For Hawaii DOT, Boulderscape value-engineered a 25,000-square-foot wall into native lava rock — sculpting structural and architectural shotcrete into a Kona Volcanic Formation finish, delivered in 12 days at 41% below traditional construction.
Record Installation Time
Savings Over Alternatives
Wall Square Footage
The Hawaii Department of Transportation required a soil nail wall that would stabilize the hillside while preserving the natural volcanic character of the surrounding landscape. Boulderscape value engineered the architectural wall system to provide a more economical solution without compromising the appearance required for this highly visible highway corridor.
Boulderscape developed and installed its Kona Volcanic Formation finish across the entire wall surface, hand sculpting natural lava rock textures, fractures, and relief inspired by the surrounding volcanic terrain. A custom volcanic ash stain was applied to replicate the color variation and weathered appearance of native lava rock, allowing the retaining wall to blend naturally into the Hawaiian landscape.
The project encompassed 24,538 square feet of wall surface consisting of an 8" thick structural shotcrete section with an average 3" thick architectural relief over a soil nail wall system using a 4,500 PSI mix design. The entire scope was completed in just 12 days, delivering a durable slope stabilization solution that preserved the natural character of the corridor. 41% 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”- 4” thick architectural shotcrete.
Kona Volcanic Formation
Volcanic Ash Blend
Soil Nail Wall
4,500 PSI
8%-10% air was needed to help reduce chances of cracking in winter.
