Geobrugg GBE-3000A User manual

European Technical
Assessment ETA–10/0084
ETAG 027: Category A
Energy Class 6: 3000 kJ
Height: 5 –6 m
Date: 27.09.2016
Edition: 164-N-FO / 15
Associated test institute:
Federal research institution WSL
Birmensdorf, Switzerland
© Geobrugg AG
CH-8590 Romanshorn
PRODUCT MANUAL GBE-3000A

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PURPOSE AND STRUCTURE OF THE MANUAL
This system manual ensures that Geobrugg rockfall protection systems are manufactured free from defects in
accordance with the latest technology, that their range of applications is defined, their functional reliability is
ensured, and that the installation of the systems is carried out professionally and is also inspected.
See the appendix at the end of the manual for the system overview
The system manual is divided into the following sections:
Proof of quality assurance
Staking out
Assembly details
System overview / rope system
ISO 9001 certificate
This document does not claim to be exhaustive. The manual describes general standard applications and does
not take any project-specific parameters into account. Geobrugg cannot be held liable for any additional costs that
may be incurred in special cases. Please contact the manufacturer if anything is unclear. Geobrugg AG's General
Terms and Conditions of Contract apply.
RESPONSIBLE FOR CONTENT:
Geobrugg AG
Protection Systems
Aachstrasse 11
Postfach
CH-8590 Romanshorn, Switzerland
[email protected]
www.geobrugg.com
Romanshorn, September 27th 2016
(Stamp / legally-binding signatures)

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RANGE OF APPLICATION
The engineering of rockfall protection systems is based on detailed investigations by specialist engineering
companies, which take the following geotechnical aspects in particular into account to define the range of
applications:
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, formerly the Geobrugg Protection Systems division of Fatzer AG, Romanshorn, Switzerland, has
been certified with registration number CH-34372 in accordance with the quality management system
requirements (ISO 9001:2008) since August 22, 1995. The certification body is the SQS (Swiss Association for
Quality and Management Systems), which belongs to IQNet. The quality manual provides a complete
specification regarding how the individual system components (primary materials, third-party products, and
finished products) are to be comprehensively tested in order to rule out any deficiencies in quality. The relevant
certificates can be found in the appendix.
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" and Swiss Guidelne (FOEN) in Wa-
lenstadt, 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-3000A system is ETA –10/0084.
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 behavior 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 CONTENT
1HAZARD WARNINGS ......................................................................................................... 8
2TOOLS FOR INSTALLING ROCKFALL BARRIERS ............................................................. 9
3USE OF WIRE ROPE CLIPS.............................................................................................. 10
4STAKING OUT SUBJECT TO TERRAIN ........................................................................... 12
5STAKING-OUT GEOMETRY ............................................................................................. 14
6ROPE ANCHOR –INSTALLATION.................................................................................... 18
7ANCHORING OF THE BASE PLATE ................................................................................. 19
8PREPARATION OF THE NETS AND POSTS ..................................................................... 21
9CRANE OR HELICOPTER INSTALLATION....................................................................... 24
10 INSTALLING THE SUPERSTRUCTURE ........................................................................... 25
11 ASSEMBLY DETAILS ....................................................................................................... 27
12 ADDITIONAL SOLUTION TO THE STANDARD................................................................. 37
13 FINAL INSPECTION......................................................................................................... 38

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EXPLANATION OF SYMBOLS
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
1HAZARD 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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2TOOLS FOR INSTALLING ROCKFALL BARRIERS
STAKING-OUT WORK
Tape measure 30 to 50 m
Measure stick
5 red and white surveyor’s pegs
Inclinometer
Aerosol can
Small wooden or iron pegs (min. 3 pegs per field)
Hammer
Product manual
INSTALLATION WORK
Fork or ring wrench
Socket wrench with ratchet
Torque wrench, range 25-400 Nm (see specified tightening torque for wire rope
clips and anchor nuts)
Open-ended wrench for anchor nuts
Felco C16 or C112 wire rope cutter or equivalent; cutting capacity 12 mm
Motorized disk cutter or hammer wire rope cutter; cutting capacity 28 mm
Pliers, flat-nose pliers
2 mm galvanized wire rope strand or wire
Angle spirit level
Roll of adhesive tape
Rope clamp –small 8-16 mm / large 14-26 mm (at least 2)
At least 2 tension belts
Cable winch hoist, e.g. LUG-ALL®
Chain hoist or come-along, at least 1.5 tons (15 kN)
Auxiliary ropes

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t
e
3USE OF 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 ex-
ceed 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
attached directly next to the thimble. For loops without a thimble the length h
between 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 h
of 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) untill 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
CAUTION: Changeover of wire rope clips
Starting from fall 2016 we will deliver a new type of wire rope clip FF-C-450 type 1 class 1. To ensure correct
assembly please use the table below and the rope assembly drawings in the attachement of this manual.
Please use this document for installation of wire rope clips. The details contained in
the manuals are no longer correct.

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Wire rope
diameter
[mm]
Size
of the
wire rope clip
Required
amount of
wire rope clips
Required
tightening
torque
lubricated
[Nm]
Required
tightening
torque
unlubricated
[Nm]
Wrench
size
[mm]
3 - 4
1/8‘‘
2
4
8
10
6 - 7
1/4‘‘
2
10
25
15
8
5/16“
3
20
50
18
9 - 10
3/8“
3
30
75
19
11 - 12
7/16“
3
40
110
22
14 - 15
9/16“
3
50
150
24
16
5/8“
3
90
170
24
18 - 20
3/4‘‘
4
90
180
27
22
7/8“
4
150
330
32
22 GEOBINEX
7/8“
5
150
330
32
A visible contusion of the wire ropes
positively indicates that the wire rope
clips have been tightenend to the
required tightening torque.
Wire rope clips always have to be installed and used with the required tensioning torque. It is not allowed
to re-use clips once they have been detached.
After the first load application the tightening torque has to be checked and if
not fulfilled adjusted to the required value.

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4STAKING OUT SUBJECT TO TERRAIN
GENERAL PRINCIPLES FOR STAKING OUT
Position of the barrier
Established simulation programs are available for calculating the optimum position of the barrier. Unfavorable
locations with excessive bounce heights or shadows are identified.
Barrier line
The barrier line must be designed so that it is as straight and horizontal as possible. An irregular course as well
as depressions and cambers in the terrain between the posts must be avoided or corrected wherever possible.
Placing the foundations
The baseplate support of the foundation must be designed based on the terrain so that the lower support rope
remains close to the ground.
The baseplate must be positioned in such a way that the lower support rope is routed past the edges of the
foundations without being damaged by them.

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Height differences in the barrier line
h: Barrier height
x: Distance between posts
n: Adjustment of the net lengths
h: Height difference between two adjacent posts


Tab. 2
Post distance
6-8 m
8-10 m
10-12 m
h
< 0.50m
< 1.00m
< 1.50m
No adjustment necessary
h
> 0.50m
> 1.00m
> 1.50m
Net must be adjusted
If the height difference is greater than in Tab.2 you must contact Geobrugg to enable the correct length
of nets to be determined.
h
h
x

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5STAKING-OUT GEOMETRY
GENERAL PRINCIPLES FOR STAKING-OUT GEOMETRY
Standard staking-out dimensions
If the standard staking-out dimensions shown on the following pages and their dimensional tolerances are
adhered to, the supplied barrier can be installed without any problems and every component will function correctly
should a rockfall event occur.
Adapting to the terrain
The type of terrain may mean that it is not possible to adhere to the standard staking-out parameters. Making a
number of small adjustments relating to the cross-section or length of nets, ropes, or posts, etc. will ensure that
the barrier will function correctly in these cases too.
Informing Geobrugg about the deviations enables you to work together to quickly find a solution that is
adapted to your requirements.
1)
5)
3)
4)
2)
1)
Rope anchor
Lateral rope
2)
Change in direction towards the
mountain
Valley-side anchoring
3)
Intermediate anchor rope
with support rope separation
4)
Change in direction towards
the valley
Mountain-side anchoring
5)
Intermediate anchor
rope
without support rope
separation

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STANDARD STAKING-OUT PARAMETERS FOR A STRAIGHT BARRIER LINE
a
x
x/2
c
d
A
C
D
x/2
The table below is valid for slopes of 30°- 90°.
Dimensions in m; Dimensional tolerance ± 0,20 m
h
a
c
d 1)
e
4.00
6.00
1.30
6.80
2.00
5.00
7.50
1.65
8.50
2.50
6.00
9.00
2.00
10.20
3.00
In a ground slope of less than 30°, the distance between the retaining rope
is to be adapted.
Length
h: Barrier height
x: Post distance
a: see Tab.3
c: see Tab.3
d: see Tab.3
Anchor point
A: Top support rope
B: Bottom support rope
C: Lateral rope
D: Retaining rope
1)
Tab. 3
0°- 29°
d
e
D
Length
d: see Tab.3
e: see Tab.3
Anchor point
D: Retaining rope
T: downslope anchor
rope
1.5 m
B
h
T

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CHANGE IN DIRECTION TOWARDS THE MOUNTAIN
In the case of a change in direction towards the mountain at an angle of 5° - 15°, valley-side anchoring (T) is
additionally required. The rope anchor will be positioned on the valley side at the distance (e) from the post.
The valley-side anchoring has a diameter of d = 22 mm GEOBINEX.
INTERMEDIATE ROPE SUSPENSION
SEILANKER FÜR TRAGSEILTRENNUNG MIT ZWISCHENABSPANNUNG
e
T
x/2
5°<y<15°1)
x/2
x
2)
Length
e: see Tab.3
x: post distance
y: angle of change in
direction
Anchor point
T: valley side
anchoring
In the case of a change in direction towards the mountain of more than
15°, an intermediate anchor rope must be installed and the valley-side
anchoring is omitted.
5)
Length
a: see Tab.3
c: see Tab.3
y: change in direction
Anchor point
Z: intermediate
suspension
15°<y<25°
a
a
Z
Z
c
c

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ROPE ANCHORS FOR SUPPORT ROPE SEPARATION WITH INTERMEDIATE ANCHOR ROPE
A support rope separation also contains an intermediate anchor rope. In straightforward terrain conditions and
when using appropriate equipment, we recommend positioning a support rope separation after approx. 80 m –
100 m.
Note: In the case of changes in direction towards the mountain of more than 25°, support rope separation
must also be positioned for the intermediate anchor rope.
CHANGE IN DIRECTION TOWARDS THE VALLEY
In the case of a change in direction towards the valley of more than 30°, two additional retaining ropes (D) are
mounted on the post. The change in direction towards the valley must not exceed 40°.
c
a
a
Z B
B Z
30°<y<40°
d
D
D
4)
Length
d: see Tab.3
y: change in direction
Anchor point
D: Retaining rope
Length
a: see Tab.3
c: see Tab.3
Anchor point
B: bottom support rope
Z: intermediate
suspension
3)
1.5m

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6ROPE ANCHOR –INSTALLATION
The post angle is dependent on the terrain slope, see table 4.
For a slope inclination with < 30° und > 45° small adjustments may be made with respect to the
stakeout such as length of the retaining ropes, angle between retaining rope and post inclination of the
ground plate, etc.
The anchor holes are drilled in the pulling direction, with a minimum angle of > 15° to the horizontal.
Example: foundation with flexhead anchor



=75
>15°
>35°
D
T
ß
Ω
0°-30°
15°
32°
17°
34°
19°
36°
21°
38°
23°
40°
25°
42°
27°
44°
29°
45°
30°
: The angle must be between 60° - 85°.
: The angle between slope and post is 75°
as standard.
Tab. 4
d
e
The anchors 01 are horizontal when
mortared up to the marking and insert into
the anchor hole.
In use of rod anchors with flex head the foundation 03 must
be designed with reinforcement 02 against the shear forces.
01
02
03
15°

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7ANCHORING OF THE BASE PLATE
SOIL:
Base plate inclined 0° –30° from horizontal
Drill the anchor holes (vertical and 45° inclined to the base
plate)
Prepare foundation 111; dimension and reinforcement of the
concrete foundation 111 is set by the project engineer
(reccomendation Geobrugg: 0.6 x 0.5 x 0.2 m)
Insert anchor 05, washer plate 09 und nuts 10, the
calculation of the anchor length is set by the project engineer
Optional: stabilization tube 04 for vertical anchor
Important: Washer plates und nuts must be installed on
both sides of the base plate 29
Grout the anchor 05 in soil 110
Pour concrete foundation 111
Fasten the nuts 10 until an initial tensile force of approx.
30 kN is reached
CONCRETE:
For all types of soil and rock
Excavate foundation pit 111
Drill the holes for tie back anchoring 07, the calculation of the
anchor length is set by the project engineer
Prepare concrete foundation 111 dimension and
reinforcement of the concrete foundation 111 is set by the
project engineer
Grout tie back anchoring 07 with nuts 10 and washer plates
09
Install both anchors 08 with help of the base plate 29, washer
plates und nuts must be installed on both sides of the base
plate 29;
Length of anchor 08 = 500 mm
Pour concrete foundation 111
Fasten the nuts 10 until an initial
tensile force of approx. 30 kN is reached
09,10
09,10
04,05
110
29
0.2 m
0.5 m
0.6 m
09,10
05
111
07
07
29
09,10
111
09,10
09,10
08

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ROCK:
Level the rock 0° - 30° from horizontal underneath the base
plate 29
Drill into rock 112 the two holes perpendicular to the base
plate 29
Grout in the anchors 08, the calculation of the anchor length
is set by the project engineer
A thin leveling layer ensure a stable placement of the base
plate
Position base plate 29 into leveling layer
Fasten the nuts 10 until an initial tensile force of approx. 30
kN is reached
Tightening torque for nuts to reach an initial tensile force of approx. 30 kN:
Swiss Gewi NG 28
Swiss Gewi NG 32
Tightening torque
400 Nm
400 Nm
Frost and icing-salt resisant mortar has to be used
Reinforcement: 12 mm-rod diameter in distance of 150 mm
If requestet a drilling template can be supplied.
It is important to ensure that the anchors have sufficient contact with the mortar and make good bond,
and a sufficient area to the surrounding material.
Further information about the anchoring of the base plate can be found on the anchor forces date sheet.
The forces generated in a rockfall event are not to be underestimated. The civil engineering and
installation work are therefor the be expertly.
08
29
09,10
112
09,10