Architectural Cast Stone

Pool House Addition
POOL HOUSE ADDITION (PRIVATE RESIDENCE IN WICHITA, KS)
WICHITA, KS

I. What is the scope of the project? This is a pool house addition for a private residence in Wichita, KS. Cast stone is used throughout the project in a variety of applications, including a stepped wainscot, pilasters, jambs, pilaster capitals, cornices, lunettes, surrounds, parapet coping, and caps. The pilaster capitals had to match existing capitals on the existing residence, which proved to be a complicated process.
II. What special molding or casting techniques were necessary to illustrate the Architect’s concept on the project? Reproducing the original pilaster capitals required several processes that we had not used before. The architect used software that pieced together dozens of photographs of the capitals to create digital 3D models of the capitals. From there, we trimmed the unnecessary information from the digital models to isolate the capitals. Then, we used software to modify the digital models so that they could be 3D printed at full scale. Finally, rubber casts were made from the 3D prints and were used to create the molds. The resulting wet-cast capitals faithfully replicate the originals.
III. Degree of difficulty. This was moderately difficult. The process involved in recreating the original capitals was a first, not only for us, but for the architect and the builder as well. There was a steep learning curve for these processes, and it took several attempts to get the digital models to a point where they could be successfully 3D printed and used to create the molds.
IV. Were there project requirements that presented particular challenges, and how were they met? The pilaster capitals had to match the existing capitals on the house, but the homeowner would not allow any of the existing capitals to be removed so that a mold could be cast from them, and would not allow a cast to be made on site from the existing capitals, to eliminate the possibility of damage to the existing capitals. We were able to get around this challenge by working with the architect and builder, using technologies that are relatively new. SPT Architecture, Born Masonry, LLC

I. What is the scope of the project? This is a new private residence in Andover, KS. Cast stone is used throughout the project in a variety of applications, including a stepped wainscot, sills, transition band, pilaster and pier caps, coping, planter bowls, and a large fireplace. II. What is the role of Cast Stone? The smooth cast stone contrasts with the rough natural stone used on the house. The light color of the stepped wainscot, sills, and band, create bold horizontal lines, which fits with the Prairie Style architecture of the house. III. How was Cast Stone critical to the success of the project? The wainscot, and the simple, clean lines created by the sills and bands, are common elements in the Prairie Style of Frank Lloyd Wright. They are used to similar effect in this house, creating an aesthetic that is instantly recognizable. Wright’s influence extends to the house’s interior, where the fireplace is accented with geometric designs cast into large blocks that are reminiscent of his work in the Mayan Revival style.
Shelden Architecture, Hutton, ML Nevius Builder Photos courtesy of Essential Images Photography

Pool House Addition
POOL HOUSE ADDITION (PRIVATE RESIDENCE IN WICHITA, KS)
WICHITA, KS

I. What is the scope of the project? This is a pool house addition for a private residence in Wichita, KS. Cast stone is used throughout the project in a variety of applications, including a stepped wainscot, pilasters, jambs, pilaster capitals, cornices, lunettes, surrounds, parapet coping, and caps. The pilaster capitals had to match existing capitals on the existing residence, which proved to be a complicated process.
II. What special molding or casting techniques were necessary to illustrate the Architect’s concept on the project? Reproducing the original pilaster capitals required several processes that we had not used before. The architect used software that pieced together dozens of photographs of the capitals to create digital 3D models of the capitals. From there, we trimmed the unnecessary information from the digital models to isolate the capitals. Then, we used software to modify the digital models so that they could be 3D printed at full scale. Finally, rubber casts were made from the 3D prints and were used to create the molds. The resulting wet-cast capitals faithfully replicate the originals.
III. Degree of difficulty. This was moderately difficult. The process involved in recreating the original capitals was a first, not only for us, but for the architect and the builder as well. There was a steep learning curve for these processes, and it took several attempts to get the digital models to a point where they could be successfully 3D printed and used to create the molds.
IV. Were there project requirements that presented particular challenges, and how were they met? The pilaster capitals had to match the existing capitals on the house, but the homeowner would not allow any of the existing capitals to be removed so that a mold could be cast from them, and would not allow a cast to be made on site from the existing capitals, to eliminate the possibility of damage to the existing capitals. We were able to get around this challenge by working with the architect and builder, using technologies that are relatively new.