.

 

 

ART AND SCIENCE OF STONE MANUFACTURING: DESIGN FREEDOM WITH CUSTOM PANELS

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Concrete and stone products have enabled architectural design of buildings for hundreds of years.

The manufacturing technology combined with opportunity to develop fully integrated solutions for construction projects enable wide range of new design possibilities using architectural stone panels. The project specific focus leads to not only more flexibility and options in design, but also much simpler construction at lower cost.

Learn more with this video how the AAS team is able to start with project specifications, work through the design process, and develop products that create un-paralleled design freedom.

 

Advantages of manufactured architectural stone panels:

  • Combine different product materials for optimum value while maintaining seamless design aesthetic
  • Get consistent product characteristics throughout the project of any size and design complexity
  • Simplify construction and mitigate risk with pre-engineered, built-in installation support
  • Create highly complex shapes for wall panels with stringent tolerance requirements
  • Customize color to any control sample

 

AAS PRODUCTS OVERVIEW >>                     PROJECTS GALLERY >>

 

 

SMU COMMONS: EXTERIOR VENEER, CLADDING, HARDSCAPE DESIGN USING STONE PANELS

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Advanced Architectural Stone (AAS) has extensive track record for manufacturing cast stone, architectural precast and GFRC for cladding, exterior veneer, and almost any other architectural design.

These pictures are of a number of buildings at the Southern Methodist University (SMU) campus. You are viewing a new dining hall and housing complex call the SMU Commons; the vision was to integrate these buildings with the overall identity of the campus. At the same time, the designers wanted to create a contemporary feel to the buildings to reflect the school’s cutting edge approach to education and its fun, nurturing, and exciting environment for students.

The AAS team proposed carrying out the design including the exterior cladding and stone veneers using two different products: cast stone and glass fiber reinforced concrete panels (GFRC).

 

Anita and Truman Arnolds Dining Commons, SMU | Unparalleled Design Freedom with Manufactured Stone | Cast Stone, GFRC Cladding, Veneer Design | TECHNOLOGY: CUSTOM MOLD MAKING >>

Unparalleled Design Freedom with Manufactured Stone | Cast Stone, GFRC Cladding, Veneer Design

 

Precision molds combining the use of the CNC technology and employee craftsmanship made it possible to create veneer wall panels that fit together seamlessly for look of monolithic stone. With computerized batch mixing as part of the integral manufacturing process, the stone panels, using both  cast stone and GFRC (Glass Fiber Reinforced Concrete), had the required structural properties, as well as matching color and finish.

The new buildings are huge success for the campus since they excite students, faculty and visitors.

 

Anita and Truman Arnolds Dining Commons, SMU | Cast stone, Architectural GFRC | Custom Molds, Customer Project Management Simplified Installation, Achieved Design with Precision

Cast stone, GFRC | Monolithic Stone Facade, Veneer Design, Stone Capping | Custom Molds, Customer Project Management Simplified Installation

 

PROJECT: SMU Commons | Architectural Stone Cladding

PROJECT: SMU Commons | Architectural Stone Cladding Developed Quality Experience

 

Stone Panels | Technology, Design Flexibility | GFRC, Cast Stone and Wet-percast Concrete Products Materials Combined for Uniform Aesthetic Accent

Stone Panels | Technology, Design Flexibility | GFRC, Cast Stone and Wet-percast Concrete Products Materials Combined for Uniform Aesthetic Accent

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

 

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

 

WALL COPING, PIER CAPS, HARDSCAPE >>