Geobrugg VX Series User manual

Attending testing institute:
Swiss Federal Institute for
Forest, Snow and Landscape
Research WSL
Birmensdorf, Switzerland
Date: 07/11/2016
Edition: 164-N-FO / 05
© Geobrugg AG
8590 Romanshorn,
Switzerland
Product Manual
VX/UX
Debris Flow Barriers

Product Manual VX/UX
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© Geobrugg AG, Switzerland
Purpose and organization of the manual
This product manual ensures that Geobrugg debris flow protection systems are manufactured free from
defects in accordance with the latest technology and that the range of applications is clearly defined, the
functional efficiency is given, and the installation of the system is professionally carried out and controlled.
The product manual is divided in the following sections:
 Proof of quality assurance / verification of conformity
 Classification of debris flow barrier systems
 Installation manual
 Input parameter for barrier design
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 incurred for special cases. In case of uncertainties, please contact the manufacturer. The General
Sales Conditions of Geobrugg AG are applicable.
Responsible for the content of this manual:
Geobrugg AG
Aachstrasse 11
Postfach
CH-8590 Romanshorn / Switzerland
E-Mail [email protected]m
Romanshorn, 07.11.2016
(stamp / authorized signatures)

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© Geobrugg AG, Switzerland
I Range of application
The design of debris flow protection systems is based on detailed investigations by specialized engineering
firms, particularly taking into account the following geotechnical aspects to define the range of possible
applications:
 Former debris flow events
 Catchment area (condition of soil, inclination, size)
 Estimated rainfall intensity
 Debris flow input parameter (volume of decisive surge and total volume, density, middle front velocity)
 Composition of debris flow (debris fraction, water content, density)
 Probability of occurrence
 Calculation of decisive load cases
 Barrier location (Consideration of local topography)
 Anchorage conditions
II Quality of the system components
Geobrugg AG is certified under the registration no. 34372 in accordance with the Quality Management
Systems Requirements (ISO 9001: 2015). The certifying body is the Swiss Association for Quality and
Management Systems (SQS), which belongs to IQNet. The quality manual completely specifies how to test
the system components (raw material, commercial and end products) comprehensively in order to exclude
deficiencies in quality. The relevant certificates are attached as appendices.
III Functional efficiency of the barrier systems
The functional efficiency of the system is based on one-to-one field tests at the Illgraben test site (Canton
VS, Switzerland). The tested barriers could retain a volume of 700 m3 in 2005 and 1'000 m3 in 2006 and
were overtopped with several debris flows with more than 10.000 m3 of material. Important input parameters
could be measured like debris flow velocity, density, flow height and impact forces and helped to develop
a full design concept.
IV Quality control for installation
This product manual describes in detail the different steps for installation of the barriers. These steps must
be faithfully followed by local building contractors.

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© Geobrugg AG, Switzerland
V Product liability
Rockfall, landslides, debris flows or avalanches are sporadic and unpredictable. The cause is human (build-
ings, 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 apply good engineering practices, and by using predictable parameters along with the corresponding
implementation 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 pollution 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
recommendations 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 standard barrier.

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© Geobrugg AG, Switzerland
Contents
I Range of application ......................................................................................................................... 3
II Quality of the system components ................................................................................................. 3
III Functional efficiency of the barrier systems .................................................................................. 3
IV Quality control for installation ......................................................................................................... 3
V Product liability ................................................................................................................................. 4
1 Introduction ....................................................................................................................................... 6
1.1 Validity of installation instructions ....................................................................................................... 6
1.2 Construction ........................................................................................................................................ 6
1.3 System drawing of the rope guiding for UX/VX systems .................................................................... 9
1.4 Anchor forces .................................................................................................................................... 10
2 Installation of the barrier ................................................................................................................ 10
2.1 Installation steps for UX - barriers ..................................................................................................... 10
2.2 Recommended installation tools ....................................................................................................... 11
2.3 Use of wire rope clips ........................................................................................................................ 12
3 Anchorages ...................................................................................................................................... 14
3.1 Marking of the anchorage locations .................................................................................................. 14
3.2 Position of the anchors for the retaining ropes ................................................................................. 15
3.3 Anchorage of the post foundation ..................................................................................................... 17
3.4 Post foundation ................................................................................................................................. 18
3.5 Anchorage of the support and retaining ropes .................................................................................. 19
3.6 Arrangement of flexible heads .......................................................................................................... 20
4 Superstructure ................................................................................................................................. 21
4.1 Installation of the posts, support and retaining ropes ....................................................................... 21
4.2 Installation of the ring net .................................................................................................................. 23
4.3 Installation of the abrasion protection ............................................................................................... 25
5 Final inspection ............................................................................................................................... 26
6 Service and Maintenance ............................................................................................................... 27
6.1 Accessibility ....................................................................................................................................... 27
6.2 Regular inspection ............................................................................................................................. 27
6.3 Inspection after events ...................................................................................................................... 28
6.4 Criteria for servicing .......................................................................................................................... 28
6.5 Tools for debris flow barrier maintenance ......................................................................................... 31
6.6 Emptying and clearing out the barriers ............................................................................................. 31
7 Standard system drawings ............................................................................................................ 33
8 Input values for barrier dimensioning........................................................................................... 34
9 Maintenance form for field inspection .......................................................................................... 36

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© Geobrugg AG, Switzerland
1 Introduction
1.1 Validity of installation instructions
This installation manual is valuable for Geobruggs VX/UX Systems up to a debris pressure of
180 kN/m/hfl. If the expected debris pressure is more than 180 kN/m/hfl, contact Geobrugg AG for a possi-
ble solution.
1.2 Construction
The debris flow barrier system consists of the following components:
 ROCCO®- ring net
The ROCCO ring net is the main element of the system and
consists of high-tensile wire with a tensile strength of 1770
N/mm2 and a diameter of 3 mm. Different types are used in
the debris flow systems according to their design resistance.
 Support and retaining ropes
The job of the support ropes is to transmit the forces occurring
in the net over the posts to the anchors.
 Abrasion protection
The abrasion protection protects the upper support ropes from
abrasion if the barrier is completely filled and gets overtopped.

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© Geobrugg AG, Switzerland
 Spiral rope anchor
The support and retaining ropes are anchored in the soil or
rock by means of Geobrugg spiral rope anchors.
Alternative self drilling anchors (for example Typ Titan or IBO)
can be use. The spiral rope anchors are equipped with a flex-
ible head, which ensures that forces not working directly in the
pulling direction can also be transmitted. Two galvanized
tubes over the anchor head, plus the galvanized spiral rope,
provide double corrosion protection.
 Brake rings
The task of the built-in Geobrugg brake elements (brake rings)
is to dissipate energy via plastic deformation and friction, and
to protect the support ropes from overload. The steel tubes
also protect the rope from corrosion and mechanical damage.
 Base plate
The base plates are the base for the posts and are either set
on a concrete foundation. The concrete foundation is fixed
with tension and pressure anchors in the ground of the torrent.
The posts are hinged on the plates. All elements that come in
contact with the ropes are finished without sharp edges to
avoid rope damage.
 Hinged post
The posts have the function to keep the system height after
filling the barrier. HEB type steel posts are used. The rope
guides at the post head are finished without sharp edges to
protect the ropes. The posts are held in position with the help
of retaining ropes. The order in which the ropes are arranged
on the post head corresponds to the installation sequence.

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© Geobrugg AG, Switzerland
 Shackles
The connections between the ring net and the ropes are made
with shackles. They guarantee that the net can slide on the
rope without damaging it. The nets are also connected verti-
cally with shackles. In general, the shackles are designed to
produce the stronger connection than the net itself. The
shackles can be bonded with adhesive (e.g., with Loctite) if
they are required to be theft-proof.
 Wire rope clips
The ropes are delivered with pressed loops on one side of the
rope. The free end has to be fixed with wire rope clips accord-
ing to EN 13411-5 (DIN 1142). It is very important to use the
right number of wire rope clips with the required torque values.
The wire rope clips can be bonded with adhesive (e.g., with
Loctite) if they are required to be theft-proof.

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© Geobrugg AG, Switzerland
1.3 System drawing of the rope guiding for UX/VX systems
The end of the ropes with pressed loops is fixed with shackles at the flexible head of the anchors. On the
other side the ropes will be spanned and fixed with wire rope clips. In the same way also the winglet rope
is installed. With shackles it is additional fixed to the upper support rope. The border rope is fixed to the
flexible head of the winglet rope and will be guided through every flexible head down to the lowest anchor-
age of the bottom rope and will be fixed with wire rope clips.
System drawing VX
System drawing UX
Upper support rope
Bottom support ropes
Border rope
Winglet rope
Middle support rope
Winglet rope
Middle support ropes Upper support ropes
Lower support ropes
Posts
Abrasion protection
Abrasion protection

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© Geobrugg AG, Switzerland
1.4 Anchor forces
The force caused by a debris flow can be very high. Therefore the underground engineering and installation
work has to be done precise and accurate. The length of the anchors is based on the measured rope forces
of the 1:1 field tests and depending on the quality and soil bearing capacity.
2 Installation of the barrier
2.1 Installation steps for UX - barriers
The step by step installation is divided in the following topics. The detailed steps are described in each
chapter. The manual describes the installation of UX barriers including posts. The installation of VX barriers
without posts are accordingly, without the described steps to install the posts, base plates and retaining
ropes.
Preliminary work Chapter 3
 Site preparing
 Stake out the anchor positions
Foundation construction Chapter 3
 Drilling of the anchors and injecting
 If self drilling anchors are used, the flexible heads have to be fixed to the anchors
 Construction of the post fundaments
 Place the base plates on the anchors
Construction of the superstructure Chapter 4
 Fix the upper ropes to the anchors and pull them by a chain hoist or Habegger. Same installation
approach has to be done with the winglet rope. Support ropes have not to be tensioned yet.
 Place the posts
 Tension the retaining ropes
 Tension the upper support ropes. If there are several ropes hold them together with a shackle.
 Tension the winglet ropes. The winglet ropes are fixed with shackles to the upper ropes.
 Loop and tension the border ropes
 Tension the lower ropes. If there are several ropes hold them together with a shackle.
 Clamp the ring net to the upper ropes
 Connect the net panels together with shackles
 Clamp the net to the bottom ropes with shackles
 Installation of the middle support ropes. If there are several ropes hold them together with a shackle.
 Installation of the abrasion protection with a crane, chain hoist or helicopter. It is fixed to the upper
support and the winglet ropes with the welded shackles.