Along the Queen K Highway in Hawaii, Boulderscape matched the island’s lava-rock masonry on an HDOT wall — sculpting 4,100 square feet of structural and architectural shotcrete into a Pahoehoe Dry Stack Masonry finish, delivered in 3 days at 36% below traditional construction.
Record Installation Time
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The Hawaii Department of Transportation required a soil nail wall along the Queen K Highway that reflected the appearance of traditional Hawaiian lava rock masonry. Because the wall was located within a highly visible corridor, the architectural finish needed to replicate the texture, color, and character of native dry stack stone construction. Boulderscape developed a series of full scale mockups for evaluation, and HDOT selected the Pahoehoe Dry Stack Masonry finish.
Boulderscape hand sculpted the Pahoehoe Dry Stack Masonry finish across the entire wall surface, carefully replicating the appearance of traditional lava rock masonry found throughout the Hawaiian Islands. The finished wall blended naturally into the surrounding landscape while preserving the architectural character desired for the corridor.
The project encompassed 4,100 square feet of wall surface consisting of an 8" thick structural shotcrete section with an average 2" thick architectural relief over a soil nail wall system using a 5,000 PSI mix design. The entire scope was completed in just 3 days, delivering a durable slope stabilization solution that complemented the surrounding environment. 36% under traditional cast in place construction. See our sculpted shotcrete process or explore more shotcrete finishes.
Install an 8” thick structural shotcrete and a 1”-2” thick architectural shotcrete.
Pahoehoe Dry Stack masonry
Mission Brown
Soil Nail Wall
5,000 PSI
Warmer climate. No additional additives were added to the concrete mix. A rheology modifier was used to bind the coral aggregate in the mix.
