2025
Ainley industrial estate, Elland, West Yorkshire
A-Safe
Tobias James
Geoman
Ainley Industrial estate
Early stage of MacWall 4.0 installation
MacWall 4.0 taking shape
ParaGrid Geogrid reinforcement
Close up of geogrid reinforcement
MacWall 4.0
MacWall 4.0 curved corner
Challenge
As part of its continued growth, A-Safe Ltd required an extension to its manufacturing facility in Elland, West Yorkshire. A critical component of this expansion was the construction of a new car park to accommodate increased staff and operational capacity. However, the proposed location for the car park presented a significant geotechnical challenge: the site was situated on a natural slope adjacent to an already fully developed industrial estate.
The steep gradient of the terrain meant that a conventional cut-and-fill approach or the use of a natural or steepened slope would not provide the necessary horizontal footprint to support the new car park platform. Additionally, spatial constraints and proximity to existing infrastructure limited the feasibility of extensive earthworks or large-scale excavation. A robust and space-efficient retaining solution was required to create a stable, level platform while maintaining structural integrity and minimising environmental impact.
Solution
To address the site’s topographical constraints, Maccaferri proposed the use of its MacWall 4.0 segmental retaining wall system. This modular solution was selected for its proven performance, aesthetic flexibility, and ease of integration with existing structures. A 6-metre-high retaining wall was constructed along the length of the extended car park, effectively creating the required plateau while maximising usable space.
The new wall was designed to seamlessly tie into a previously constructed MacWall system from an earlier phase of development. Thanks to the modular nature of MacWall 4.0, this integration was executed efficiently, minimising construction time and ensuring continuity in both structural and visual aspects.
Given the tight site conditions and limited storage capacity, Maccaferri coordinated closely with the contractor, installer (Williams Walling), and supply chain partners to implement a just-in-time delivery schedule. This logistical strategy reduced on-site congestion, avoided delays, and ensured smooth progress throughout the construction phase.
In alignment with sustainability goals, the design incorporated site-won granular fill as part of the reinforced backfill. This approach significantly reduced the need for imported materials and eliminated the disposal of excavated soil, thereby lowering the carbon footprint of the project. It also minimised construction traffic on local roads, contributing to reduced environmental and community impact.
The geotechnical design was carried out by Geoman, ensuring compliance with relevant standards and optimal performance of the retaining structure under site-specific conditions.
Used Products
