B08_-_ATT_3_-_2022-12-01_Phase_III_Armor_Rock_Procurement_SpecsV2.pdf

PHASE III ARMOR ROCK PROCUREMENT

MIDWAY ISLAND SEAWALL REPAIR PHASE III ARMOR ROCK PROCUREMENT

PART 1 – GENERAL

1.1 DESCRIPTION

A. This section includes requirements for the production of armor and filter rock including testing, handling, loading, transporting and reporting. The CONTRACTOR is to provide all plant, labor, and materials required to complete the work.

1.2 REFERENCES

A. Hawaii Department of Transportation Standard Specifications

B. ASTM C 127-88 (R93) – Specific Gravity and Absorption of Coarse Aggregate

C. ASTM C 127-88 (R93) – Absorption

D. ASTM C295/C295M (2019) Standard Guide for Petrographic Examination of Aggregates for Concrete

E. ASTM C535 – L.A. Abrasion

F. ASTM D6473 (2015) Specific Gravity and Absorption of Rock for Erosion Control

G. ASTM C88 – Soundness-Magnesium Sulfite

H. ASTM D4992 – Evaluation of Rock to be Used for Erosion Control

I. ASTM D5313 – Evaluation of Durability of Rock for Erosion Control Under Wetting and

Drying Conditions (80 cycles)

J. COE CRD-C 148 (1969) Method of Testing Stone for Expansive Breakdown on Soaking in Ethylene Glycol

K. Construction Industry Research and Information Association (CIRIA), June 1, 2007,” The

Rock Manual: C683: The Use of Rock in Hydraulic Engineering (CIRIA Report)”

L. USACE Coastal Engineering Manual, Part VI – Chapter 4, Material and Construction

Aspects

M. USACE EM-1110-1-1005 – Topographic Surveying

N. USACE EM-1110-2-1003 – Hydrographic Surveying

1.3 SUBMITTALS

A. One (1) copy of each submittal shall be delivered to the ENGINEER:

1. Work plan

2. Daily reports

3. Rock quality test results and reports

4. Quantity computations

1.4 QUALITY ASSURANCE

A. Work and material shall comply with provisions specified herein.

B. Daily Report of Operations

1. A daily report of operations shall be prepared and submitted to the ENGINEER. The following information will be included: date, personnel on-site, equipment used, and quantity of rock delivered. The report shall include the results of all inspections, surveys, and monitoring activities, as well as methods for how loaded tonnage is calculated. The report shall be signed by the CONTRACTOR's on-site superintendent.

C. Work Plan

1. The CONTRACTOR shall identify its proposed rock source and obtain rock that meets all requirements specified herein. The CONTRACTOR shall comply with all federal, state, and local laws and regulations pertaining to surface mining, safety, and protection of the environment. The CONTRACTOR shall be responsible for obtaining all permits and/or easements for the rock source quarry operations.

2. The CONTRACTOR shall identify and describe procedures for production of rock, inspection and testing of rock (quality and production testing), cleaning, loading, transport, and unloading. The work plan shall identify equipment to be used during all operations, including but not limited to excavators, loaders, transportation vehicles, ramps, and scales.

3. Development of a new or existing off-site quarry for furnishing rock required by this contract may require review by local, state, and federal agencies. The CONTRACTOR is responsible for investigating and obtaining all necessary reviews and permits from local, state, and federal agencies.

PART 2 – PRODUCTS

2.1 MATERIALS

A. Rock shall be rough, angular, dense, sound, and durable. Rounded rock will not be accepted. Laboratory tests and visual geologic examinations shall be made to determine the acceptability of materials. Rock shall be composed of hard, strong, and durable materials that will not flake or deteriorate upon exposure to the action of water or atmosphere; shall not contain cracks, joints, faults, seams, laminations, planes of weakness, blast fractures, or bands of minerals or deleterious materials that would result in breakage during or after placement; and shall be free of expansive or other materials that would cause accelerated deterioration by exposure to project conditions.

B. Rock shall be from a source pre-approved by the ENGINEER.

C. Materials shall meet the following test requirements for quality:

1. Bulk Specific Gravity Range: All stone shall have a minimum bulk specific gravity, saturated surface dry (SSD), of 2.65, based upon saltwater having a unit weight of 64 pounds per cubic foot. The method of test for bulk specific gravity SSD shall be ASTM D6473.

2. Unit Weight and Absorption: The stone shall have an absorption value less than 2% unless other tests and service records show that the stone is satisfactory. The test method for unit weight and absorption shall be ASTM D6473, except the unit weight shall be calculated in accordance with Note No. 5 using bulk specific gravity, SSD.

3. Petrographic Examination: Stone shall be evaluated in accordance with ASTM

C295/C295M. The procedure for examination shall include provisions appropriate for the examination of large stone in section 12 and the procedures required by ASTM D4992, section 10, Petrographic Examination. The petrographic examination shall be used to identify micro fractures, seams, expansive minerals, or other defects that might cause accelerated deterioration from exposure to a harsh marine environment. The petrographer shall include a narrative in the report discussing the suitability of the rock for use as shore protection in a marine environment. The narrative shall address any qualities that might cause accelerated deterioration. The petrographic examination shall be done by a qualified petrographer with five or more years of experience in petrography.

4. Resistance of Rock to Wetting and Drying: Stone shall have a maximum loss of 10% after 80 cycles and no major progressive cracking when tested in accordance with ASTM D5313/D5313M. The sample shall consist of at least five pieces per lithologic (rock) unit. Testing shall be conducted on the largest possible rock and the test samples should be sawed so as to include at their edges as much of the surface of the material received for testing as possible. The report shall include “Before” and “After” color photographs, as required in section 11.1.7 of the ASTM.

5. Abrasion: Durability of stone shall be verified by testing in accordance with ASTM

C535, with a maximum loss of 20% for armor rock when subjected to 1,000 revolutions of the testing apparatus. Testing shall be conducted on aggregate meeting Grading 1.

6. Soundness: Soundness of stone shall be tested in accordance with ASTM C88 with magnesium sulfate. Maximum permitted loss is 5%.

7. Accelerated Expansion (Ethylene Glycol): Stone shall be evaluated in accordance with COE CRD-C 148-69. Stone shall not exhibit any breakage unless other tests and service records show that the stone is satisfactory.

8. Dimensions: The greatest dimension of each rock shall be no greater than 2.5 times the least dimension. Length-to-thickness ratio (LT) is defined as the maximum length (l) divided by the minimum distance (d) between parallel lines through which the particle would just pass (Figure 1). The ratio is sometimes termed the aspect ratio. A maximum LT of 2.5 is to avoid long, thin, plate-like stones.

Figure 1. Illustration of Armor Stone Shape Measurement Systems

D. QUALITY TESTING. All testing shall be performed by an independent commercial test laboratory currently validated by the U.S. Army Corps of Engineers and approved by the ENGINEER. A current list of commercial laboratories along with the test methods they are validated to perform is available at the Engineering Research and Development Center’s Materials Testing Center website: https://mtc.erdc.dren.mil/. Copies of laboratory test reports shall contain the name and address of the testing laboratory, the date(s) of the tests to which the report applies, the project name and location, and the quantity and date(s)of shipment, or delivery, to which the certificates apply.

E. ROCK QUALITY ACCEPTANCE. Rock that has met previous USACE riprap requirements for seawall construction shall be accepted (within 7 years). Existing USACE testing requirements and test results shall be provided. Contractor shall still be required to test provided rock to these specifications and provide that information upon completion of the contract so the USFWS knows the rock characteristics of what was actually provided.

No further laboratory testing of rock will be necessary if results meet the specified requirement, and a continuous visual geologic examination of the rock by the ENGINEER indicates no change in rock type or quality from rock passing the laboratory tests. Rock exhibiting significant changes in type or quality will be rejected unless additional testing shows that the rock meets the specified requirements.

All rock material must be approved by the ENGINEER prior to it being loaded onto the barge, then again after it is placed on the barge deck. Rock will be accepted or rejected by the ENGINEER based on evaluation of all test results as well as visual geologic examination of the rock. The CONTRACTOR shall allow three days for inspection of rock material by the ENGINEER, prior to loadout to the barge.

F. GRADATION. All materials shall meet the following sizes:

1. Armor Rock:

Armor Rock Class I % Smaller Rock Size (pounds)

Rock Size (tons)

Wmax 100 8,000 4.0 W50 25-50 6,500 3.25

Wmin 0 4,800 2.4

Armor Rock Class II % Smaller Rock Size (pounds)

Rock Size (tons)

Wmax 100 5,500 2.8 W50 25-50 4,350 2.2

Wmin 0 3,275 1.6

2. Filter Rock:

% Smaller Rock Size (pounds)

Wmax 100 850 W50 25-50 650

Wmin 0 450

3. Granular Fill shall be clean well-graded gravel.

2.2 PRODUCTION TESTING

A. Samples shall be taken at the source of the material and at subsequent points during transport, as directed. No failing tests shall count toward meeting the minimum number of representative tests. Production tests shall be evenly spaced throughout production. Tests shall be performed by actual weighing. Results shall be provided to the ENGINEER within 24 hours or sooner if requested.

1. Armor Rock – Test at least three (3) representative samples. Each sample shall be approximately 50 cubic yards in volume.

2. Filter Rock – Test at least three (3) representative samples. Each sample shall be approximately 25 cubic yards in volume.

B. GRADATION TESTING. Tests shall consist of determining the total weight of all the rocks and the individual weight of each rock in the sample, respectively. Percent smaller by weight shall be determined by dividing the total weight of the sample into the sum of the total weight of the rocks smaller than the specified rock weight.

Determining the weight of rock delivered by the truck shall occur by certified weigh bills provided by the supplier. Weigh bills and scales used for weighing of trucks and materials contained therein shall have approval by the ENGINEER prior to notice to proceed is issued. The CONTRACTOR shall submit a copy of the truck scale’s certification of accuracy from the local weights and measures regulating agency. The CONTRACTOR shall also submit weight bills, including certification of exact weight and time of weighing for each load of rocks delivered.

C. DROP TESTING. For comparability, the test stone shall be dropped from a bucket or cherry picker onto a rigid surface or second stone of comparable size from a height not less than half the average diameter of the stone. Dumping from a truck is not acceptable. The stone shall be examined carefully prior to testing and after completion of the test. Failure criteria includes the development of new cracks, opening of old cracks, breakage, or the loss of pieces from the surface of the stone. A minimum of 10 stones from each sample shall be tested. Each stone shall be dropped a total of five (5) times for evaluation purposes with examination after each drop.

PART 3 - EXECUTION

3.1 GENERAL

A. The CONTRACTOR shall display at least one typical rock, for each of the following weights (+/-5%).

3,275 lbs 4,800 lbs 5,500 lbs 6,250 lbs 7,000 lbs 8,000 lbs

The displayed rocks shall be visible to the OWNER’s designated inspector during all phases of the loadout including the quarry loadout area and the barge loadout area so that proper sizing can be monitored. The weight shall be clearly marked on each rock.

B. Quarried armor rock shall be stockpiled for a curing period of 45 days. The curing operations on freshly quarried stone are to allow it to release stored energy and moisture.

Curing will also allow the stone to demonstrate that it will not fracture during the energy release and drying-out phase. Any method of stockpiling which could cause segregation within the stockpile or excessive breakage will not be permitted. Armor rock shall not be piled more than three rocks high.

3.2 EQUIPMENT

A. Loading/unloading equipment shall be capable of handling stone individually without dropping the stone from more than 1 foot. Stone-placing equipment shall have adequate safe capacity to load and offload all materials identified in this specification. Loading and unloading will include moving the stone from the ground to the transport vehicles and from the transport vehicles to the ground, or designated barge deck.

B. Size of equipment shall include consideration for handling overweight stones.

C. All ramps and accessory equipment used for loading the barge shall be of adequate capacity capable of supporting the loads expected during barge loading/unloading.

D. The operator of rock-handling equipment shall use appropriate care to avoid rock breakage.

3.3 ROCK CLEANING

A. U.S. Fish and Wildlife Service adopted an implementation plan as part of the Seawall Long-Term Maintenance Project located at Midway Atoll National Wildlife Refuge (NWR) to mitigate the impacts associated with the seawall repair. This plan requires that all rock material being used for the repair is clean and free of sand, soil, organic materials, insects, seeds, and other deleterious materials. The CONTRACTOR shall pressure wash all rock on a concrete surface or coarse gravel pad prior to loading onto barges. Prior to loading cleaned rock onto the barge, the rock will be inspected by a qualified biologist to verify that the rock is free of insects and seeds. If the cleanliness of the rock if found to be inadequate, the CONTRACTOR shall re-clean the rocks at no additional cost to the OWNER. It is the responsibility of the CONTRACTOR to arrange for this inspection to occur in a manner that will limit the amount of time the rock is stored after cleaning and before being transported. The CONTRACTOR shall ensure that all materials are stored on clean concrete/asphalt.

3.4 LOADING FOR TRANSPORT

A. Size of equipment shall include consideration for handling overweight stones. Armor rock shall be placed individually and in such a manner to avoid damaging.

B. The CONTRACTOR shall not drop armor rock more than 1 foot; end dumping methods will not be allowed.

C. Loading methods that segregate or damage the rock and stones will not be permitted.

D. Sort and manipulate stones by mechanical equipment until acceptable by the ENGINEER.

E. Materials that do not meet the specified requirements for size, shape, quality, or distribution of sizes shall be removed and replaced with suitable materials.

F. Any materials found to break during loading shall be removed and replaced with suitable materials.

END OF SECTION