In Pocono, Pennsylvania, Boulderscape sealed and structurally rebuilt a failing tunnel envelope — placing 470 cubic yards of high-performance, silica-fume structural shotcrete across 21,000 square feet, finished as Class A Sponge Float and delivered in 18 days at 46% below traditional construction.
Record Installation Time
Savings Over Alternatives
Wall Square Footage
A deteriorating tunnel lining in Pocono, Pennsylvania had begun to leak and required demolition and reconstruction. Boulderscape installed a new high performance tunnel lining system consisting of drainage board, structural reinforcement, and silica fume enhanced structural shotcrete placed over a rock bolt support system. The new lining was designed to provide both long term water management and structural support for the tunnel.
The project encompassed 21,000 square feet of tunnel surface and included the installation of all drainage board, reinforcement, and shotcrete. The completed lining received a Class A Sponge Float finish, providing a clean and uniform architectural appearance.
The project consisted of a 4" thick to 9" thick structural shotcrete section over a rock bolt support system using a 5,000 PSI mix design. The entire scope was completed in just 18 days, delivering a durable tunnel rehabilitation solution while minimizing disruption to tunnel operations. See our sculpted shotcrete process or explore more shotcrete finishes.
Installation 470 cubic yards of a high performance silica fume enhanced structural shotcrete to seal and structurally support an existing tunnel envelope in Pocono, PA.
Class A Sponge Float
Gray
4-9"
Rock Bolt
5,000 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. Silica fume and other additives were used to seal and strengthen the shotcrete
