Prediction of in-situ block size distributions with reference to armourstone for breakwaters

Understanding a quarry in terms of its potential for breakwater construction materials presents a special challenge for the engineering geologist. Unlike blasting in aggregates and mining operations, optimisation of the extraction process has a focus on the potential for production of large blocks for armourstone. These blocks weighing many tonnes are used for cover layers to resist wave action. The quarry-run is used for breakwater core. If the quarry has been developed as a source of materials dedicated to a breakwater construction project, the success of the project depends greatly on the blasting and production of rock sizes that are required and the avoidance of leaving a massive quantity of unused materials behind in the quarry after project completion. Prediction of in-situ block sizes such as from joint spacing data, provides the most critical input for the prediction of the blast pile block size distribution (BBSD), which in turn is a vital early design input if the constructed breakwater is to be economical as well as effective.This paper is part of a series of papers that introduces the coastal engineering motivation for this work on engineering geology, giving reasons why the prediction of the fragmentation curve of the blast products in a dedicated quarry is of such economic importance for breakwater projects. The first step towards blasted block size distribution (BBSD) prediction is the prediction of the in-situ block sized distribution (IBSD), the main subject of this paper. Drawing together research methods from the 1990s and the rock mechanics principles of discontinuity analysis, a practical step by step methodology for IBSD assessment that includes approaches that are not reliant on specialised computer software is presented. Continuing on the practical theme, a new extension of the volumetric joint count approach is suggested for IBSD prediction for the case when sparse borehole data is all that is available. A case study of IBSD assessment and the associated BBSD and blast assessment is presented from a Carboniferous limestone quarry. For clarity, details of blast design and yield curve prediction that are recommended for use in the context of armourstone production, have been presented in a companion paper. The Rosin-Rammler equation is used as an example form for the BBSD prediction of a dedicated quarry and the potential for breakwater project optimisation is illustrated. The final section sets out a method for directly comparing yield curves together with the demand for materials set by the breakwater design. On the same plot, sizes where there is a relative shortfall in production can be identified. The dependence of effective breakwater design on accurate quarry yield prediction and quarry blasting performance is discussed.