On the Louisville–Ohio River Bridges project, Boulderscape’s sculpted walls beat every alternative on cost — placing 126,000 square feet of structural and architectural shotcrete in Kentucky Fractured Granite and Drystack Stone finishes, delivered at 45% below traditional construction.
Record Installation Time
Savings Over Alternatives
Wall Square Footage
The extension of Route 841 from Louisville, Kentucky toward Ohio required retaining walls through environmentally sensitive terrain where conventional construction methods proved costly and difficult to construct. After an extensive evaluation of multiple retaining wall systems over the course of a year, the project team selected soil nail walls with Boulderscape's architectural shotcrete finishes as the most economical and efficient solution.
Boulderscape furnished and installed all structural reinforcement and shotcrete throughout the corridor, including approximately 256,000 square feet of reinforcement and more than 128,000 square feet of structural and architectural shotcrete. The project featured both Kentucky Fractured Granite and Dry Stack Stone finishes, hand sculpted to complement the surrounding landscape while providing long term structural performance.
The project encompassed 128,320 square feet of wall surface consisting of a 72" thick structural shotcrete section with an average 3" thick architectural relief over a combination rock bolt, soil nail, and formed wall systems using a 5,000 PSI mix design. The entire scope was completed in just 64 days, delivering a durable retaining wall solution for one of Kentucky's largest transportation projects. 45% under traditional cast in place construction. See our sculpted shotcrete process or explore more shotcrete finishes.
Supply and installed all structural reinforcement and structural/architectural shotcrete layers. Structural shotcrete layer 8”-72” thick. Architectural shotcrete 1”-5” thick. Stained with a multi-colored stain.
Kentucky Fractured Granite & Kentucky Drystack Stone.
Multi-Color Stain System
72"
Rock Bolt, Soil Nail, Formed Wall
5,000 PSI
Steel fiber was added when shooting the inner tunnel lining. 6%-8% air was needed to help reduce chanced of cracking in winter.
