An active landslide threatening the critical infrastructure of the Buffalo Trace Distillery in Frankfort, Kentucky, triggered a high-stakes, 21-day emergency design-build project, ENR reported.
The movement of the slope occurred while crews were working to protect the historic bourbon producer, which sits along the banks of the Kentucky River. The stabilization effort faced immediate complications from a historic flood that introduced rockfall, debris, and unstable ground conditions to the site.
GeoSpecialties, the project owner, mobilized a response team within 10 hours of the initial threat. The crew worked continuously for three weeks, adjusting construction methods in real time to manage the shifting terrain and difficult access points.
To secure the distillery’s property, the engineering team utilized a combination of deep stabilization and surface armoring. The technical solution integrated 200-foot micropiles and soil nails with reinforced shotcrete to anchor the moving earth.
A large-scale A-wall system was a major part of the defense. This near-vertical structure allowed the distillery to preserve approximately 30 feet of usable property that might otherwise have been lost to the riverbank erosion.
The construction process focused on minimizing environmental impact and long-term maintenance needs. By reinforcing the slope in its existing position, the team reduced the necessity for large-scale excavation, hauling, and subsequent environmental disturbance.
Long-term performance was a primary concern given the distillery’s proximity to the Kentucky River. Engineers implemented several features to manage the physical pressures exerted by water and soil:
- The use of No. 57 stone and cellular grout to stabilize the foundation.
- One-way drainage systems designed specifically to reduce hydrostatic pressure.
- The installation of prefabricated panels and accelerated shotcrete to increase installation efficiency.
- Rock armoring to protect the shoreline from future flood debris.
The project was a collaborative effort involving several specialized firms. Anderson Professional Services, a GeoSpecialties company, served as the lead design and structural/civil engineering firm, while Thermal Tech Engineering acted as the general contractor.
The successful completion of the stabilization project ensures the continued operation of the distillery’s manufacturing facilities despite the volatile conditions of the riverbank. The project has since earned an Award of Merit for Safety, Manufacturing, and Best Project within its category.
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