Category Archives: Manufacturing

GFRC Cladding Case Study: Design Flexibility with Simplified Installation: VIDEO >>

GFRC (Glass Fiber Reinforced Concrete) products are hollow from inside with thickness of 3/4th of an inch. While they are much lighter in weight, unique fiber materials and manufacturing technology gives products strength. This higher strength to weight ratio makes GFRC ideally suited for a number of architectural applications.

GFRC products have pre-engineered, built in connections that simply the installation. Products are much easier to handle on the construction site. GFRC is able to achieve the exact same look and feel as architectural precast enabling possibilities to combine the products as well.

See in this video more about GFRC connections that simplify installation while achieving required design objectives for cladding of Delta Gamma Sorority House at the Southern Methodist University (SMU).

GFRC products are much more durable compared to Stucco or EIFS.

GFRC Fulted Columns, Corinthian Capitals – SMU Delta Gamma Sorority House

Cladding Design using Custom Architectural GFRC Panels | Fluted Columns, Corinthian Capitals, Coping, Exterior Window Surround Trims

Ask us about GFRC for your project requirements.

Phone: 480.968.5400
Email: sales@mesaprecast.com

Distressed Finish with Architectural Precast Concrete

The wet cast architectural precast opens up options to create different finishes.

See in this video, precast concrete column with distressed finish. The wet casting process used with architectural precast concrete and GFRC (Glass Fiber Reinforced Concrete – also known as light weight concrete) allows for variety of finishes on the product.

The column here is in natural grey color. Mesa Precast has 18 standard colors to choose from for column colors. As required, the technology and manufacturing process allows for matching custom colors as well.

Manufacturing Fluted GFRC Columns: Video Clips

See in this post manufacturing steps to manufacture GFRC (Glass Fiber Reinforced Concrete) Fluted columns.

Mesa Precast used custom mold making technology to create modular fiber glass molds …

The GFRC casting process is carried out in three steps –

Applying the face mix for smooth finish,
Spraying and packing the spray mix with fibers over three iterations, and
Thickening the edges.

See these three steps in video clips below…

Applying face mix …

Spray mix applied over three iterations …

Thickening the edges …

Mesa Precast manufactured these fluted GFRC columns for the Advanced Architectural Stone (AAS) project – new sorority house at the Southern Methodist University (SMU) in Dallas, TX.

Balusters and Balustrade Systems

Mesa Precast has a number of different design options for balusters and balustrade systems.

With 18 different color options, a designer has options in selection of the right color, and then customize finish as required. Mesa Precast has in house inventory of molds; this gives company flexibility in manufacturing and delivering the required balustrade system components quickly.

See in this video, a couple of different types of balusters.

Mesa Precast has a product that can serve as baluster wall on fence or any other application to create separate areas in a space. See the mold and example finished product in this video…

See Mesa Precast balusters and balustrade System component products in online catalog…

Video Clips: See Manufacturing Steps for Architectural GFRC Cornices

Watch video clips to see manufacturing steps for an Architectural GFRC product (also known as light weight concrete).

This video series explain custom design, engineering and manufacturing of GFRC cornices used for the new Girls Sorority building at the Southern Methodist University (SMU).

Step One: Creating Custom Molds

The GFRC cornices used for exterior of the building are large with unique shapes.

Mesa Precast team designed and manufactured custom molds while collaborating closely with project team at Advanced Architectural Stone (AAS) that was in charge of the customer requirements and design.

Step Two: Preparation and Application of the Facing Mix

Facing mix is without fibers. This allows for smooth surface of the cornice which was then acid etched for the required finish.

See application of the facing mix…

Careful brushing eliminates bubbles and makes it consistent …

Step Three: Spraying Back up Mix

Mesa Precast team developed specific composition of the spray mix that had the right admixture with fibers. These fibers lend strength to GFRC panels even though they are only 3/4th of an inch thick.

See back up mix being sprayed in this video …

See back up mix being rolled and compacted in this video …

Step Four: Attaching Steel Frame to the Cornice

Mesa Precast team pre-engineered installation frame that is attached to the GFRC cornice panels during the manufacturing. With this precise embedding of the frame right in to the GFRC material of the Cornice, installation of the cornice at the site became much simpler.

Last step in manufacturing is to thicken the edges, to make the product stronger and structurally more sound.

GFRC cornice ready for finishing and shipping…

GFRC Columns – Art of Engineering

Architectural GFRC (Glass Fiber Reinforced Concrete) creates light weight, structurally sound, durable and yet highly creative architectural solutions.

See in this video, the process of making a GFRC column. With specialized admixture sprayed and packed with the mold, GFRC column is hollow with ¾” thickness. The glass fibers in the spray mix still gives columns required strength.

Following video shows a GFRC column base being manufactured. The design of GFRC columns is modular creating flexibility to combine different column sizes with column base as well as column capitals.

With custom molds and unique manufacturing technology, Mesa Precast can design and manufacture custom columns of desired size and aesthetic appeal. Choose from the standard 18 colors of Mesa product lines, or talk to use to get the custom color and finish of your choice.

Following video shows GFRC columns at our facility ready to ship out…

Project Story: Gilbert Christian High School

See high design GFRC columns in this project. The columns, Corinthian capitals, window surrounds, wainscots, high elevation building arches, balustrade system in the front …etc all is designed in GFRC for this project.
The project used custom color and finish, and also unique molds that enabled architect’s vision for the shapes and design appeal.

Architectural GFRC columns, corithian capitals, window, entry way surrounds, balustrade systems - Mesa Precast Architectural Stone Products

Architectural GFRC columns, Corinthian capitals, window, entry way surrounds, balustrade systems – Mesa Precast Architectural Stone Products

Mesa Precast – GFRC Products for High End Architectural Design at Gilbert Christian High School

Mesa Precast Architectural GFRC – Support for Construction, onsite Installation

Architectural GFRC Columns, Corithian Capitals, window surrounds, eaves moldings, custom exterior facade panels at higher elevation