natural rock and stone

SECTION 02061 NATURAL ROCK AND STONE

TABLE OF CONTENTS

Item No Title Page No

PART 1 GENERAL............................................................................................................1

1.01 DESCRIPTION OF WORK ..................................................................................1

1.02 SECTION INCLUDES..........................................................................................1

1.03 RELATED SECTIONS .........................................................................................1

1.04 REFERENCES.....................................................................................................2

1.05 DEFINITIONS.......................................................................................................3

1.06 SUBMITTALS.......................................................................................................5

1.07 QUALITY CONTROL ...........................................................................................6

1.08 HEALTH AND SAFETY CONSIDERATIONS......................................................7

1.09 VERIFICATION ....................................................................................................7

1.10 JOB CONDITIONS...............................................................................................8

1.11 DELIVERY, HANDLING AND STORAGE ...........................................................8

PART 2 PRODUCTS .........................................................................................................9

2.01 GENERAL ............................................................................................................9

2.02 MATERIALS.........................................................................................................9

PART 3 EXECUTION ......................................................................................................12

3.01 PREPARATION .................................................................................................12

3.02 INSTALLATION..................................................................................................12

3.03 PROTECTION....................................................................................................15

3.04 CLEAN UP .........................................................................................................16

Rev 0 i Contract No:


PART 1 GENERAL

1.01 DESCRIPTION OF WORK

A. The Contractor shall furnish all labor, tools, materials, equipments and tests necessary for supply and placement of natural rock and stone, as specified herein and indicated on the Contract Drawings.

1.02 SECTION INCLUDES

A. This Section includes the supply and placement of the following types of materials:

1. Angular Gravel: Crushed.

2. Round Gravel: Uncrushed.

3. Stone Mulch: Round and Uncrushed.

4. Local Mountain Stone: Angular.

5. Local Mountain Stone: Round.

6. Pit Run Gravel: Uncrushed.

1.03 RELATED SECTIONS

A. Section 01320 Construction Progress Documentation

B. Section 01330 Submittal Procedures

C. Section 01410 Regulatory Requirements

D. Section 01450 Quality Control

E. Section 01650 Product Delivery Requirements

F. Section 01660 Product Storage and Handling Requirements

G. Section 02310 Grading

H. Section 02315 Excavation and Fill

I. Section 02370 Erosion and Sedimentation Control

J. Section 03310 Structural Concrete

K. Section 04060 Masonry Mortar

L. Section 07920 Joint Sealants

Rev 0 1 of 16 Contract No:


1.04 REFERENCES

A. The referred codes and standards are intended to provide an acceptable level of quality for materials, products and workmanship. In case of conflict between these standards and the text of this Specification, the Specification text shall govern.

B. The latest revision of the referred codes and standards shall be used wherever applicable. In case of conflict, the Contractor shall propose equipment, materials and processes conforming to one group of codes and standards.

C. AASHTO American Association of State Highway and Transportation Officials

1. AASHTO T85 Specific Gravity and Absorption of Coarse Aggregate

2. AASHTO T96 Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los

Angeles Machine

3. AASHTO T104 Soundness of Aggregate by Use of Sodium Sulfate or Magnesium Sulfate

D. ASTM American Society for Testing and Materials

1. ASTM C33 Standard Specifications for Concrete Aggregates

2. ASTM C97 Standard Test Methods for Absorption and Bulk Specific Gravity of Dimension Stone

3. ASTM C127 Standard Test Method for Density, Relative Density (Specific Gravity) and Absorption of Coarse Aggregate

4. ASTM C131 Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

5. ASTM C136 Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

6. ASTM C150 Standard Specification for Portland Cement

7. ASTM C207 Standard Specification for Hydrated Lime for Masonry Purposes

8. ASTM C241 Standard Test Method for Abrasion Resistance of Stone Subjected to Foot Traffic

9. ASTM C535 Standard Test Method for Resistance to Degradation of Large-Size Course Aggregate by Abrasion and Impact in the Los Angeles Machine

10. ASTM D653 Standard Terminology Relating to Soil, Rock, and



Contained Fluids

11. ASTM D698 Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Standard Effort (12,400 ft-lbf/ft3 (600 kN-m/m3))

12. ASTM D1556 Standard Test Method for Density and Unit Weight of Soil in Place by the Sand-Cone Method

13. ASTM D1557 Standard Test Method for Laboratory Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m3))

14. ASTM D4644 Standard Test Method for Slake Durability of Shales and Similar Weak Rocks

1.05 DEFINITIONS

A. aggregate: A grouting and relatively inert granular mineral material, such as sand, gravel, slag and crushed stone.

B. angular aggregates: Aggregate, the particles of which possess well defined edges formed at the intersection of roughly planer faces.

C. base course: A layer of specified or selected granular material of planned thickness constructed on the sub-base for the purpose of serving one or more functions such as distributing load, providing drainage etc.

D. bedrock: In-place solid rock of indefinite thickness in its native location.

E. boulder: A rock fragment, usually rounded by weathering or abrasion, with an average dimension 305 mm or more.

F. borrow material: Material obtained from sources other than from site excavation. This is a reference to the source of supply and not to the characteristics of the material.

G. cement: Chemically bonding substance mixed with sand and/or gravel, for mortar or concrete.

H. cement grout: A grout in which the primary cementing agent is portland cement.

I. coarse aggregate: A material that will retain on No. 4 sieve.

J. coating: A protective or decorative covering applied to the surface or impregnated into stone for such purposes as waterproofing, enhancing resistance to weathering, wear and chemical action, or improving appearance of stone.

K. compaction: The artificial densification of a soil by means of mechanical manipulation (e.g. rolling, tamping, vibration, or other means). The percent compaction is defined as the ratio, in percent, of the as-compacted field dry density to the laboratory maximum dry density.



L. concrete: Mixture of cement, sand, gravel, and water to form a solid material.

M. contraction joints: Spaces where panels are joined, and which expand as the panels contract.

N. contractor: The individual, firm or corporation contracted for performing the work described in the Contract Documents.

O. crack: A break, split, fracture, fissure, separation, cleavage or elongated narrow opening, however caused, visible to the normal human eye and extending from the surface into the stone.

P. dry wall: A dry wall is a stone wall that is constructed one stone upon the other without the use of any mortar. Generally used for retaining walls.

Q. elevation: Height above the sea level or other datum.

R. equipment: Includes all machinery, tools, apparatus together with their spare parts, required for the proper construction and acceptable completion of the work.

S. erosion: The wearing away of the ground surface as a result of the movement of wind, water.

T. excavation: (a) The act of taking out material (e.g. soil); (b) the materials taken out; (c) the cavity remaining after materials have been taken out.

U. fill: A deposit of earth material placed by artificial means.

V. fine aggregate: Aggregate passing No. 4 sieve and retained on No. 200 sieve.

W. grade: The vertical location of the ground surface.

X. grading: Any excavating or filling or combination.

Y. gravel: The rounded or semi rounded particles of rock that will pass a 76.2 mm and be retained on a No. 4 (4.75 mm) U.S. standard sieve.

Z. grout: A material injected into a soil or rock formation to change the physical characteristics of the formation (soil or rock grouting).

AA. leveling course: The layer of material placed on an existing surface to eliminate irregularities prior to placing an overlying course.

BB. mortar: A plastic mixture of cement, lime, sand, and water used to bond masonry units.

CC. pointing: The final filling and finishing of mortar joints that have been raked out. The final mortaring of joints.

DD. purchaser: The person, company, or organization that purchases any materials or work to be performed is known as the purchaser.

EE. quality assurance: All those planned and systematic actions necessary to provide



adequate confidence that a product or service will satisfy given requirements for quality.

FF. quarry: The location of an operation where a natural deposit of stone is removed from the ground.

GG. riprap stone: Material generally less than 2 tons in mass, specially selected and graded, when properly placed prevent erosion through minor wave action, or strong currents and thereby preserves the shape of a surface, slope, or underlying structure.

HH. rock: Any naturally formed aggregates of mineral matter occurring in large masses or fragments.

II. rubble: Rough stones of irregular shapes and sizes, broken from larger masses either naturally or artificially, as by geological action, in quarrying, or in stone cutting or blasting.

JJ. sand: Particles of rock that will pass the No. 4 sieve and be retained on the No. 200 sieve.

KK. slope: An inclined ground surface, the inclination of which is expressed as a ratio of horizontal distance to vertical distance.

LL. soil: Naturally occurring superficial deposits overlying bedrock.

MM. spalls: Are primarily used for taking up large voids in rough rubble or mosaic patterns. Sizes may very from chip-size to one- and two-man stones.

NN. specifications: The formal directions, provisions and requirements which outline the work to be done, the way it is to be done, the character of the materials and mixtures to be used or the results to be obtained.

OO. stability: The condition of a structure or a mass of material when it is able to support the applied stress for long time without suffering any significant deformation or movement that is not reversed by the release of stress.

PP. stone: Crushed or naturally angular particles of rock.

QQ. subgrade: A prepared and compacted surface for supporting foundations of structures, embankments, pavements, etc.

RR. supplier: The party who supplies materials or services, who may or may not be a manufacturer.

1.06 SUBMITTALS

A. The Contractor shall submit to the Royal Commission, under the provisions of SECTION 01330, the following items for review and approval before commencing work:

1. Supplier’s List

a) The Contractor shall, within 30 days of signing the Contract, provide a



list of suppliers, which shall include:

1) Item name and number.

2) Name and address of the supplier.

3) Past service records.

4) Location of quarry or pit.

5) Key contact person.

6) Contact number.

2. Samples

a) The Contractor shall, within 30 days of signing the Contract, supply the following samples in labeled, durable wooden crates covered with wooden lids:

1) 15 to 20 mm diameter gravel; rounded, 20 L crate, full.

2) 110 to 200 mm diameter stone; rounded, 20 L crate, full.

3) 20 mm diameter crushed gravel; 20 L crate, full.

4) 400 to 800 mm diameter stone; round; sufficient 200 mm diameter samples to include the complete range of colors and stone types.

5) Local mountain stone; sufficient 200 mm diameter samples to include the complete range of color and stone types.

3. Test Report

a) The Contractor shall submit a test report of the proposed materials for the Royal Commission’s review.

1) Test report shall include the name of the testing service, location of the source, description of the material and its properties.

2) The test report shall be made available at the Contractor’s site office so that it may be inspected at any time by the Royal Commission.

3) All test results shall be signed, attesting to their accuracy and conformance with the specification requirements, by both the testing service and the Contractor.

4. Shop Drawings

a) The Contractor shall prepare the Shop Drawings, illustrating the work of this Section and submit them to the Royal Commission for approval.

1.07 QUALITY CONTROL

A. The Contractor shall be responsible for the quality of work and shall develop and propose programs and methods of construction and testing such as to achieve the specified quality to the approval of the Royal Commission in accordance with SECTION 01450.



B. Material testing and inspection services for quality control shall be conducted by an independent test laboratory, approved by the Royal Commission.

C. The Royal Commission reserves the right to test the materials at any time to verify their conformance with the specification.

D. Quality Assurance

1. Depending upon their use, the materials shall meet the following quality requirements:

a) Minimum specific gravity shall be 2.56, when tested in accordance with ASTM C97.

b) Abrasion loss shall not exceed 40% after 500 revolutions, when tested in accordance with AASHTO T 96.

c) Maximum absorption shall not exceed 6% when tested in accordance with ASTM C127.

d) Weight loss after 5 cycles shall not exceed; 10% when Sodium Sulfate is used; or 15% when Magnesium Sulfate is used during the soundness test, conducted in accordance with AASHTO T 104.

1.08 HEALTH AND SAFETY CONSIDERATIONS

A. All works undertaken in relation to this Specification are to be completed in full accordance with the respective health and safety requirements established by the following:

1. Kingdom of Saudi Arabia

a) Legislation, Regulation, Standards and Codes.

2. Royal Commission Regulations

a) Standards, Contractual Conditions, and Health and Safety Systems.

3. Contractor

a) Health and Safety Standards and Systems as accepted by the Royal Commission.

B. In the absence of any of the above, best accepted industry practice shall be employed throughout.

1.09 VERIFICATION

A. Site Conditions

1. The Contractor shall verify suitability of subgrade level and conditions to



receive the work of this Section in accordance with SECTION 02310.

B. Material Conformance

1. The Contractor shall ensure that the material delivered to site conforms to the samples approved by the Royal Commission.

1.10 JOB CONDITIONS

A. The Contractor shall provide materials of each type from the same source throughout the work.

B. The Contractor shall provide sufficient quantities of all types of materials to meet the project schedule and requirements. When necessary, materials shall be stored on site in advance of the requirement.

C. The Contractor shall coordinate work with other Sections affecting, or affected by this work, as necessary to assure the steady progress of work under this Contract.

1.11 DELIVERY, HANDLING AND STORAGE

A. The Contractor shall deliver, handle and store materials in accordance with SECTIONS 01650 and 01660, as well as the following requirements:

1. The Contractor shall use all means necessary to protect the materials from damage before, during and after installation.

2. The Contractor shall prevent excessive mud, wet cement, epoxy and similar materials, which may affix them, from coming in contact with other materials.

3. When materials need to be stored on site, the Contractor shall adopt the following precautionary measures:

a) Isolate differing materials with dividers or stockpile them separately to prevent their intermixing.

b) Prevent contamination of materials.

c) Store materials in well ventilated area.

d) Protect stockpiles from erosion and deterioration of materials from weather, moisture, temperature, light, and other harmful conditions.



PART 2 PRODUCTS

2.01 GENERAL

A. Material Procurement

1. All goods and products covered by these Specifications shall be procured, when available, from an in-Kingdom manufacturer. Procurement of all goods and products manufactured out-of-Kingdom must be approved by the Royal Commission.

B. Inspections at Source

1. The Royal Commission shall, at all times, have access to all places where materials are being produced or where tests are being conducted, and shall be accorded full facilities for inspection and observation of tests. The Royal Commission shall have the right to independently inspect and interview proposed producers and suppliers.

C. Samples

1. The approved samples will become the basis for acceptance/rejection of all materials delivered to the site, notwithstanding the other conditions of this Specification.

D. Rejection of Sources or Suppliers

1. The Royal Commission may reject particular producer’s pits or quarries if there is reasonable doubt that the particular producer or supplier cannot adequately meet the specifications, quality, quantity or schedule of this Contract.

a) In such cases, the Contractor shall arrange an alternate supplier at no additional cost to the Royal Commission, which satisfies the conditions of the Contract.

2.02 MATERIALS

A. General

1. Rock and stone shall be durable, sound and of sufficient hardness to resist weathering and shall be free of flaws, reeds, rifts, laminations, cracks, seams, and other blemishes which may impair their strength, durability or function. Use of porous and soft rock shall not be allowed in any type of the construction work.

B. Gravel

1. 20 mm Diameter, Crushed

a) The gravel shall be angular and crushed limestone and shall have the following composition by volume:



1) 15 to 25 mm diameter size, 80% or more

2) 5 to 15 mm diameter size, 18% maximum

3) Smaller particles, not more than 2%

2. 15 to 20 mm Diameter Gravel, Round

a) The gravel shall be well rounded uncrushed stone, light brown to buff color, salt free, clean and uncoated.

C. Stone Mulch

1. 110 to 200 mm Diameter Stone, Round

a) The stone mulch shall be well rounded, uncrushed, clean and uncoated, light brown to buff color and shall be salt free. It shall match with the 15 to 20 mm diameter round gravel in color and type and the longest dimension shall not exceed twice the smallest dimension.

D. Local Mountain Stone

1. Angular Stone

a) This type of stone shall be obtained from an approved local quarry and shall be angular (not rounded) and dark brown to gray brown in color. It shall be clean and uncoated and free of artificial markings such as blasting bore holes. All such stones shall be supplied from one deposit within one quarry and shall be of the following sizes:

1) 400 to 800 mm average diameter.

2) Larger Diameter Stones

(a) The supply size shall range in cubic meter per stone as stipulated on the drawings or smaller pieces shall be mortared together to form face appearance of massive stone.

2. Rounded Stone

a) The stone shall be well-rounded and uncrushed and dark brown to medium brown in color. The longest dimension of the stone shall not exceed twice the smallest dimension and shall be of the following sizes:

1) 400 to 800 mm average diameter.

E. Pit Run Gravel

1. Pit run gravel shall be uncrushed and unsorted gravel. The size shall range from 2 to 150 mm diameter with less than 5% volume of 10 mm diameter and smaller. It shall be dense, durable, sound and free of clay, organic matter and debris.

F. Mortar

1. The mortar shall be prepared by combining 1 part of cement to 2 parts of sand



and adding water in amount that will be just sufficient to obtain consistency of heavy cream.

a) Cement shall conform to ASTM C150.

b) Sand shall comply with ASTM C33.

c) Water shall be potable and clean.

G. Concrete

1. Concrete shall be prepared in conformance with the requirements of SECTION 03310.



PART 3 EXECUTION

3.01 PREPARATION

A. The Contractor shall inspect the substrate to verify that it is dry and free of soft, muddy and spongy surfaces; and that the gradients and elevations are correct.

B. The Contractor shall correct the irregularities in the substrate gradient and elevation by scarifying, reshaping, and re-compacting to obtain a grade which is reasonably smooth and free of mounds, or dips as required for performing this work.

C. The placement of fill to meet design grades and elevations shall be of an approved material, and placement shall include adequate compaction of the materials as set forth in SECTION 02315.

D. The Contractor shall construct curb ramps and other protective measures required to protect existing curbs and pavements from damage and shall remove such protective measures immediately after the completion of this work.

E. The Contractor shall stake out all gravel and stone items as described on the Contract Drawings and approved Shop Drawings.

F. The Royal Commission’s approval of layout shall be required prior to the commencement of the construction work.

3.02 INSTALLATION

A. General

1. 20 mm Diameter Crushed Gravel

a) The Contractor shall use crushed gravel for various base course layers as illustrated on the Contract Drawings.

b) The Contractor shall place the crushed gravel in layers of thickness not exceeding 200 mm and compact to 95% maximum dry density.

2. 15 to 20 mm Diameter Gravel, Round

a) The Contractor shall place the rounded gravel to a minimum depth of 35 mm.

b) This size of material shall be placed after the placement of other stone and gravel.

3. 110 to 200 mm Diameter Stone, Round

a) The Contractor shall place this material in a single layer minimum with less than 5% of soil surface visible as seen from direct over-head.



b) It shall be placed after the placement of other angular and larger stones.

c) The Contractor shall conceal soil lines, or clean stones to obscure visible soil lines.

d) It shall be placed on smooth graded subgrade in areas with less than 4:1 slope, resulting in an irregular stone surface in such conditions.

e) On slopes over 4:1, larger stones shall be placed into grade such that overall surface of stone is at a smooth continuous grade.

4. 400 to 800 mm Diameter Round Stones

a) The Contractor shall place these stones in a manner that ensures a reasonably homogenous distribution of different sizes of stones, with the larger stones uniformly distributed and firmly in contact with the smaller stones and spalls filling the voids between the larger stones. Care to be taken that the larger stones do not overlay the smaller stones.

b) In order to provide appropriate key, the Contractor shall excavate subgrade such that stones are securely anchored and firmly bedded and so that a maximum of ½ of the height of the stone projects above the level of adjacent stone or earth.

c) The Contractor shall place the stones in such a manner as to avoid the displacement of the underlying subgrade.

d) In order to avoid formation of pockets of void spaces, the Contractor shall place stones in such a manner that individual large stones have their weights supported by the underlying material and not by the adjacent stones.

e) The Contractor shall conceal soil lines, or clean stones to obscure visible soil lines.

f) The Contractor shall ensure that stones are not dislodged on slopes by foot traffic or moisture. If necessary, stones shall be bedded in lean concrete mixture to prevent dislodging.

B. Local Mountain Stone Retaining Walls

1. The Contractor shall adopt the following procedure to construct the local mountain stone retaining walls.

a) Submit Shop Drawings of the retaining wall to the Royal Commission showing elevation of each wall segment at 1:10 scale, which illustrates the placement of stones, the general shape of each stone and the locations of planting voids. Receive the Royal Commission’s approval before proceeding.



b) Place lean concrete or gravel base to levels required.

c) Soak stones for 30 minutes immediately before use.

d) Ensure that the stones are free of dirt and dust.

e) Build-up mortared stone rubble backing as required and only where approved specifically by the Royal Commission.

f) Select face stones for each wall segment, which are of related colors and shapes.

g) Use larger stones on the lower portion of the wall with smaller rocks for the top.

h) Provide tilt-back or batter, when shown on the Contract Drawings.

i) Bridge joints on each successive layer to enhance the stability of the retaining wall. Do not allow continuous, straight vertical joints.

j) Ensure that each stone is placed firmly in its position so that none of them is dislodged by foot traffic or moisture.

k) Place bond stones in each layer which are comparatively larger in length and extend into the backfill to provide anchorage to the retaining wall. Offset these bond stones in each successive course.

l) Backfill in 200 mm layers and tamp firmly behind the wall as the construction of wall progresses.

m) After the stone, mortar and lean concrete are well set, smooth sharp points or edges to the satisfaction of the Royal Commission. Also obscure any artificial markings or soil lines which are visible.

n) Fill voids with soil. In all cases, the soil shall penetrate to contact with subgrade fill.

o) Ensure that no mortar is visible on surfaces or among voids in the wall.

C. Mortared Stone Facings

1. The Contractor shall adopt the following procedure to construct mortared stone facings.

a) Where indicated on the Contract Drawings and approved Shop Drawings, stone is to be bedded in masonry mortar over a substrate of cast-in-place concrete.

b) Pour concrete substrate to levels needed to create the finish stone surface elevations required.



c) Ensure that concrete surface is rough enough to permanently bond with mortar or alternatively use epoxy based bonding agent if required, in accordance with the manufacturer's written instructions.

d) Soak stone for 30 minutes immediately before use.

e) Ensure that the stones are free of dirt and dust.

f) Lay mortar and stone continuously across each segment of concrete, that is, between adjacent edges and contraction joints. If required, employ bonding agent to ensure a continuous seamless mortar bed throughout each segment.

g) For submerged and normal exterior conditions, use masonry mortar mixes in accordance with SECTION 04060.

h) Wet stones thoroughly before placing, to ensure maximum bonding.

i) Mortar should extend around the base of and between stones to fill all voids to approximately 2/3 the depth of the stone; adjacent stones should touch each other.

j) Remove all dirt, excess mortar, stains and other defacements and clean all exposed stone surfaces.

k) Ensure that the finished surfaces adjacent to stone work are adequately protected from soiling, staining and other damage.

l) Ensure that the exposed surfaces are free from spots, spalls, chips, stains, discoloration or other defects which are not within the approved sample range and are likely to affect its appearance.

m) Ensure that edge stones and large stones can withstand foot traffic or moisture without dislodging.

n) Ensure that all joints are clean and free of plaster, mortar, grout or other rigid materials so as to receive joint sealant in accordance with SECTION 07920.

o) Lay edge stones and adjacent loose stone to create an invisible edge between mortared stone and loose stones.

3.03 PROTECTION

A. While handling the stones, all workers shall wear steel-toed boots and protective gloves.

B. When shaping or splitting stone, no person shall be permitted within the 10 m range of the working area without wearing protective eyewear and the public shall be excluded from such work locale.



3.04 CLEAN UP

A. Stone rubble and waste mortar shall be removed daily from publicly visible areas.

B. The site shall be left in a neat and clean condition.

END OF SECTION
