METHOD STATEMENT

FOR

ARTIFICIAL ROCK WORK

AKAR TECHNICAL SERVICES CO LLC

P O Box 14652, Dubai, UAE
Tel : 04-3479889 / 04-3479886
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ROCKWORK
_________________________________________________________________________

PART 1. – SPECIFIC PROJECT

1.1 DEFINITION

A. The term “Cast Rockwork”, “Mold-Cast Rockwork” of “GFRC

Rockwork”, means simulated or artificial rock formations constructed
and/or installed on the site by skilled craftsmen utilizing an approved
system of assembling prefabricated glass fiber reinforced concrete panels
into a monolithic structure.

1.2 DESCRIPTION OF WORK

A. The work of this Section includes but is not limited to:

1. The furnishing of all labor, equipment, materials, supervision and

all incidentals as necessary and required for the construction of real
and simulated rock formations, edge conditions, ledges,
outcroppings, planting pockets, waterfalls, including GFRC and
positive cast artificial rockwork, natural boulders, cobbles, gravel,
etc., as indicated on the Drawings and specified herein.
2. Anchorage and secondary support structures for Rockwork, as
indicated and required.
3. Integration and co-ordination of waterproofing, finishes, grout,
gunite and Rockwork.
4. Alteration of the texture and color of installed rockwork may be
required to provide continuity in the overall project design.
5. Coordinate work with that of all other trades affecting, or affected
work of this Section. Cooperate with such trades to assure the
steady progress of all work under the Contract.
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1.3 RELATED WORK SPECIFIED ELSEWHERE

A. Review requirements of other Sections for items related to or required for

this work.

B. Refer to Architectural, Structural and related Landscape Documents.

1.4 QUALITY ASSURANCE

A. Quality Standards : The standards referenced are specified to establish

standards of quality, performance and design concept.

B. The products and work shall be supplied by an experienced installer, having

a minimum of three years experience in the construction of simulated
Rockwork, and shall provide a list of recent projects for review by the
Architect/Owner. No allowance shall be made for lack of skill on the part
of the installer.

C. In addition to all other required guarantees or warranties, warranty all

Rockwork for a period of one year and as described in the appropriate
section of the Architect’s Specifications. Any cracks, separations of texture
coat from structural coat, color, efflorescence or other failures shall be
repaired at no expense to the Architect/Owner.

D. The Contractor may submit alternate methods, materials, finishes, etc., for
approval. Alternates shall meet performance criteria specified in this section
for similar materials, shall be in keeping with artistic intent of the Project as
interpreted by the Designer and Architect, and shall comply with the
provisions of the appropriate sections of the Specifications.

1.5 STANDARDS

A. To the extent possible, Cast Rockwork shall be produced from molds

presently in the Contractor’s inventory. However, all molds shall conform
to the type, style and configuration indicated by the sample provided and as
described in the big documents. The Architect/Owner shall choose the
texture and formations to be used from said inventory. If the Contractor
does not have acceptable molds in inventory, it shall be the Contractor’s
responsibility to provide such molds.
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B. Structural Requirements :

1. All Cast Rockwork connections and attachments shall conform to the

Uniform Building Code, current edition.
2. The Cast Rockwork shall equal or exceed the following live loads in
addition to all dead loads (refer to Drawings for additional
information) :
Vertical Live load 100kg/m2 (20 PSF)
Point Load 90 kg (200 lb)
Impact up to Eight Feet 360kg (800 lb)
Tension 105 kg/cm2 (1500 PSI)
3. All simulated Rockwork tunnels, overhangs, etc., shall be designed
and calculated to support the dead loads and lateral loads for their
intended uses.
4. Conform to the applicable provisions of Codes and Laws. The
Contractor’s Engineer is to provide field reconnaissance sufficient to
ensure that the work is safely and properly performed.
5. Maintain records at the job site of the Engineer’s services.
6. Calculations, drawings and records are to bear the seal and the
signature of the Contractor’s Engineer.
7. Upon completion of all the engineering services, the Contractor’s
Engineer is to prepare and submit all forms and reports required by
the Building Code for inspection of work covered by the engineering
services.
8. Refer to drawings for additional information.
9. All safety connections and anchoring devices shall meet the above
loads with a minimum safety factor 2.5. Water pools constructed of
Cast Rockwork shall be designed to support the water in addition to
all other live loads.
10. Spanning and Supports : All Cast Rockwork panels shall be
designed to span a minimum of 0.75 M horizontal distance;
unsupported and fully loaded.

1.6 SUBMITTALS

A. Provide submittals in accordance with the submittals Section of the

Architect’s specifications.
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B. Submittals :

1. Shop Drawings : Provide shop drawings showing location, size, and related
details of Rockwork for review. Shop drawings are to include the
following:

a. Cast Rockwork layout plans, sections, and elevations.

b. Foundations, framing, elevations and engineered structural drawings
of all artificial rock and edges, including details and structural
connection methods.
c. Construction details, typical connections to framing or supports,
footings, walls, all edge conditions and panel joints.
d. Cast Rockwork support, connections and anchors : Provide
information and data on the proposed system of support, connections
and methods of anchoring Cast Rockwork. Information shall be in
the form of drawings. The following situations shall be explained :
(1) Secondary structural support systems.
(2) Structural connection or method of anchoring Cast Rockwork
to the walls and slabs.
(3) Method of anchoring Cast Rockwork on horizontal surfaces
or supports and on surfaces or supports. Each substrate or
support material shall have its method of attachment detailed.
(4) Detail and method of making water tight connections for both
vertical and horizontal surfaces in Cast Rockwork as
appropriate.
(5) Method and materials of coloring and approval of color
selection shall be made prior to start of work based on the job
site mock-up.
e. Waterproofing detail for streams, waterfalls and planting
pockets/beds. Indicate products to be used and method(s) of
application.
f. Latex stains and paints, additives, thinners carriers and penetrating
agents. Provide color samples for review by the Architect/Owner.

(1) Field Samples : Provide field sample panels indicating each

texture and color.
(2) Samples and Mock-Ups:

g. Provide completed mock-up examples of the proposed Rockwork.

This sample area shall indicate the final appearance, texture and
coloring. These samples shall be approved by the Architect/Owner
prior to the installation of the Rockwork. The approval installed
mock-up shall serve as a standard of quality for the Rockwork and if
acceptable may become a permanent part of the work.
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h. Individual samples shall be a minimum of (1.25 X 1.25 M (4’ x 4’)

unless other wise permitted by the Owner. Mock-up shall be a
minimum of 1.5 X 3.0 M (5’ x 10’).
i. Construct a sample 1.25 M(4’) long section of a typical stream bed
and edge condition, using the same techniques and materials as the
final construction. Upon approval, the approved sample section
shall serve as the standard for stream construction.

1.07 PRODUCT HANDLING

Coordinate the delivery and installation schedule. Do not deliver materials unduly long
before they are required in the Work.

A. Transport, store and handle Cast Rockwork and accessories in a manner that
will prevent damage or deformation. Replace damaged materials. Store
Cast Rockwork clear of the ground and protect.

B. Delivery, Storage and Handling :

1. Deliver products to site in sealed and labeled containers; inspect to

verify acceptance.
2. Store paint materials within minimum and maximum ambient
temperatures required by manufacturer’s instructions.
3. Take precautionary measures to prevent fire hazards and
spontaneous combustion.

C. Environmental Requirements :

1. Provide continuous ventilation and heating facilities to maintain

surface and ambient temperatures for application time period
required by manufacturer’s instructions.
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PART 2. – PRODUCTS

2.1 MATERIALS

A. Glass Fiber Reinforced Concrete (GFRC) Artificial Rock Panels:

Cement/aggregate slurry panels reinforced throughout with chopped glass
fibres. Cast from molds. The average panels will vary in size from 0.5 M x
0.5 M to 0.8 M x 0.8 M.

1. Cement : ASTM C150, Type I or Type II.

2. Sand : ASTM C144 washed silica sand passing a U.S. No. 20 sieve.
3. Glass Fibers : Alkali-resistant (AR) fiber specifically designed for
use in concrete and chopped to 25 to 50 mm (1 to 2”) lengths.
4. Thickness of the Cast Rockwork panels : Minimum of 20 mm
arranging to 50 mm depending on the face configuration.

B. Embossing Mortar : Site mixed cement/aggregate meeting the same criteria

as above, but omitting glass fibres; for filling the irregular voids between
mold-cast panels.

C. Secondary Support : Steel angles fixed on to retaining walls and welded on

site to form the profiles. Angles then coated with sea water resistant epoxy
primer and paint as per manufacturer’s recommendation.

D. Finished Rockwork to meet the following minimum requirements :

1. Flame spread shall meet ASTM E-84 (tunnel test) 25 or less.

2. Smoke development index of 450 or less.
3. All connections and anchoring devices shall meet the structural load
requirements.

E. Coloring Agents : All exposed Rockwork construction shall receive a finish

coloring in the areas visible.

1. Latex based stains and paints with approved additives, thinners,

carriers and penetrating agents.
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PART 3. – EXECUTION

3.01 INSPECTION

A. Prior to commencing Work of this Section, carefully inspect the existing

conditions and installed work of other trades and verify that all such work is
complete to the point where installation may properly commence.

B. In the event of discrepancy, do not proceed with installation in areas of

discrepancy until all such discrepancies have been resolved.

3.02 INSTALLATION

A. Provide secondary structural support as required.

B. Provide anchors, bolts or other built-in items as indicated and required.

C. Provide all anchor bolts and other items required to be embedded into
related and/or surrounding work.

D. Grout solid behind all waterfall & water course areas.

E. Grout solid behind panels below water level, to a height of approximately

18 cm above water line.

F. Finish surface of the Rockwork must meet the standards established by the
approved samples and mock-ups. If the finished surfaces do not meet the
approved sample installation, the material shall be removed and replaced
with new material which meets the approved sample.

G. No changes in the construction method from that used on the approved

sample will be permitted unless approved in writing by the Architect.

H. All voids behind the Rockwork shall be vented as required. All vent
openings shall have a bird screen and shall be placed in locations where they
are not visible to visitors and which will not allow run-off water or debris to
enter any cavities behind or under the Rockwork in exterior areas.

3.03 CLEAN-UP

A. Maintain the site in a neat and orderly condition. Upon completion of this
work, remove from the jobsite all debris, refuse, and equipment arising from
the work of this Section.
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3.04 PROTECTION

A. All work of this section shall be carried out in a manner that will prevent
damage to the building structures and finishes. Care shall be taken in the
handling of materials to prevent overloading of structural members and
slabs. No work may be constructed in such a way that loads are applied to
the building structure, unless so indicated, without prior written approval
from the Architect/Owner. Care shall be taken to prevent physical damage
to surrounding surfaces and to protect surrounding surfaces from overspray,
staining, etc. All damage caused to the building structure, surfaces, and
finishes shall be repaired to original condition without additional cost to the
Owner.

3.05 INSTRUCTION

A. Upon substantial completion and acceptance by the Owner, instruct the

Owner’s maintenance personnel in the proper maintenance of the installed
Rockwork and in the best use of the manual as a maintenance guide.

END OF SECTION