Geobrugg GBE-500A-R User manual

European Technical
Assessment ETA 16/0329
ETAG 027: Category A
Energy class 2: ≥500 kJ
Height: 3 – 3.5 m
Associated test institute:
Swiss Federal Institute for
Forest, Snow and Landscape
Research WSL
Birmensdorf, Switzerland
Date: 08.10.2018
Edition: 15
© Geobrugg AG
CH-8590 Romanshorn
Product Manual
GBE-500A-R
ROCKFALL BARRIER

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PURPOSE AND ORGANIZATION OF THE MANUAL
This product manual ensures that Geobrugg Rockfall protection systems are manufactured free from defects in
accordance with the latest technology and that the range of applications is clearly defined, the functional efficien-
cy is given, and the installation of the system is professionally carried out and controlled.
For an overview of the system, see the appendix at the end of this manual
The product manual is divided into the following sections:
•Proof of quality assurance
•Installation manual
•System drawing / rope assembly drawing
•ISO 9001 certificate
No claims are made that this document is complete. The manual describes standard applications and does not
take into account project-specific parameters. Geobrugg cannot be held liable for any extra costs that may be in-
curred for special cases. In case of uncertainties, please contact the manufacturer. The General Sales Conditions
of Geobrugg AG are applicable.
RESPONSIBILITY FOR THE CONTENT:
Geobrugg AG
Protection Systems
Aachstrasse 11
PO Box
CH-8590 Romanshorn, Switzerland
[email protected]
www.geobrugg.com
Romanshorn, 08.10 2018
(Stamp / legally valid signatures)

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I RANGE OF APPLICATION
The engineering of rockfall protection systems is based on detailed investigations by specialist engineering com-
panies, which take the following geotechnical aspects in particular into account to define the range of applica-
tions:
•Previous rockfall events
•Condition of the rockfall breakout zone
•Assessment of the stability of the entire rockfall zone
•Frequency of rockfall
•Size of the rocks to be caught
•Trajectories and bounce heights of the rocks
•Calculations of the kinetic energy
•Barrier position (taking the local topography into account)
•Anchoring conditions
II QUALITY OF THE INDIVIDUAL SYSTEM COMPONENTS
Geobrugg AG, previously the Geobrugg Protection Systems department of Fatzer AG, based in Romanshorn,
Switzerland, has been certified to quality management system requirements (ISO 9001:2008) since August 22,
1995, registered under the number CH-34372. The certifying body is the SQS (the Swiss Association for Quality
and Management Systems), to which IQNet belongs. The Quality Manual provides complete information on how
individual system parts (primary material, commercial products and end products) must undergo extensive testing
to rule out insufficient quality.
III FUNCTIONAL RELIABILITY OF THE BARRIER SYSTEMS
The system's functional reliability is based on 1:1 rockfall tests, performed and tested in accordance with Europe-
an Technical Approval Guideline ETAG 027 "Falling Rock Protection Kits" in Walenstadt, SG (Switzerland). The
1:1 rockfall tests involve performing vertical impacts into the middle field of a three-field barrier, where the posts
are spaced at 10 m and an impact speed of at least 25 m/s is reached. The tests are accepted by a notified body
and receive an approval, known as an ETA (European Technical Approval). The approval no. of the GBE-500A-R
system is ETA –16/0329.
IV QUALITY CONTROL FOR INSTALLATION
This system manual provides a detailed description of how to design and install the barrier.

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V PRODUCT LIABILITY
Rockfall, landslides, debris flows or avalanches are sporadic and unpredictable. The cause is human (buildings,
etc.), for example, or forces beyond human control (weather, earthquakes, etc.). The multiplicity of factors that
may trigger such events means that guaranteeing the safety of persons and property is not an exact science.
However, the risks of injury and loss of property can be substantially reduced by appropriate calculations that ap-
ply good engineering practices, and by using predictable parameters along with the corresponding implementa-
tion of flawless protective measures in identified risk areas.
Monitoring and maintenance of such systems are an absolute requirement to ensure the desired safety level.
System safety can also be diminished through events, natural disasters, inadequate dimensioning or failure to
use standard components, systems and original parts, but also through corrosion (caused by environmental pollu-
tion or other man-made factors as well as other external influences).
In contrast to the one-to-one rockfall tests, which indeed test an extreme load case but still only demonstrate a
standardized situation, in the field the layout and design of a protection system can vary greatly because of the
topography. The influence of such alterations and adaptations cannot always be determined exactly. Critical
points are, for example, post spacing, changes in direction, placement angle of the rope anchor, and the direction
and velocity of impact.
Geobrugg can assist with estimating the influence of larger deviations and special situations, and can offer rec-
ommendations for feasible solutions. Geobrugg cannot, however, guarantee the same behaviour as in the one-to-
one rockfall tests. In critical cases, it is advisable to reinforce particular components as compared with the stand-
ard barrier.

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TABLE OF CONTENTS
1HAZARD WARNINGS ......................................................................................................... 8
2TOOLS FOR INSTALLING ROCKFALL BARRIERS ............................................................. 9
3USING THE WIRE ROPE CLIPS ....................................................................................... 10
4STAKING OUT SUBJECT TO TERRAIN ........................................................................... 12
5STAKING-OUT GEOMETRY ............................................................................................. 14
6ANCHORING THE BASEPLATE ....................................................................................... 18
7PREPARING THE POSTS AND NETS ............................................................................... 20
8CRANE OR HELICOPTER INSTALLATION ....................................................................... 23
9INSTALLING THE SUPERSTRUCTURE ........................................................................... 24
10 ASSEMBLY DETAILS ....................................................................................................... 26
11 ADDITIONAL SOLUTION TO THE STANDARD................................................................. 35
12 FINAL INSPECTION......................................................................................................... 36

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EXPLANATION OF SYMBOLS USED
Safety instruction: must be strictly observed
Note / reminder to enable system to be installed easily and correctly
Consultation with Geobrugg is recommended
Mountain-side
Valley-side
1 HAZARD WARNINGS
GROUP LEADER QUALIFICATIONS
Only a qualified group leader may be responsible for overseeing the installation.
ROPES UNDER TENSION
Ropes are under tension. During the installation and tensioning of the ropes, you must make sure that no
persons are present in the hazard area.
REMOVAL OF PARTS UNDER TENSION
The removal or separation of components under tension is to be avoided whenever possible. Should such
work be necessary, however, the utmost caution must be taken.

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2 TOOLS FOR INSTALLING ROCKFALL BARRIERS
STAKING-OUT WORK
•30 –50 m measuring tape
•Measure stick
•5 red and white ranging poles
•Inclinometer
•Spray can
•Wooden peg or iron peg (min. 3x for each field)
•Hammer/mallet
•Manual
INSTALLATION WORK
•Open-ended or ring wrench
•Socket wrench set with ratchet
•Torque wrench, range 25 –400 Nm (see tightening torque required for wire rope clips and base
plate fastening nuts)
•Open-ended wrench for base plate fastening nuts
•Felco C16 or C112 wire rope cutter or similar; 12 mm cutting capacity
•Cutting-Off wheel or hammer wire cutter; 28 mm cutting capacity
•pincers, flat-nose pliers
•2 mm galvanized wire strands or wire
•Angle spirit level
•Roll of adhesive tape
•Rope clamp, small 8 –16 mm / large 14 –26 mm (min. 2x)
•At least 2 tension belts
•Cable winch hoist, e.g. LUG-ALL®
•Chain hoist or HABEGGER wire rope hoist, min. 1.5 t (15 kN)
•Auxiliary ropes

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t
e
3 USING THE WIRE ROPE CLIPS
Instructions below apply to all wire rope clips according FF-C-450 type 1 class 1
(similar EN 13411-5 type 2) delivered by Geobrugg AG.
The distance ebetween the wire rope clips should be at least 1 x t but not exceed 2
x t , where tis the width of the clamping jaws. The loose rope end has to be 3 x e at
a minimum. Geobrugg recommends looping up the remaining free section and fixing
it directly behind the last wire rope clip on the tightened rope.
If you are using a thimble in the loop structure, the first wire rope clip must be at-
tached directly next to the thimble. For loops without a thimble the length hbetween
the first wire rope clip and the point of load incidence must minimally be 15-time the
nominal diameter of the rope. In unloaded condition the length hof the loop should
be not less than the double of the loop width h/2.
The clamping brackets (U-brackets) must always be fitted to the unstressed end of the rope, the clamping jaws
(saddle) must always be fitted to the strained rope („never saddle a dead horse“).
During tightening the nuts have to be tensioned equally (alternately) until the required tightening torque is
reached.
The required tightening torques with lubrication apply to wire rope clips whose
bearing surfaces and the threads of the nuts have been greased with Panolin CL
60 multipurpose lubricant spray (or an equivalent lubricant).
FF-C-450 type 1 class 1
min. 3 x e
h/2
h