Products — Aquacast International

Product information

Designed for the problem, not the catalogue.

Each formation is designed for a specific purpose depending on the nature of the problem, letting our engineers select the most suitable cast from the available range — and advise where required.

The units are precast for flexible, demountable application using the latest piling technology, allowing precise location and efficient use of time and materials. They assemble quickly in almost any weather, with minimal ground preparation and manpower — a cost-effective option at any scale.

Diagram of Aquacast cast formations: V cast, double V cast, square cast variants, W cast, octagon cast and Stanley cast variants — The cast range — formations selected by application

Product animations

See the system assemble.

Two short animations show how the W-block and V-block methods build up course by course — reinforcing a riverbank, and forming a sea defence along the coast.

W-Block — riverbank & retaining-wall assembly

V-Block — sea-defence assembly

The process

The factory travels to the project.

Aquacast production is mobile. A complete casting plant ships to site, comes off the trailer, and begins producing finished interlocking blocks where they're needed — removing the haulage, the lead times and the carbon of shipping precast units across continents.

Industrial process — mobile plant, on-site casting & installation

Built work

What it looks like once it's standing.

A completed ReadyAquawall retaining wall in service, and archive footage of the blocks being placed by machine — two men, a lifting frame, and no wet concrete on site.

Completed wall — interlocking courses with capping units

W-Block assembly — blocks placed by lifting frame

Concrete products

Materials, finishes & handling.

Recycled material

The prime material is concrete, reinforced by one or two U-shape steel bars embedded around the slot locations. To reduce landfill, Aquacast is developing uses for waste materials — power-station ash, crushed aggregates, glass and recycled rubber — applied according to the requirement.

Finishes

Various finishes, including stone and brick, harmonise with environmental needs. The designed slots also form cavities that can be filled, or left to encourage vegetation growth when filled with soil.

Ease of use

The most popular block — 400 × 400 × 100 mm — suits retaining walls, river and canal reinforcement, landslides, sea defences and traffic partitions. At 35 kg it sits within the two-man handling limit, needing no machinery. Whatever the size, cast-in lifting sockets ease machine handling in waterlogged land, canals and rivers — even on builds starting below water level.

Stone-textured Aquacast W-blocks assembled into a low wall outdoors — Stone-finish W-blocks — one of several available textures

Easy to assemble and self-locating; work from one side where necessary
Simple engineering design, suitable for heavy and light loading
Environmentally sound — produced with a range of finishes and textures
Strong, rigid interlocking assembly resistant to earth pressure and turnover forces, for a long life span
Extra casts can be added to an existing structure at any time
Precast away from the worksite — unaffected by weather, prepared in advance
Precise production — a very fine finish where the design requires it
Replaces site formwork; the self-locating slot locks together in waterlogged ground or extreme weather, with no curing wait
Compact dimensions make transport to site straightforward

Block 400 × 400 × 100 mm Weight 35 kg Reinforcement U-shape steel bar

Design data

Wall design at a glance.

Indicative block counts, wall and base dimensions, reinforcement and factor of safety for finished wall heights from 500 to 3000 mm — straight from the Aquacast design brochure.

Aquacast wall design table: blocks per metre run, wall width, base width and depth, top and bottom steel, surcharge and factor of safety for wall heights from 500 to 3000 mm — Wall design table — sizing & reinforcement by finished wall height (500–3000 mm)

Water management & reservoirs

Fast, demountable water-retaining structures.

The W and V block fast-erection application builds demountable reservoirs in a relatively short period. Water can be diverted from a high-pressure point — rivers, canals, high-tide areas — and stored temporarily to prevent flooding.

Other programmes include agricultural uses such as fish farming, leisure pools and garden ponds. The blocks dismantle and store for re-use elsewhere, or on an annual basis as required.

Stacked interlocking Aquacast concrete blocks — Interlocking casts — assembled and demountable

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A revolutionary system of interlocking concrete units.