Highway 23 Emergency Wall Failure Stabilization
GeoStabilization delivered emergency slope stabilization and retaining wall repair along Highway 23 in Haywood County, North Carolina after heavy rainfall caused the failure of a dry-stacked retaining wall and the loss of roadway shoulder width along Church Street. The failure created a safety risk for motorists and required a rapid stabilization solution to restore roadway integrity and prevent further slope movement.
The project stabilized approximately 186 feet of roadway corridor, reinforcing the failed slope and restoring lost roadway support in this highly visible transportation route.
Reconstructing the Failed Roadway Slope
Following debris removal by transportation agency crews, GeoStabilization re-excavated the failed slope to a 0.25:1 (H:V) grade, reaching depths of up to 16 feet. Excavation was completed in controlled 4–5-foot lifts to maintain slope stability and allow safe access to the failure plane during construction.
This staged excavation approach allowed crews to safely rebuild the slope while preparing the site for installation of permanent structural reinforcement.
Soil Nail Reinforcement and Structural Shotcrete Wall
To stabilize the reconstructed slope, GeoStabilization installed 165 total soil nails, including:
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109 self-drilling soil nails up to 20 feet long
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56 soil nails up to 30 feet long
These structural anchors reinforced the upper embankment fill and tied the slope back into stable ground behind the wall system.
Following soil nail installation, crews applied 2,520 square feet of 8-inch reinforced shotcrete, forming a structural facing that protects the slope from erosion while distributing loads across the soil nail reinforcement system.
Restoring Lost Roadway Width
The wall failure had reduced the roadway shoulder width along Church Street, requiring reconstruction to restore safe travel conditions. GeoStabilization installed a 25-foot shotcrete shoulder buildout, which was backfilled with flowable fill to provide structural support and allow for future guardrail installation.
This reconstruction ensured the roadway corridor regained its full width and long-term structural stability.
Decorative Shotcrete Finish for Corridor Aesthetics
Because of the corridor’s visibility within the surrounding community, the project also included optional aesthetic enhancements. Crews installed stained and sculpted shotcrete with a 6-inch decorative finish, creating a natural rock appearance that blended with the surrounding landscape while maintaining structural performance.
Long-Term Stabilization for Highway Infrastructure
Completed between September and December 2021, the stabilization project restored long-term slope stability, improved roadway safety, and delivered a durable repair solution for this important transportation corridor.
By combining soil nail reinforcement, structural shotcrete, and roadway reconstruction, GeoStabilization provided a resilient slope stabilization system capable of protecting the roadway from future failure.
Slope Stabilization Techniques Used
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Soil Nail Wall Construction
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Reinforced Shotcrete Retaining Wall
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Emergency Roadway Slope Stabilization
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Dry-Stack Retaining Wall Failure Repair
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Flowable Fill Shoulder Reconstruction
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Decorative Shotcrete Rock Sculpting
