The architectural GFRC (Glass Fiber Reinforced Concrete) presents a unique opportunity for architects and contractors.
The panels are only 3/4″ thick and yet are strong. This minimizes the structural support requirements. The panels can achieve the look and finish of other stone products. With the AAS technology and fabrication technique, the panels can be large in size when required with intricate shapes.
For renovating the Marriott Hotel in downtown Ft. Worth, the designers wanted to use GFRC panels to conform to existing building profile conditions. The AAS team worked closely with the architect and contractor to achieve panels with more than 20 ft. of length and highly complex angles. The connections to hang the panels were built-in during the engineering and manufacturing process, simplifying the installation.
Images below show an example CAD drawing, a large panel with pre-engineered connections ready for shipment, and installation progress on the site.
CAD Drawing for One Panel
Coordination between a column cap and a cornice – Detailed engineering confirmed design feasibility and simplified installation process
Example: Custom-fabricated Large GFRC Panel
GFRC panel being Cast with Steel Frame Attachments
GFRC panel with Pre-engineered Connections Loaded for Shipping | More than 20 ft long architectural GFRC
Installation Site: Marriott Hotel, Ft. Worth, TX
Detailed Engineering for Seamless Coordination of Columns and Cornices
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
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
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
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.
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.
Cast stone, GFRC | Monolithic Stone Facade, Veneer Design, Stone Capping | Custom Molds, Customer Project Management Simplified Installation
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
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.
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.
