Geobrugg GBE-500A-R User manual

European Technical
Approval ETA–11/0034
ETAG 27: Category A
Energy class: 500 kJ
Height: 3 - 3.5 m
Date: 28.10.2016
Issue: 156-N-FO / 13
Associated test institute:
Eidg. Forschungsanstalt WSL
Birmensdorf, Switzerland
This manual is not
subject to change.
© Geobrugg AG
CH-8590 Romanshorn, Switzerland
GBE-500A-R PRODUCT MANUAL

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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 ac-
cordance with the latest technology, that their range of applications is defined, their functional reliability is en-
sured, 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, October 28th, 2016
(Stamp / legally-binding 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, 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 require-
ments (ISO 9001: 2000 rev. 2007) since August 22, 1995. The certification body is the SQS (Swiss Association
for Quality and Management Systems), which belongs to IQNet 9000. The quality manual provides a complete
specification regarding how the individual system components (primary materials, third-party products, and fin-
ished products) are to be comprehensively tested in order to rule out any deficiencies in quality. The relevant cer-
tificates 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" 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 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 CONTENTS
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
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................................................................. 33
12 FINAL INSPECTION......................................................................................................... 34

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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
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
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
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) until the required tightening torque is
reached.
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.
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