Location:Centerville, VA, USA
An architectural shotcrete finish identified as the M48 Centerville Ashlar finish was provided by Boulderscape for permanent soil nail wall systems along the I-66 corridor in Centerville, Virginia. The finish was applied to approximately 78,863 square feet of engineered soil nail wall shoring constructed to support roadway slopes and associated infrastructure improvements.The soil nail wall system consisted of a structurally designed soil nail system with a sculpted shotcrete facing that served both structural and architectural functions. The exposed shotcrete surface was hand sculpted in the plastic state to achieve an ashlar-style stone appearance, providing a refined, masonry-inspired aesthetic without the use of form liners, molds, or applied veneers.The M48 Centerville Ashlar finish was selected in lieu of traditional form liner finishes to achieve comparable visual quality while allowing for accelerated installation schedules and significant cost savings. The sculpted approach enabled continuous placement and artistic shaping, reducing labor requirements, material costs, and schedule impacts associated with liner fabrication, handling, and alignment.Final surface coloration was achieved using topically compatible, cementitious or mineral-based post-applied stains. The approved color palette consisted of medium Grey Shale tones, coordinated to visually integrate with adjacent retaining and sound wall structures along the I-66 corridor. Color application was intentionally variegated and non-uniform to avoid repetitive patterning and to enhance the natural stone appearance.All sculpting and staining work was performed by craftsmen experienced in architectural shotcrete finishes. Mockups were provided as required to establish texture, scale, color range, and overall visual intent, and approved mockups served as the standard for workmanship and appearance. .The completed finish demonstrated the successful integration of engineered soil stabilization and architectural surface treatment, providing a durable, UV-stable, and low-maintenance retaining solution appropriate for high-profile transportation infrastructure projects where visual consistency and contextual compatibility were critical design criteria.Boulderscape Finish: M48 Centerville Ashlar Color Scheme: Grey Shale Shotcrete Thickness: 1” - 3” Average Relief: 2 1/2” Retaining Wall System: Soil Nail Wall Shotcrete Mix: 5,000psi 1. 30% - 40% cheaper than form-liner finishes. 2. Faster to install that form-liner or stone veneer. 3. No repetition in the sculpted face. 4. Use of fly-ash in shotcrete contributes to LEED points. 5. All finishes are created by hand-tools. 6. All finishes can be easily customized to fit any project.