HS2 Gabion Retaining Wall Solution at Crackley to Beechwood

High Speed 2 (HS2) is one of the UK’s most significant and complex infrastructure projects, developed to deliver a high-speed rail network connecting London with the West Midlands. The scheme is designed to increase capacity, reduce congestion on the West Coast Main Line, and enhance connectivity between major cities. With approximately 140 miles of new railway infrastructure, HS2 demands robust, durable and high-performance engineering solutions capable of operating under intensive and challenging conditions.

Within the Crackley to Beechwood section, located near Kenilworth and Burton Green, a critical retaining wall was required to support a cut slope and facilitate the construction of the Burton Green Tunnel South Portal Building. Paul Mulcair, acting as the installation contractor, engaged Maccaferri following the specification issued by Balfour Beatty Vinci (BBV), which called for double twisted hexagonal mesh gabions with a PVC coating over galvanised wire.

Given the proximity to the HS2 alignment, the structure would be subject to increased dynamic loading, frequent vibration and long-term environmental exposure. As a result, a more advanced and resilient solution was required to ensure long-term performance and reliability. The retaining wall extended approximately 164 metres in length, with varying heights ranging from 1.5 metres to 4.0 metres, placing significant demands on structural integrity and durability.

Maccaferri supplied a high-performance engineered solution using Polimac polymer-coated double twist gabion baskets. This system was specifically selected for its superior corrosion resistance, enhanced durability and extended design life when compared to traditional PVC-coated alternatives, making it ideally suited to demanding rail infrastructure applications.

In total, 646 Polimac-coated gabion baskets were delivered to site, together with the necessary tools to support efficient assembly and installation. The advanced polymer coating provides increased resistance to aggressive environmental conditions, ensuring long-term asset performance in line with HS2 requirements.

Installation was undertaken by Paul Mulcair, who delivered the works with a high level of precision, care and efficiency. Their proactive approach enabled the retaining wall to be completed ahead of programme, ensuring readiness for subsequent construction activities associated with the Burton Green Tunnel South Portal.

This project highlights Maccaferri’s capability in delivering durable, high-performance gabion retaining wall solutions for major UK rail infrastructure schemes, combining engineering expertise with long-term reliability.