Innovative Reclamation at Westrock Residences

Expertise

Civil Engineering & Design| Engineering| Land Surveying

Location

Hartland, WI

Client

Three Lead Partners
Walbec_Horizontal-color-01

About the Project

The former Palmer Sand & Gravel quarry sat largely dormant for decades after mining operations ceased in the 1970s. Numerous redevelopment attempts stalled due to the site’s challenging topography, unstable perimeter slopes, and complex infrastructure constraints. Walbec provided the integrated surveying, engineering, planning, and construction support needed to transform the 45-acre former industrial site into a vibrant multi-family residential community while preserving the site’s natural features and maximizing long-term value.

Walbec's integrated engineering and construction expertise addressed a range of complex challenges, including:

  • Stabilizing steep quarry slopes while preserving development density.
  • Designing stormwater infrastructure for an internally drained site with no natural outlet.
  • Repurposing and balancing on-site materials to minimize imports and reduce construction costs.
  • Managing legacy concrete debris and historic environmental constraints.
  • Accommodating significant elevation changes while maintaining walkability, utility performance, and emergency access.
  • Preserving adjacent natural areas through strategic grading and retaining wall design.

The project showcased Walbec's full range of integrated capabilities, including:

  • Topographic surveying using sUAS LiDAR
  • Site planning and civil engineering
  • Municipal zoning approvals and permitting
  • Site reclamation and permanent slope stabilization
  • Concrete crushing and recycling
  • Mass earthwork and site balancing
  • Sanitary, water, and stormwater utility design
  • Large retaining wall design
  • Construction surveying and staking
  • Construction administration
  • Post-construction stormwater inspections

Project Results

By combining engineering innovation with construction expertise, Walbec transformed a site that had remained undeveloped for decades into a successful residential community. The integrated approach reduced construction costs through material reuse and optimized grading, streamlined project delivery under a single partner, and delivered a safe, sustainable development that met the owner’s vision while addressing complex site constraints.

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