Mack Industries partnered with Marvel Engineering and Sitescapes to deliver a customized retaining wall solution for The Montage, a residential development in Raleigh, NC. The challenge involved designing and installing a large retaining wall system where traditional geogrid reinforcement was not feasible due to lot placement and site conditions.
The wall needed to reach nearly 20 feet at its tallest point, accommodate multiple penetrations, and navigate numerous inside and outside corner bends. By leveraging the flexibility of the Recon Retaining Wall Block System, Mack Industries provided a cost-effective, durable, and visually appealing solution that met the project’s complex requirements.
Key Design Challenges
Geogrid Restrictions: With subdivision lots located too close to stormwater ponds, a geogrid-reinforced wall system could not be used.
Soil Conditions: Site soils required innovative design adjustments to achieve proper stability.
Wall Height: Sections of the wall needed to reach up to 19 feet, demanding careful engineering for safety and performance.
Complex Geometry: The design required multiple penetrations, along with inside and outside corner bends.
Engineering Solution
Mack Industries collaborated closely with the engineering and construction teams to customize the wall design.
Double-Stacked Blocks: The first five layers were double-stacked to achieve the necessary toe slope and stability.
Special Fit Blocks: To address penetrations and corner bends, Mack utilized its Special Fit blocks, ensuring a precise fit without compromising strength.
Simplified Installation: The solution required no geogrid reinforcement and no specialized equipment, making installation smoother and more cost-efficient.
Project Information
Contractor: Sitescapes
Engineering Partner: Marvel Engineering
Product: Recon Retaining Wall Block System
Wall Area: 6,636 sq. ft.
Tallest Section: 19 ft. high
Benefits Delivered
Ease of Installation: The block system allowed the contractor to complete the project efficiently without heavy specialty equipment.
Custom Engineering: Special Fit block options allowed the wall to adapt seamlessly to the project’s complex layout.
Durability & Low Maintenance: The precast system ensures long-term structural performance with minimal upkeep.
Aesthetics & Functionality: The retaining wall not only solved critical engineering challenges but also enhanced the subdivision’s overall appearance.
Why It Matters
The Montage project highlights Mack Industries’ ability to deliver engineered retaining wall systems tailored to challenging site conditions. By combining innovative block design, collaborative engineering, and hands-on field support, Mack Industries provided a long-lasting, low-maintenance retaining wall solution that met both structural demands and client expectations.
