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The A38 dual carriageway bypass at Liskeard in Cornwall, constructed in 1976, features a deep rock cutting through Devonian slate. To stabilise the excavation, engineers installed a retaining wall system consisting of anchored concrete kingposts spaced at 3-metre intervals, with precast concrete panels spanning between them. The void behind the structure was backfilled with loosely compacted granular material. Designed by Freeman Fox & Partners, the system delivered long-term performance and structural stability for several decades. However, routine inspection and monitoring of the A38 retaining wall identified emerging structural concerns. While the ground-anchored concrete kingposts remained in good condition, several precast concrete panels began to show signs of localised deterioration and reduced strength. This raised safety concerns, particularly the risk of concrete spalling or falling debris onto the carriageway below, posing a hazard to motorists and requiring urgent remediation.

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Maccaferri were approached by leading civil engineering contractor Jones Brothers (Henllan) Ltd to provide an effective rockfall protection solution for a high-risk site. The steep rockface presented a significant hazard, with the potential for falling debris to impact nearby properties and endanger residents. A comprehensive assessment of the rockface condition and site topography highlighted the need for a reliable rockfall mitigation system capable of controlling loose material and preventing uncontrolled rockfall events. The solution required not only immediate risk reduction but also long-term durability, low maintenance, and compliance with recognised industry standards.

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The primary access route to Paul’s Hill Windfarm in Aberdeenshire runs through a narrow rock cutting carved into the rolling landscape. This critical infrastructure corridor is essential for both construction and ongoing operations, yet the steep rock faces on either side created a significant rockfall hazard. The instability of the cutting posed a continuous risk to vehicles and site personnel, with the potential for falling debris to obstruct access or cause serious safety incidents. Due to the combination of steep slopes, exposed rock, and geological variability, the location was identified as a high-risk area requiring a robust slope stabilisation and rockfall protection solution.

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