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

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Wire rope di-
ameter
[mm]
Size
of the
wire rope clip
Required
amount of
wire rope clips
Required
tightening
torque lubricat-
ed
[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 pos-
itively indicates that the wire rope clips
have been tightened to the required tight-
ening 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 lo-
cations 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 for the foundation must be designed based on the terrain so that the lower support rope
remains close to the ground.
The foundations must be placed in such a way that the lower support rope is routed past the edges of the founda-
tions 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
h< 2 m : No adjustment necessary
h> 2 m : Height difference outside standard staking-out parameters. Net must be adjusted
The standard net length is acceptable up to a height difference in the barrier line of 2 m and if the distance be-
tween the posts is between 6 m and 12 m.
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 ad-
hered 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)
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
1)
5)
3)
4)
2)

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STANDARD STAKING-OUT PARAMETERS FOR A STRAIGHT BARRIER LINE
ANCHOR POINT FOR INTERMEDIATE ANCHOR ROPE
a
x
c
A
B,C
c
a
a
Z
Z
The table below is valid for slopes of 30°- 90°.
Dimensions in m; Dimensional tolerance ± 0.20 m
h
a
c
e
2.00
3.00
0.65
1.00
3.00
4.50
1.00
1.50
3,50
5,30
1,15
1,75
4.00
6.00
1.30
2.00
Length
h: Barrier height
x: Distance between
posts
a: see Tab.3
c: see Tab.3
Anchor point
A: Upper support rope
B: Lower support rope
C: Lateral rope
1)
Tab. 3
Length
a: see Tab.3
c: see Tab.3
Anchor point
Z: intermediate
suspension

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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 ad-
ditionally 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 = 14 mm.
e
T
5°<y<15°1)
x
2)
INTERMEDIATE ANCHOR ROPE
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.
Length
e: See Tab. 2
x: Distance between
posts
y: Angle of change in
direction
Anchor point
T: Valley-side
anchoring
5)
Length
a: see Tab.3
c: see Tab.3
y: angle of 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
B,Z
B,Z
30°<y<40°
a
Length
a: See Tab.3
c: See Tab.3
Anchor point
B: Lower support
rope
Z: Intermediate
anchor rope
3)
4)
Length
a: see Tab.3
y: angle of change i
direction
Anchor point
Z: intermediate suspension
Z
Z

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6ANCHORING THE BASEPLATE
Soil:
Baseplate inclined 0-30° from the horizontal
Bore hole for main anchor 0-30° from the vertical
Optional: Install the stabilization tube 04
Install main anchor 05, support plate 09, and fastening nuts
10
Cement the main anchor into the loose rock 110, length is
variable
Optional: Lightly reinforced head foundation 111
Bore the retaining anchor 06 by hand, use the baseplate
as a template. Length is L = 1000 mm
Concrete
The dimension and the reinforcement of the foundation 111
is given by the project engineer.
Install both anchors 08 using a template.
Grout the concrete foundation
Concrete / rock:
Taper the ground around the baseplate to 0-30° from the
horizontal
Bore both holes for the anchor rods into the rock 112 vertical-
ly to the baseplate
Cement the rock anchor 08, length is variable
Place the baseplate in the bed of cement
Tighten the fastening nuts once the cement has fully
cured
The anchor length must be adapted to the environmental
conditions
111
09,10
04,05,09,10
110
112

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The forces generated during a rockfall event are not to be underestimated. The civil engineering and in-
stallation work must therefore be completed professionally.
Cement that is resistant to de-icing salt must be used.
Reinforcement: 12-mm steel diameter at a distance of 150 mm
You must ensure that the anchors have sufficient contact with the cement, produce a strong structure,
and have a sufficient lateral surface to the surrounding material.
The anchor holes are bored in the direction of movement at a minimum gradient of > 15° from the horizontal.
Example:
A reinforced concrete foundation with the
dimensions indicated opposite is recommended
for soil.
2 bar anchors 05 with support plate 09and
fastening nuts 10
2 optional stabilization tubes 04
Baseplate with post 29
The manufacturer of "Swiss Gewi NG
28/32/40" bar anchors recommends that the
nuts are tightened to a torque of approx.
400 Nm, which corresponds to a preload
force of approx. 30 kN.
04
0.5 m
0.2 m
1.0 m
29
During cementing, the anchors 01 are to be
inserted into the borehole horizontally up to
the orange marker.
When using bar anchors with flex head inserts, the
foundations 03 must be installed with reinforcement 02 to
prevent shear forces.
01
02
03
15°

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A
33,87
83
67
76
42
39
7PREPARING THE POSTS AND NETS
PREPARING THE POSTS
33 1 pcs running wheel
39 2 pcs U-profiles as support rope guide
42 1 pcs TECCO mesh bundle
67 1 pcs lateral rope
76 1 pcs post head rope
83 2 pcs 5/8" shackles