Background

The A50 is a critical strategic route through Stoke on Trent, carrying high traffic volumes between junctions at Blurton and Trentham Lakes. As part of highway improvement works, a new retaining wall was required alongside the existing carriageway.

Given the importance of the route, minimising disruption to road users was a key priority. This placed strict constraints on construction methodology, programme and access, with works needing to be carried out primarily overnight.

The challenge

The scheme required a retaining wall solution that could:

  • Be installed adjacent to a live highway
  • Be constructed largely during short overnight closures
  • Deliver structural performance within a restricted working window
  • Progress rapidly to reduce overall programme duration
  • Maintain safety for operatives and road users

A total wall length of 270 metres, with retained heights up to 2.15 metres, needed to be delivered under these demanding conditions.

The solution

Marshalls supplied the Redi Rock™ modular retaining wall system, enabling rapid installation using large gravity blocks.

The wall configuration comprised:

  • A base course primarily constructed using Redi Rock 150 series gravity blocks
  • Subsequent courses built using 104 series and 71 series gravity blocks

To significantly reduce disruption:

  • Construction was carried out predominantly in 5 hour night shifts
  • The entire 270 metre bottom course was completed in just 5 night shifts (25 hours)
  • Once the base was established, installation accelerated, with up to 120 blocks (approximately 64 m²) installed per 5 hour shift

The modular nature of Redi Rock™ allowed consistent productivity even within the limited overnight working window.

The outcome

The retaining wall was delivered safely, efficiently and with minimal impact on traffic flow along this key highway corridor.

  • 270 m long, 2.15 m high retaining wall successfully installed
  • Majority of works completed during night shifts
  • Significantly reduced disruption to road users
  • High productivity rates achieved under constrained conditions
  • Robust, long term earth retention solution installed alongside live traffic

Carnell Group commented:

“These outputs couldn’t have been bettered.”

The project demonstrates how bespoke construction planning combined with modular retaining systems can enable major highway works to be delivered efficiently on heavily trafficked routes.