To shield the Bergen Light Rail from rockfall, Boulderscape rappelled up to 204 feet down a New Jersey cliff — hand-sculpting 234,000 square feet of architectural shotcrete in a Fractured Basalt finish, delivered in 84 days at 22% below traditional construction.
Record Installation Time
Savings Over Alternatives
Wall Square Footage
This project stabilized the cliffs above New Jersey's Bergen Light Rail to protect the railway from falling rock and slope instability. Rock bolts provided the required structural stabilization, but the installation left large exposed areas across the cliff face that required architectural restoration. Boulderscape developed a solution that restored the natural appearance of the rock while preserving the long term performance of the stabilization system.
Working from ropes at heights exceeding 204 feet, Boulderscape artisans hand sculpted approximately 234,000 square feet of Fractured Basalt finish across the cliff face. The finish was carefully crafted to replicate the surrounding geology, restoring the appearance of the natural rock formations and minimizing the visual impact of the rockfall mitigation system.
The project encompassed 234,000 square feet of wall surface consisting of an 8" thick structural shotcrete section with an average 5" thick architectural relief over a rock bolt stabilization system using a 5,500 PSI mix design. The entire scope was completed in 84 days, delivering a durable rockfall protection system that blended naturally into the surrounding cliff face. 22% under traditional cast-in-place construction. See our sculpted shotcrete process or explore more shotcrete finishes.
Installed an 8” thick structural shotcrete and a 1”-6” thick architectural shotcrete.
Fractured Basalt
Midtown Gray Blend
Rock Bolt Wall
5,500 PSI
8%-10% air was needed to help reduce chances of cracking in winter. Hydration stabilizers were used to maintain concrete temperature and extend the finishing time.
