This document presents information on precast modular block retaining walls called Stone Strong walls. It discusses the concept, components, design theory, and construction details of the Stone Strong system. It also provides examples of innovative applications of Stone Strong walls, including integrated structures, bridge abutments, pipe penetrations, and hybrid applications. The document is intended to showcase the versatility and engineered design of Stone Strong precast modular retaining walls.

1. The Innovative Precast
Retaining Wall Solution
PRESENTED BY:
Adam T Baker, LHV Precast
NYS County Highway Superintendents

2. Precast Modular Block
Retaining Walls
• The Stone Strong Story
• Concept
• Components
• Design Theory
• Construction Details
• Innovative Solutions

3. The Stone Strong Story
The largest retaining wall block in the industry!
3’
8’ 44”
Patent No. 6,796,098

4. The Concept of
Stone Strong Firebaugh Precast
Dillon, CO
Retail Development
Size/Mass
- Gravity Retaining Walls
- ROW/Utility Issues
- Inherent Stability
- Visual Scale MBO Precast
Middlesboro, MA
Oak Point Retirement Community
Innovative Stone
Lincoln, NE
Capital Beach Erosion Control

5. The Concept of
Stone Strong Innovative Stone
Lincoln, NE
Williamsburg Village Shoreline Protection
Versatility
- Flexible Geometry
- Adaptable
- Speed of Installation /
Productivity LHV Precast
Rensselaer County, NY
Caretakers Rd., Walloomsac River
Innovative Stone
Omaha, NE
Harrison Street Reconstruction

6. The Concept of
Stone Strong
8Size/Mass
8Versatility
Engineered System
- Lifting Loops
- Recesses
- Voids
- Drainage

7. The Concept of
Stone Strong
Precast

8. Systems
Components
24 SF Block
96” x 36” x 44” Weight: 6,000 lbs
Innovative Stone
Nebraska City, NE
MBO Precast
Milford, MA
Patent No. 6,796,098

9. Systems
Components
24 SF Top Block
96” x 36” x 44” Weight: 5,400 lbs
Egyptian Concrete
Carbondale, IL
Aspen Court
Innovative Stone
Lincoln, NE
Pioneer Business Park

10. Systems
Components Innovative Stone
Lincoln, NE
6 SF Block
48” x 18” x 44” Weight: 1,500 lbs

11. Systems
Components
Accessories
Dual Face Block End/Corner Block
Corner Blocks
Patent No. 7,073,304
Built-In versatility

12. Systems
Components
Mass Extender Block
96” x 36” x 56” Weight: 10,000 lbs

13. Systems
Components
24SF-62 Block
96” x 36” x 62” Weight: 6,600 lbs

14. Systems
Components
24SF-86 Block
96” x 36” x 86” Weight: 7,400 lbs

15. Behind Stone Strong
Engineering Manual
Sound Engineering
www.stonestrong.com

16. Engineering Manual
www.stonestrong.com

17. HITEC Evaluation
Third-party review
Rigorous review
by committee of
national experts

18. HITEC Evaluation
What DOT can take from the report:
- Evidence of conformance w/ AASHTO methodologies
- Rigorous technical review
- Viable alternative to traditional retaining systems

19. Design Theory
AASHTO Bridge Manual
FHWA-NHI-00-043, MSE
Walls and Reinforced
Soil Slopes
Barbour Concrete Co.
Trinity Woods
Independence, Missouri
ECI Concrete
Mishawaka, Indiana

20. Gravity Walls
Design Methodology
COULOMB
ACTIVE EARTH PRESSURE COEFFICIENT
cos2
Ka 2
2 sin sin
cos cos 1
cos cos β

21. Gravity Walls - IBC

22. Gravity Walls - AASHTO

23. Gravity Walls
Load Resistance Factor Design (LRFD)
Innovative Stone
Missouri River Bridge
Yankton, South Dakota

24. Gravity Walls - LRFD

25. Gravity Walls - Vertical

26. Gravity Wall Analysis

27. Gravity Wall Analysis

28. Trial Wedge Method
Well established methodology
to resolve complex loading
conditions & geometry
Not commonly used due to
computational effort
More accurate assessment of
actual load applied outside of
Coulomb contributory area
Variation of Coulomb
technique
Still consistent with AASHTO
and other standards

29. Geogrid Reinforced Walls
Interaction Reports

30. Construction Details
Detail Library
- Web site www.stonestrong.com
- CAD detail files available

31. Construction Details
Corners / Radius
- 24 SF
MBO Precast
Massachusetts
Innovative Stone
Lincoln, NE

32. Construction Details
Corners / Radius
- 6 SF

33. Construction Details
Top End / Steps
Innovative Stone
Lincoln, Nebraska
Office Park

34. Construction Details
Base / Embedment

35. Construction Details
Backfill Compaction
- Proper compaction (and moisture control) is critical part
of retaining wall construction.

36. Construction Details
Typical Compaction
Requirements
- No reduced compaction
requirement behind face
- Less sensitive to
displacement
- Able to support
compaction equipment Innovative Stone
Lincoln, Nebraska

37. Innovative
Solutions
Integrated Structures
Innovative Stone
Omaha, Nebraska
Harrison Street

38. Innovative
Solutions
Bridge Abutments
LHV Precast
New York
County Bridge Abutment

39. Application of Design & Assembly Of Components

40. Orange Co Bull Mill Bridge

41. Orange Co Bull Mill Bridge

42. Orange Co Bull Run Bridge

43. Orange Co Bull Mill Bridge

44. Orange Co Bull Run Bridge

45. Innovative
Solutions
Pipe Penetrations
MBO Precast
Massachusetts
Deerfield Crossing

46. Innovative
Solutions
Hybrid Applications
Innovative Stone
Omaha, NE
Shadow Lake Box Culvert

47. Engineered Solution

48. Orange Co Rte 105 – Hurricane Irene

49. Orange Co Rte 105

50. Hamilton Co

51. Dry Brook Rd Bridge Ulster Co

52. Cascade Brook – Hurricane Irene

53. Cascade Brook Ulster Co