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6. BRE AKW ATERS

6.1 GENER AL

6.1.1 Scope
This specification details the requirements for the supply and installation of rock for
the construction of rubble-mound breakwaters.

6.1.2 Standards
This sections deals with the minimum requirements of breakwater works.
In case of conflict between standards and codes of practices, the most stringent code
shall apply, or execution shall be as directed by the Engineer.
All standards cross-referenced within the listed documents shall also be considered
as project standard / specification references.
Following precedence shall apply and shall supersede any other clause spelling out
precedence that may appear in this specification.
This Specification;
BS EN Standards;
British Standards;
European Standards;
American Standards;
Other Standards.
The design and construction shall also comply with the requirements of local
authorities having jurisdiction over the site. In case of conflict, the most stringent
requirements shall govern.
The design standards and codes of practice, which are referenced within this
Specification, are listed in table below. All design, fabrication, procurement and
installation shall conform to the requirements of the latest editions of the following
codes and standards of practice except as explicitly varied by this Specification
section:
Table 6-1: Applicable Standards and Guidelines
Reference Title Description
ASTM 4355: 2015 Standard Test Method for Deterioration of Geotextiles by Exposure
to Light, Moisture and Heat in a Xenon Arc Type Apparatus
ASTM D4533: Standard Test Method for Trapezoid Tearing Strength of
2015 Geotextiles
ASTM D4632: Standard Test Method for Grab Breaking Load and Elongation of
2015 Geotextiles
BS 812: 2005 Testing aggregates. Methods for the determination of density

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Reference Title Description

BS 812-111:1990 Testing aggregates. Methods for determination of ten per cent fines
value (TFV)
BS 812-112:1990 Testing aggregates. Method for determination of aggregate impact
value (AIV)
BS 812-121:1989 Testing aggregates. Method for determination of soundness
BS EN 1097-2: Tests for mechanical and physical properties of aggregates.
2010 Methods for the determination of resistance to fragmentation
BS EN 1926: 2006 Natural stone test methods. Determination of uniaxial compressive
strength
BS EN ISO 9863- Geosynthetics - Determination of thickness at specified pressures -
1:2005 Part 1: Single layers (ISO 9863-1:2005)
BS EN ISO 9864: Geosynthetics - Test method for the determination of mass per unit
2005 area of geotextiles and geotextile-related products
BS EN ISO Wide-width tensile test
10319:1996
BS EN 10320: Geotextiles and geotextile-related products. Identification on site
1998
BS EN ISO 11058: Geotextiles and geotextile-related products. Determination of water
2010 permeability characteristics normal to the plane, without load
BS EN ISO 12236: Geosynthetics. Static puncture test (CBR test)
2006
BS EN ISO 12956: Geotextiles and geotextile-related products. Determination of the
2010 characteristic opening size
BS EN ISO Geotextiles and geotextile-related products. Characteristics
13253:2000 required for use in erosion control works (coastal protection, bank
revetments)
BS-EN-13383-1: Armourstone. Specifications
2013
BS-EN-13383-2: Armourstone. Test Methods
2002
CIRIA C683: 2007 Rock Manual
CEM: 2006 Coastal Engineering Manual
EAU Report: 2004 Recommendations of the Committee for Waterfront Structures
Harbours and Waterways
ISRM: 1985 International Society for Rock Mechanics- Suggested Methods for
Determining Point Load Strength
Any conflicts or inconsistencies between the specification and other contract
documents shall be brought to attention of the Engineer for resolution. If
inconsistencies exist between the requirements of this specification and those of
contract documents, the more stringent requirements shall apply as determined by
the Engineer.

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6.1.3 Submittals
The Contractor shall provide detailed petrological descriptions of all rock types and
shall submit test results for the proposed source from an independent laboratory,
demonstrating compliance with these Specifications, to the Engineer for approval.
The Contractor shall submit with the Tender Package:
Relevant information about the rock supplier and records of the supply of similar
systems in the region;
Any notable exceptions or changes from the Drawings and this specification.

6.2 ROCK

6.2.1 Qualit y
All rock shall be naturally occurring, dense, sound material quarried from an approved
source. It shall be free from weathering, mechanical weakness and chemical
decomposition, and of such character that will resist disintegration and erosion by the
action of air, water, wetting and drying, extremes of temperature and impact due to
wave action or any other natural or climatic factors. It shall also be free from
significant discontinuities such as cracks, veins, stylolite seams, laminations, foliation
planes, cleavage planes, unit contacts or other such flaws which could lead to
breakage during loading, unloading or placing. It shall be free from dirt, soil, peat,
loam, clay or any organic matter and all holes drilled for blasting purposes. It shall be
capable of being handled and placed without fracture or damage. Quarried rock shall
not contain visually observable or chemically detectable impurities or foreign matters
in such quantities that are damaging for the constructive application of the quarried
stone or for the environment in which the quarried stone is to be placed.

6.2.2 Sources
All armour rock used on the Project shall be from the same source to provide an
approved uniform colour to the finished works. Providing the rock meets or exceeds
all specified material requirements and the rate of supply required to satisfy
programme requirements is met, rock may be obtained from either local quarries or
imported from other sources. There shall, however, be no mixing of locally obtained
and imported material unless approved by the Engineer.

6.2.3 Qualit y Plan

Prior to the agreement to use a proposed source, the Contractor shall provide
evidence of rock selection quality control procedures in operation at the quarry. This
evidence shall include, but not be restricted to:
Assessments of any changes anticipated in the geology of the production faces
during the duration of the Contract likely to affect rock quality, type, block
composition or integrity;
Evidence of the selection of a blasting pattern which minimizes the production of
latent fractures;
Evidence of orientation of rock production faces to minimise the influence of
fractures and discontinuities;
Length of time, if rock is stockpiled;

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Evidence of rejection of out-of-size and flawed materials prior to dispatch;

Anticipated incidence of block fracture on site, based either on controlled drop
tests, or rock breakages during transit.

6.2.4 Grading

6.2.4.1. Rock Grading Cl asses

Rock shall be supplied in the grading classes defined in Table 6-2 if not clearly
specified in the drawings. The grading system is generally in accordance with the
system described in CIRIA Publication C683 – The Rock Manual (2007), BS EN
13383.
Table 6-2: Rock Grading Classes
Rock
Mem Mem
Size
ELL NLL NUL EUL Lower Upper
Layer Type D50
kg kg kg kg limit limit
Nominal
kg kg
m
Primary Armour 3-
2000 3,000 6,000 9,000 4,200 4,800 1.20
6 tonne
Primary Armour 1-
700 1,000 3,000 4,500 1,700 2,100 0.90
3 tonne
Primary Armour /
Under layer 300- 200 300 1000 1500 540 690 0.60
1000 kg
Primary Armour /
Under layer 200- 140 200 300 450 200 250 0.45
300 kg
60-300 kg 30 60 300 450 130 200 0.40

Quarry Run 1 5 200 500 NA NA 0.3

Non-standard
* 300 700 * * * *
grading
* To be proposed by contractor for engineer approval
Notes:
“D50 Nominal” refers to the face dimensions of a notional cube.
ELL (extreme lower limit) - the mass below which no more than 5% passing by
mass is permitted
NLL (nominal lower limit) - the mass below which no more than 10% passing by
mass is permitted
NUL (nominal upper limit) - the mass below which no less than 70% passing by
mass is permitted
EUL (extreme upper limit) - the mass below which no less than 97% passing by
mass is permitted

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6.2.4.2. Rock Shape Ratio

Rock in armour and underlayer grades shall not contain more than 50 percent by
weight of stone with a length to thickness (Ud) ratio greater than 2. Not more than 5
percent of the rocks shall have a Ud ratio greater than 3, where the length, L, is
defined as the greatest distance between two points on the stone and the thickness,
d, as the minimum distance between two enclosing parallel planes through which the
stone can just pass. Testing for shape ratio determination shall be undertaken on
samples of at least 50 pieces taken at random from stones of mass W15 or greater.

6.2.5 Operations, St ockpiling and Testing at Quarr y

6.2.5.1. Method Stat ements

Contractor shall submit to the Engineer for approval the methods to be used to
quarry, select, grade, handle, load, transport and place the rock and the quality
control procedures to be adopted at the quarry, during delivery and on site.

6.2.5.2. Test Val ues

The Contractor shall provide detailed petrological descriptions of all rock types and
shall submit test results for the proposed source from an independent laboratory,
demonstrating compliance with the following criteria, to the Engineer for approval.
Testing of the following criteria shall be carried out throughout the contract at the
frequencies indicated in these Specifications.
Density: The average saturated surface-dry relative density shall be greater
than 2,650 kg/m3 with 90 percent of the stones having a density of at least
2,550 kg/m3 for armour and underlayer, and not less than 2,400 kg/m3 for
other rock grades when sampled, tested and reported in accordance with
CIRIA Rock Manual 2007.
Water Absorption: The average water absorption shall be not more than 2
percent for armour rock and underlayer, and not more than 3 percent for other
rock grades when sampled, tested and reported in accordance with CIRIA
Rock Manual 2007.
Resistance to Weathering: Magnesium Sulphate Soundness for sampling
testing and reporting in accordance with BS 812: Part 121: 1984 shall be less
than 8 percent. Notwithstanding the requirement above, if the rock is basaltic,
there shall be no occurrences of Sonnenbrand effect in the first 20 stones
tested or no more than one occurrence in the first 40 stones tested when
sampled, tested and reported in accordance with CIRIA Rock Manual 2007.
Impact Resistance: The aggregate impact value shall be less than 30 percent
for the standard test fraction when tested in accordance with BS 812: Part
112: 1990.
Crushing Resistance: The force required to produce 10 percent fines shall
not be less than 100 kN when tested in accordance with BS 812 : Part 111:
1990, and either
The Franklin Point Load Index (IS50) (ISRM) shall not be less than 3.5
N/mm2 for armour and underlayer and 2.3 N/mm2 for other rock grades, or

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The uniaxial compressive strength (ISRM) shall be greater than 80 N/mm2

for armour and underlayer and 50 N/mm2 for other rock grades.
Block Integrity: Blocks shall be free from visually observable cracks, veins,
fissures, shale layers, styolite seams, laminations, foliation planes, cleavage
planes, unit contacts or other such flaws which could lead to breakage during
loading, unloading or placing. The Drop Test Breakage Index shall be less
than 5 percent when sampled, tested and reported in accordance with CIRIA
Rock Manual 2007.

6.2.5.3. Frequenc y of Testi ng

Testing shall be carried out regularly by an approved 3rd Party throughout the
Contract to monitor the quality of rock on samples selected by the Engineer. The
Contractor shall report the results without delay. The Contractor shall provide every
facility to the Engineer to witness the sampling and testing.
The minimum frequency of testing and visual inspection required for each grade of
rock is shown in Table 6-3. Additional or more frequent testing may be required if the
material varies or the quarry is worked inconsistently.
No use of any rock material is allowed prior to full compliance of all required
laboratory and field tests.
All tests must be performed from stockpiles at site not at quarry.
Table 6-3: Frequency of Testing
Rock Characteristic Frequency of Testing for All
Rock (per Quarry Face) Not
Less than One Set of Tests per
Shape, Visual Quality Inspection and
Gradation: (continuous for all rock)
Visual Inspection and Impurities Weekly or 3,000 T
Measurement
Density, water absorption and resistance
Weekly or 3,000 T
to weathering
Block Integrity Weekly or 3,000 T
Specific Gravity Weekly or 3,000 T
Impact and Crushing Resistance Point
Fortnightly or 10,000 T
Load Index/Compressive Strength

6.2.5.4. Initial Accept ance Procedures

Prior to commencement of delivery of bulk quantities of rock to the site, the Contractor
shall:
Arrange a meeting at the quarry at which the Engineer, the Contractor and the
quarry managers are present to discuss and agree the methods to be used to
inspect samples of the rock and to witness gradation and weight tests on the
samples.

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Provide test results by an independent laboratory on a minimum of three

separate samples to confirm that the rock complies with the specified
parameters in Clause 6.2.5.2.
Provide at least three samples (min one m3) of each grade of rock and, in
addition, five armour stones indicative of the size range within the required
grading to be situated both at the quarry and on site, close to the area of
production, storage and point of delivery at the works. The quantity of rock in
each sample shall be sufficient to define the grading and shape. Each sample is
to allow visual comparison with the bulk deliveries shall be kept separate and
shall be clearly described by a painted signboard. Once approved, the samples
and signboards, both at the quarry and on site, shall remain until all rock
construction is completed.

6.2.5.5. Qualit y Control Testing

Quality control testing shall be carried out by the Contractor at the quarry prior to
transportation to the site, in accordance with the approved Quality Control
Procedures. The results of tests and all non-conformances and proposed corrective
actions shall be reported to the Engineer without delay.
Rock already delivered to the site, but failing to meet the acceptance criteria shall be
removed from the site immediately and disposed of at the Contractor's expense,
unless an alternative use is agreed upon with the Engineer.

6.2.5.6. Stockpiling at Site

Material for each class of rock shall be concentrated at the Quarry into separate
stockpiles for rock that is being produced, rock that is undergoing testing and
awaiting approval and rock that has been approved. The three stockpiles shall
be clearly marked so that they can be readily identified.
A set of approved rocks for every class shall be selected by weighing and
provided as examples of the minimum, average and maximum size rocks
specified for that class. The rocks shall be marked with the value of the weight
and the set shall be located in a prominent and convenient location to provide
easy reference for quarry personnel. If necessary, several sets shall be
provided for each class, as demanded by operations at the various locations in
the quarry.

6.2.5.7. Quarr y Operations

The Contractor shall ensure that any quarry used shall:
Obtain whatever permissions are necessary for the exploitation of the quarry
and pay royalties, fees, way leaves and the like.
Operate the quarry in an approved manner and provide sufficient evidence by
means of boreholes, test holes and the like to show that the quarry contains
rock of the required quality and quantity to complete the works and shall
produce a geological map based on this evidence prior to the start of quarrying.
Work the quarry to produce rock that meets the other clauses of the
specification in every way.

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Obtain the prior written approval from appropriate Authorities, Police and the
Engineer for the use of explosives, magazine storage arrangements and
blasting procedures, and provide safety mean for the protection of persons and
property during blasting operations. Explosives shall be used only after
obtaining the express written permission of the appropriate Authorities and the
Engineer. Nothing contained in the Contract nor shall any approval or instruction
by the Engineer relieve the Contractor of any of his obligations and
responsibilities under any Statutory Acts or Regulations.
When quarrying operations are complete, the Contractor shall leave the quarry
in a safe condition to the approval of the appropriate Authorities by, inter alia:
Barring down all faces so that no loose rock remains on any face.
Bringing down overhanging rock safely.
Ensuring that the quarry is free-draining and that no accumulation of water
can occur or, in the case of a quarry below ground level, minimising the
accumulation of water and drainage to areas approved by the Engineer.
Warning notices in Arabic and English may be required at any
concentrations of water that constitute a hazard.
Stockpiling surplus rock material to a height not greater than 3 metres with
stable side slopes.

6.2.6 Tr ansportation, Stockpiling and Testing at Site

6.2.6.1. Rock Transport

Rock shall be transported to the site of the permanent works along an approved
route. The Contractor shall:
Obtain the approval of the Engineer and the appropriate Authorities before using
the public highway.
Avoid damage to public or private roads and repair any damage that does occur
at its own expense.
Ensure trucks used to transport rock for this Project are of a type specifically
constructed for hauling rock and have tailboards or scow-ends. If transporting
heavy armour stone on flat top wagon, adequate chains and slings shall be
used and verified before it leaves the quarry to ensure optimum security.
If sea transportation is used, ensure all barges are seaworthy and have the
necessary safety certificates and insurance issued by the relevant authorities.
Permission for safe mooring of sea transport vessels shall be obtained from the
relevant Authorities. The Contractor shall have an emergency procedure in
place should there be an imminent threat of sea and wind conditions beyond the
safe mooring design conditions.
The Contractors shall be solely responsible and should repair at its own
expense any damage to third party facilities that the transportation of rock may
generate.

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6.2.6.2. Stockpiling of Rock

The Contractor may be permitted to stockpile rock at or near the site of the permanent
works. Separate stockpiles shall be made for different grades of rock. The stockpiles
shall be formed so that they do not constitute a hazard. The locations, side slopes,
heights and other factors affecting safety shall be as approved.

6.2.6.3. Temporar y Haul Roads

Where the Contractor wishes, or the Engineer requires, that a temporary haul road or
track be created within or on the structure, it shall be constructed of free-draining local
material if available and suitable for this purpose, or of other free-draining material
approved by the Engineer. Such material shall be removed before placing
subsequent layers. The haul road material shall be sufficiently removed to expose
between one third and one half of the depth of the upper layer of stones of the
permanent works upon which the haul road material is placed, when measured from
the highest points. Any armour stones laid to facilitate haul road construction that do
not comply with the requirements of this specification shall be removed and replaced
as necessary.

6.2.6.4. Testing at Site

The Contractor shall make facilities available on site, staffed and equipped, for
additional testing of rock as follows:
Point Load Strength Index tests of all rock gradations: every 10,000 tonnes or
as required depending on variability of rock produced.
Rock shape ratio as per section 6.2.4.2: every 10,000 tonnes or as required
depending on variability of rock produced.
Water absorption: every 5,000 tonnes or as required depending on variability of
rock produced.
If in the opinion of the Engineer any rock received at the Site is not in accordance with
the Specification, either it shall be tested to prove compliance or it shall be rejected.
Rocks rejected for reason of size from one class may be incorporated in smaller
classes by agreement with the Engineer.

6.2.6.5. Reference Rocks at Site

For every class of rock materials, a set of approved rocks, selected at the quarry as
samples of the minimum, average and maximum sizes permissible for that class, and
marked with the value of the weight, shall be located near the work site for the easy
reference of operatives while placing rock in the work. One set for each class shall be
provided for each location where work is progressing. At the end of construction
these rocks shall be incorporated into the works.

6.3 GEOTEXTI LE FILTER

6.3.1 General
It shall be ensured that the geotextile complies with the requirements set out in the
Specification, in particular regarding the appropriate functional characteristics, that the
geotextile is sufficiently robust to withstand, without being damaged, the working

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