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…