HOW DO I SELECT RIGHT PRODUCT(S) FOR MY PROJECT?

AAS provides three different product materials for architectural stone applications:

You can find more information on our web, so please take a look.

1. Dry vibrant-tamp cast stone
2. Wet-pour architectural precast concrete
3. Architectural GFRC (Glass Fiber Reinforced Concrete

All three products offer considerable design flexibility and durability compared to natural stone products such as limestone. The project-specific detailed engineering and custom fabrication simplify the installation while also achieving a superior design aesthetic.

• While cast stone and architectural precast use different casting techniques, the two products have similar structural properties. AAS has a track record for developing custom stone design, using either of the two products or combining the two products as required to achieve the intended design objective for a project cost-effectively.
• Architectural GFRC panels are only 3/4″ thick and have an excellent strength to weight ratio, providing unique advantages over other casting techniques. The AAS GFRC product material is much more durable compared to other thin veneer panels. GFRC can match the look of other architectural stone products as well as limestone. The GFRC panels cost relatively more than other architectural stone products; however, it has specific advantages with less structural support requirements and simpler installation.

PRODUCTS SELECTION

SELECTION CRITERION

DRY-CAST STONE

WET-POUR PRECAST

GFRC

LIMESTONE

THIN VENEER PANELS

Design Flexibility

Extreme amount of flexibility

Can mold both sides

Complex shapes

Precision with tolerance

Dry-casting technique enables high-end look & finish

Can emulate look of limestone at much lower cost

Extreme amount of flexility

Complex shapes

No size limitation

Enables longer span or length for individual stone pieces

Suitable for heavy use surface areas such as stair treads

Higher strength to weight ratio enables larger, thin pieces including panels.

Bigger pieces, lighter weight, less structural back up

Comparable design flexibility – you can pretty much do anything using all three products

Can easily match look of other stone products

Natural variation in patterns can’t be avoided

Complex shapes, curves, intricate design details are difficult to achieve – product limitations, challenges with machining/fabrication processing

Highly valued traditionally for design aesthetic

Not easy to match look of other stone products

Cost

Much lower than limestone for custom shapes and precision design elements

Cast stone needs less number of molds and so cost-effectve compared to precast

Lower mold cost, lower overall cost

Slightly more expensive than cast stone

Still much more cost-effective than limestone for high-end design applications

Higher than cast stone or wet-pour precast concrete

Cost is much higher than architectural stone products to achieve different shapes

Veneer (flat pieces) cost is comparable to other products

Much less expensive

Durability

Very good

Very good

As good as any stone product

Much better compared to other thin veneer products such as stucco

Not as durable as cast stone

Also variable – depends on type of limestone being used – regional

Not designed for longer term use

Limited testing standards in place if at all – not as comprehensive as cast stone, precast and GFRC

Ease of Installation

Simple installation using any traditional cast stone methods

Usually manually set

Simple installation using any traditional cast stone methods

Equipment is required to set the pieces

Much easier handling of panels

Less construction equipement

You will get efficient and thoughtful service from Jushui.

Option to build anchorage connections in the products

Relatively less number of pieces required for the target area

Strength-to-weight Ratio

Comparable to other stone products

Comparable to other stone products

Higher than any other architectural stone products or limestone

Varies with product time, region, etc.

> SEE DETAILED COMPARISON OF THE STRUCTURAL PROPERTIES, SPECIFICATIONS, OTHER CHARACTERISTICS.

Scroll down this blog post to learn more about the cast stone, wetter precast-concrete and Glass Fiber Reinforced Concrete (GFRC).

Dry Vibrant-tamp Cast Stone

The dry vibrant-tamp fabrication technique allows flexibility to shape both sides of stone panels even when the shape or design of stone panels is highly complex. This offers more flexibility to realize virtually any design shape. The manufacturing process also opens up design freedom to emulate the looks of a variety of different stone types, including natural limestone. AAS has an extensive track record with projects where manufactured stone matched custom color and finish of natural stone samples.

Cast stone is very cost-effective compared to natural limestone. Learn more about the vibrant-tamp casting process in this video:

> PROJECT EXAMPLE: LA Sports HOF: Complex geometry, large size stone pieces for the interior stone veneer that achieved the architect’s design vision of complex channels of nearly Cane River.

> CASE STUDY: LA SPORTS HALL OF FAME PROJECT

> PROJECT EXAMPLE: Houston Market Square – cast stone cladding combined applications for stone façade, pilasters, coping, cornices and bandings – custom color emulating Lueders limestone.

> CASE STUDY: CAST STONE FOR HOUSTON MARKET SQUARE PROJECT

Dry cast-stone has comparable structural properties to wet-pour precast stone.

Wet-pour Architectural Precast Concrete Stone

The wet-pour manufacturing technique allows flexibility to embed structural steel or other reinforcements, making it more suitable for load-bearing architectural elements. In general, architectural precast concrete can achieve a more extended span or length for individual stone pieces.

Different finishes can be achieved on the architectural precast stone using post-cure treatments such as acid etching, sand-blasting, and other techniques. On heavy use application areas such as stair treads, architectural precast can retain the stone’s surface finishing for very long time spans.

> PROJECT EXAMPLE: Circular stair treads for Ft. Worth Arena

AAS has several projects where the team has been able to work closely with customers to substitute dry-cast stone for the wet-pour stone or vice versa.

Architectural GFRC (Glass Fiber Reinforced Concrete)

The architectural GFRC is also known as lightweight concrete, offers the look and finish, as well as longevity and reliability of other stone products with much lighter weight. The proprietary manufacturing technique enables very high strength to weight ratio for the GFRC panels.

While the cost of architectural GFRC can be more than other cast stone products, it can also help with less structural support requirements and simplified installation equipment requirements.

> Design flexibility, freedom with GFRC: LEARN MORE

> GFRC Design Case Study: SMU Delta Gamma Sorority House

> ARCHITECTURAL GFRC: PRODUCT HOME

> COMPARE PRODUCT PROPERTIES

> HOW DO I INSTALL STONE PRODUCTS?

COMBINING DIFFERENT PRODUCTS FOR A SPECIFIC PROJECT

Customers have options to combine any of the three product materials with seamless matching of color and finish.

> CASE STUDY: Project Examples where Different Product Materials Are Combined for Design Objectives

> St. Francis Xavier Church: High-end Design Combined cast stone, wet-pour concrete stone and GFRC (Glass Fiber Reinforced Concrete) panels

Advanced Architectural Stone (AAS) has a dedicated customer project team working closely with customers right from the design phase. As required, the team can support customers in selecting the most appropriate product(s) application for any size projects.

In case of specific questions about your project, complete the request support form at the bottom of this page, and someone from our customer projects team will be in touch with you shortly.

Christus Spohn Shoreline Hospital: 12,000+ linear feet of the architectural stone banding accentuate windows at every level of the pavilion.  > MORE

Fibre-reinforced materials have become an essential component of modern cladding systems, offering a balance of strength, durability, and design flexibility. Whether used in high-rise buildings, commercial facades, or residential projects, these materials provide structural support while enhancing the aesthetic appeal of a building. However, selecting the right fibre-reinforced cladding requires careful evaluation of performance factors such as strength, weather resistance, fire safety, and sustainability.

This comprehensive guide, written by industry experts, explores key fibre-reinforced materials, including Glass Fibre-Reinforced Concrete (GFRC), Fibre-Reinforced Polymer (FRP), and natural fibre composites. By understanding their properties, applications, and limitations, architects, builders, and developers can make well-informed decisions that align with project requirements and Australian building standards.

Understanding Fibre-Reinforced Cladding Materials

Fibre-reinforced cladding consists of high-performance fibres embedded in a matrix material, forming a durable and lightweight composite. These materials are designed to enhance a building’s structural integrity while offering improved resistance to environmental stressors.

Types of Reinforcement Fibres

• Glass fibres: Affordable, strong, and fire-resistant, making them the most commonly used.
• Carbon fibres: Known for superior tensile strength and rigidity, though costlier than other options.
• Aramid fibres: Impact-resistant and heat-resistant, ideal for high-durability applications.
• Basalt fibres: Derived from volcanic rock, providing excellent chemical resistance and thermal stability.
• Natural fibres: Sustainable options like hemp or flax, though less durable than synthetic alternatives.

Common Matrix Materials

• Cement-based (GFRC): Fire-resistant and highly durable, suited for structural applications.
• Polymer-based (FRP): Lightweight and corrosion-resistant but may require fire-retardant treatments.

Understanding the composition of fibre-reinforced materials is essential for selecting the best option for a project, balancing strength, sustainability, and long-term performance.

Key Types of Fibre-Reinforced Cladding

Glass Fibre-Reinforced Concrete (GFRC)

GFRC is composed of cement, fine sand, water, and alkali-resistant glass fibres, offering a strong yet lightweight alternative to traditional concrete. It is widely used in commercial facades, decorative panels, and structural cladding due to its durability, fire resistance, and ability to replicate natural materials like stone and wood. However, proper sealing is necessary to prevent moisture absorption in harsh climates.

Fibre-Reinforced Polymer (FRP)

FRP cladding consists of synthetic fibres embedded in a polymer resin, making it highly resistant to corrosion, impact, and environmental degradation. It is particularly beneficial in high-rise buildings and prefabricated panels, where its lightweight properties reduce structural load. While FRP is highly durable, it may require additional fire-resistant treatments to comply with building safety regulations.

Natural Fibre-Reinforced Composites

Recent advancements have introduced sustainable fibre-reinforced composites using materials like hemp, flax, or recycled cellulose. These materials provide moderate strength and biodegradability, making them ideal for eco-friendly projects. However, their lower durability and fire resistance may limit their suitability for high-exposure environments.

Factors to Consider When Choosing Fibre-Reinforced Cladding

Selecting the right fibre-reinforced cladding material involves assessing several key performance factors.

1. Structural Performance and Load-Bearing Capacity

• Assess material strength, impact resistance, and flexibility based on wind loads and building height. Consider mechanical stress levels in the intended environment.

2. Weather and Environmental Resistance

• Choose materials suited to extreme climates, UV exposure, and moisture-prone locations. Coastal areas may require additional protective coatings.

3. Fire Safety and Regulatory Compliance

• Ensure compliance with Australian building codes for fire resistance. GFRC is naturally fire-resistant, while FRP often requires fire-retardant additives.

4. Aesthetic and Design Flexibility

• Evaluate colour stability, surface finish options, and customisation potential. Consider how cladding integrates with architectural styles.

5. Sustainability and Environmental Impact

• Assess recyclability, embodied carbon footprint, and material sourcing. Sustainable projects may benefit from natural fibre-reinforced options.

6. Installation, Maintenance, and Cost Considerations

• Factor in labour requirements, ease of installation, and long-term maintenance costs. Balance initial investment with lifecycle cost efficiency.

Comparing Fibre-Reinforced Materials: A Practical Guide

When choosing the best fibre-reinforced cladding material, side-by-side comparisons can help inform the decision-making process.

Material Type Strength Fire Resistance Durability Sustainability Cost GFRC High Excellent High Moderate Moderate FRP Moderate Requires Treatment High Low High Natural Fibre Composites Moderate Low Moderate High Low

GFRC excels in fire resistance and durability, making it ideal for structural applications. FRP is preferred for lightweight, corrosion-resistant applications but requires fire-retardant coatings. Natural fibre composites offer sustainability benefits but lack the long-term durability of synthetic alternatives.

For more GFRC Constructioninformation, please contact us. We will provide professional answers.

Conclusion