Coastal Seawall Success in Florida: Redi-Rock and Coast Armor Protect Ponce Inlet Condominium

THE CHALLENGE

Building a seawall is no easy task, especially in Florida, where unpredictable, extreme weather systems can easily add another layer of difficulty. But that didn’t stop Florida contractor Osborn Construction. When they joined the project team for the Antigua Condominium seawall project in Ponce Inlet, Florida, the stakes were high.

Coastal storms eroded the shoreline, threatening the condos’ pool area and surrounding infrastructure. The property required a long-term retaining wall solution, combining Coast Armor shoreline protection systems and Redi-Rock precast modular blocks to create reliable hurricane protection and withstand Florida’s most demanding conditions, from heavy rain to powerful storm surges.

Osbourne Construction faced several challenges, including:

• Building a dependable, storm-resistant sea wall below the scour line to combat future coastal erosion.
• Installing during the mandated construction season set in place to protect sea turtles.
• Creating a retaining wall hardy enough to perform optimally in a coastal area, withstand coastal storm surges, and tidal fluctuations.
• Navigating a strict design and construction permitting process to keep the project on track and in accordance with local and state regulations.
• Limiting soil disturbance and excavation, and deal with the surprise discovery of an existing seawall from the 1940s

THE SOLUTION

Florida’s coastlines are constantly under pressure, especially during hurricane season, when rising sea levels can cause several feet of beachfront sand to be lost in a single storm. Any solution for the Antigua Condominium seawall had to be tough enough to control future erosion.

At first, project designers considered steel sheet pile and vinyl walls. However, these options came with higher costs and wouldn’t deliver the long-term durability the project demanded. Instead, they found the ideal solution using Truemont Materials’ Coast Armor and Redi-Rock precast solutions.

The benefits of using Coast Armor and Redi-Rock together for coastal communities:

• Coordinated Aesthetics: Matching textures between the two systems creates a cohesive, finished look. And the natural stone aesthetics beat the drab appearance of sheet pile or vinyl every time.
• Engineered for Shorelines: Both Coast Armor and Redi-Rock are composed of precast concrete with non-corrosive components, which is ideal for marine environments. Wet cast concrete adds strength and durability in all weather conditions.
• Stable Foundation: Coast Armor panels are water-jetted into the ground using internal and external jets, creating a strong, lasting base. Coast Armor posts can be driven up to 24 ft (7.3 m) deep, depending on the site and post length
• Minimal Excavation: The gravity wall design for Antigua reduced the need for extensive digging, simplifying the installation process.
• Built-In Drainage: Integrated drainage behind the Coast Armor wall supports wall performance during storm events and tidal surges.
• Custom Fit: Working with Truemont Materials as the local precaster allowed tailored solutions for the Antigua team, including custom 45-degree corner Coast Armor panels. This eliminated the need for a 90-degree corner, which can become a scour hazard.
• Fast, Machine-Friendly Installation: Coast Armor panels are water-jetted into place, while massive Redi-Rock blocks are quickly set by machine, adding reliable mass and speeding up the build.
• Expedited Timelines: Once Antigua’s project designers decided to combine Redi-Rock and Coast Armor, the permitting process sped up, taking only a few months for approval.
• Cost Effective: Selecting Coast Armor and Redi-Rock instead of vinyl or sheet pile walls was more economical and protected the condo association's investment for the long run.

THE PROJECT

Once the wall design was approved and permits secured, Osborn Construction got to work fast. They hit the beach ready to install, and not even Florida’s unpredictable weather slowed them down. Rain or shine, the team installed Coast Armor and Redi-Rock systems to complete one incredibly strong concrete seawall, without any delays. The only surprise was the discovery of a buried seawall from the 1940s during excavation. But even that didn’t throw them off schedule - cutting through the old structure was straightforward, and work moved forward without issue. Osborn Construction especially appreciated the straightforward process of installing Coast Armor. Once each panel reached its target depth, all they had to do was switch off the water jets - no backfill required. Even with changing tides, there was no concern about washouts.

That built-in resilience is one of Coast Armor’s standout features and a key reason it was paired with Redi-Rock. While Redi-Rock brings unmatched mass and stability, Coast Armor offers below-grade scour protection in storm-prone environments that large block systems alone can’t match. Together, they formed a complementary solution tailored to this complex coastal site.

Final Wall Specifications:

• 20 ft (6.1 m) Coast Armor Posts
• 18 ft (5.5 m) Coast Armor Panels
• 1080 sq ft (100.3 sq m) gravity retaining wall using a combination of Redi-Rock’s 41 in (1041.4 mm) Hollow-Core, 28 in (711.2 mm) Middle, and 28 in (711.2 mm) Top blocks.

THE OUTCOME

By choosing the right tools for the job - Redi-Rock and Coast Armor - Osborn Construction rose to the challenge of installing a resilient seawall on a demanding coastal site. Their expertise and adaptability turned a complex problem into a long-term solution, protecting the Antigua Condominiums from future storms and shoreline erosion.

The Antigua Condominium owners were especially pleased with the finished wall’s clean look and the efficient installation that minimized disruption to their property. With this successful project under their belt, Osborn Construction is already looking ahead. They’re actively working to have the same Redi-Rock and Coast Armor system specified and approved by the Town of Ponce Inlet for future coastal developments, setting the stage for more resilient shoreline protection throughout the area.

Products Featured

28 in (711.2 mm) Top Block Half 28 in (711.2 mm) Middle Block 28 in (711.2 mm) Middle Block 41 in (1041.4 mm) Bottom Block Half Top Corner Block 20 ft (6.1 m) Coast Armor Posts 18 ft (5.5 m) Coast Armor Panels