Geobrugg Gbe-100a User manual

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European Technical

Assessments

ETA 17/0279

ETA 17/0283

ETAG 027: Category A

Energy class 0: ≥100 kJ

Installation height: 2 –3.5 m

Rockfall Protection Net /

Product –Data Sheet

Federal Office for the

Environment FOEN

Switzerland

Energy class 0: 100 kJ

Installation height: 2 –4.5 m

Attending testing institute:

Dynamic Test Center

Vauffelin / Biel, Switzerland

ISO 17025 accredited

ISO 9001 certified

Date: 08.10.2018

Edition: 06

CH-8590 Romanshorn

Product Manual

GBE-100A

ROCKFALL BARRIER

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Page 3/41

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FUNCTION AND STRUCTURE OF THE MANUAL

This product manual ensures that Geobrugg rockfall protection systems are manufactured without errors in ac-

cordance with the latest technical findings, that their area of application is clearly defined, that their functionality is

guaranteed, and that their installation is performed and checked properly.

The product manual is divided into the following parts:

•Proof of quality assurance

•System overview/rope guide

•Staking out

•Assembly details

•ISO 9001 certificate

This document does not claim to be exhaustive. Before starting an installation, it must be ensured that the copy of

the product manual is up-to-date. It is designed for general standard applications and does not take into account

any project-specific parameters. Geobrugg cannot be held liable for any additional costs which may arise in spe-

cial cases. If anything is unclear, please contact the manufacturer. Geobrugg AG's general terms and conditions

apply.

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 AREA OF APPLICATION

Rockfall protection systems are planned on the basis of detailed research carried out by specialist engineering

companies, which take the following geotechnical aspects into account and define the area of application accord-

ingly:

•Previous rockfall events

•Condition of the rockfall outbreak zone

•Assessment of the stability of the entire rockfall zone

•Frequency of rockfalls

•Size of the rocks collected

•Trajectories and displacements of the rocks

•Kinetic energy calculations

•Positioning of the barrier (taking the local topography into account)

•Anchoring conditions

II QUALITY OF THE SYSTEM COMPONENTS

Geobrugg AG, formerly the Geobrugg Schutzsysteme (Geobrugg Protection Systems) department of Fatzer AG,

Romanshorn, has been certified according to the quality management system requirements (ISO 9001:2008) un-

der the registration number CH-34372 since August 22nd, 1995. The certification center is the SQS (Swiss Asso-

ciation for Quality and Management Systems), which is a member of IQNet. The quality manual specifies in full

the way in which the individual system components (basic material, commercial products, and end products) are

checked extensively to eliminate poor quality. You can find the corresponding certificates in the appendix.

III FUNCTIONALITY OF THE BARRIER SYSTEMS

The system functionality is based on rockfall tests that replicate real-life conditions, performed in Walenstadt (SG),

Switzerland, in accordance with the European Guideline ETAG 027 “Falling Rock Protection Kits”. In the rockfall

tests under real-life conditions, the rocks are thrown vertically into the central field of a three-field barrier with a 10

m distance between the posts of each field. An impact speed of at least 25 m/s is achieved. These investigations

are inspected by notified testing centers and obtain European approval, known as ETA (European Technical As-

sessment), as well as a Swiss inspection certificate from the Federal Office for the Environment (FOEN). The cur-

rent system GBE-100A has the inspection certificate no. ETA 17/0279, ETA 17/0283 and Rockfall Protection Net /

Product –Data Sheet

Certificates

ETA

FOEN

Height [m]

2.0 / 2.5 / 3.0 / 3.5

2.0 / 2.5 / 3.0 / 3.5 / 4.0 / 4.5

IV QUALITY CONTROL FOR INSTALLATION

This product manual describes the planning and installation of barriers in detail.

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V PRODUCT LIABILITY

Rockfall, slipping, landslides, and avalanches occur sporadically and cannot be predicted. Causes range from

human activity (building work, etc.) right through to force majeure (weather, earthquakes, etc.). Due to the wide

variety of triggers for these events, it is not possible to develop a scientific approach that will guarantee the safety

of persons and property.

However, the risk of injury and loss of property can be significantly reduced by applying appropriate engineering

calculations using foreseeable parameters and by creating proper protection measures accordingly in specific risk

areas.

These systems must be monitored and maintained to ensure the required level of safety. This level of safety can

also be diminished through incidents, natural disasters, insufficient dimensioning, failure to use standard compo-

nents, systems, or original parts, and corrosion (caused by environmental pollution, other human factors, or other

external influences).

As a contrast to the rockfall tests under real-life conditions – which test a very tough load but only illustrate a

standardized situation – very different barrier arrangements and designs may arise in the field as a result of to-

pography. The impact of these modifications and adjustments cannot always be determined exactly. Critical

points include the distance between posts, changes in direction, the installation angles of the rope anchors, the

angle of impact, and the speed of impact.

Geobrugg is able to provide assistance when you are assessing the influence of significant anomalies and special

situations, and offer suggestions for feasible solutions. However, Geobrugg cannot guarantee consistent perfor-

mance of the type demonstrated in the rockfall tests under real-life conditions. In critical cases, it is advisable to

reinforce individual components against the standard barrier.

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CONTENTS

1HAZARD NOTES ................................................................................................................ 8

2TOOLS FOR INSTALLING ROCKFALL BARRIERS ............................................................. 9

3USING THE WIRE ROPE CLIPS ....................................................................................... 10

4STAKING-OUT IN ACCORDANCE WITH THE TERRAIN................................................... 12

5STAKING-OUT GEOMETRY ............................................................................................. 14

6INSTALLING THE ROPE ANCHOR................................................................................... 19

7ANCHORING THE BASE PLATE ...................................................................................... 20

8ASSEMBLY DETAILS ....................................................................................................... 24

9SUPPORT ROPE SEPARATION (SRS) WITH INTERMEDIAT SUSPENSION ..................... 34

10 ADDITIONAL SOLUTION TO THE STANDARD................................................................. 37

11 FINAL INSPECTION......................................................................................................... 38

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EXPLANATIONS OF THE SYMBOLS USED

Safety note: Must be followed

Note/reminder that will help you to install the system easily and correctly

Consultation with Geobrugg is recommended

Upslope

Downslope

1 HAZARD NOTES

QUALIFICATION OF THE GROUP LEADER

Only a qualified group leader may be put in charge of the installation.

TENSIONED ROPES

Ropes will be tensioned. When installing and pretensioning ropes, ensure that there are no persons with-

in in the danger area.

RELEASING TENSIONED PARTS

Releasing or separating tensioned parts should be avoided wherever possible. If this is necessary, how-

ever, please exercise the utmost caution.

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2 TOOLS FOR INSTALLING ROCKFALL BARRIERS

STAKING-OUT WORK

•30 – 50 m measuring tape

•Folding meter 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

•Motor cutting disc 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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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

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Wire rope di-

ameter

[mm]

Size of the

wire rope

clip

Required

number of

wire rope

clips

distance

[mm]

Wrench

size

Distance

Required

tightening

torque lubri-

cated

[Nm]

Required

tightening

torque

unlubricated

[Nm]

11 - 12

7/16“

48 - 96

110

5/8“

52 - 104

170

Table 1

Wire ropes must be installed with the required tightening torque.

A visible contusion of the wire ropes positively indicates that the wire rope clips have been tightened to

the required tightening torque.

Wire ropes that have not been damaged can be used again, but the threads and the saddle, in particular,

must be inspected for any damage.

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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4 STAKING-OUT IN ACCORDANCE WITH THE TERRAIN

GENERAL PRINCIPLES FOR STAKING OUT

Position of the barrier

Tried-and-tested simulation programs are available for determining the optimum position of the barrier. Inappro-

priate locations with excessive displacements or terrain flaws are identified.

Barrier line

It is important to design the barrier line in a way that ensures it is as straight as possible and runs horizontally. Ir-

regular lines as well as depressions and cambers in the terrain between the posts must be avoided or corrected

wherever possible.

Position of the foundation

The base plate support of the foundation must be laid against the terrain in such a way that the lower bottom sup-

port rope remains close to the ground.

The base plate must be positioned in such a way that the bottom support rope bypasses and is not damaged by

the edges of the foundation.

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Height differences in the barrier line

h: Structure height

x: Post spacing

n: Mesh length adjustment

h: Height difference between two neighboring posts



Post spacing

6-8 m

8-10 m

10-12 m

h

< 0.50 m

< 1.00 m

< 1.50 m

No change necessary

h

> 0.50 m

> 1.00 m

> 1.50 m

Mesh must be adapted

Table 2

When the height difference is greater than specified in table 2, contact Geobrugg so that the correct net

length can be determined

h

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5 STAKING-OUT GEOMETRY

GENERAL PRINCIPLES FOR STAKING-OUT GEOMETRY

Standard Staking-Out Measurements

If you comply with the standard staking-out measurements and their tolerances specified on the next few pages, it

will be possible to install the barrier without any problems and all components will function properly in the event of

an incident.

Adjustments for the terrain

Depending on the terrain, it may not always be possible to comply with the standard staking-out measurements.

To ensure that the barrier still functions properly in these cases, you may make several small adjustments to the

cross-section or length of nets, ropes, posts, etc.

If you inform Geobrugg of these deviations, we can work together to find a adapted solution quickly.

Orientation of the foundations and base plates

Base plate type 2 can be used on a concrete foundation with two parallel anchors as well as with a 45° inclined

tie rod.

In the case of a change in direction, the base plate should be offset in such a way that it is located in the bisecting

line of the angle formed by the two directly adjacent net fields (∂,µ,π,Ω).

Orientation of the foundations and base plates

F1 – F4 = successive foundations

, , , = bisecting angle

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The distance of the upslope anchor rope 236

depends on the possible angle and must

be adjusted and the length of the upslope

anchor rope must be checked.

236





Standard Staking-Out for Straight Barrier Line

Slope angle 30° - 90°

234: Indication of a rope

The view 230 on the stakeout is at a right angle to the terrain.

The following table applies to a terrain slope of 30° – 90°

All measurements in m; measurement tolerance ± 0.20 m

Lengths

2.00

3.00

0.65

3.50

1.00

2.50

3.80

0.85

4.30

1.25

3.00

4.50

1.00

5.10

1.50

3.50

5.30

1.15

6.00

1.75

4.00

6.00

1.35

6.80

2.00

Table 3

Slope angle 0° - 29°

230

234

Lengths

h: Barrier height

x: Distance between

posts

e: see downslope

anchoring on Page 16

Anchor point

B: Bottom support rope

C: Lateral anchor rope

D: Upslope anchor rope

Page 16/41

STAKING OUT WITH SUPPORT ROPE SEPARATION WITH INTERMEDIATE SUSPENSION

Lengths Anchor points

x: Distance between posts B1: Bottom support rope section 1

a, c, d: see Table 3 Z1: Intermediate suspension section 1

B2: Bottom support rope section 2

Z2: Intermediate suspension section 2

With simple terrain conditions and suitable tools, we recommend a support rope separation after approximately

60 – 100 m.

In Switzerland, a support rope separation is required after 60 m.

In Austria, a support rope separation is recommended after 60 m.

Page 17/41

STAKING OUT WITH AN UPSLOPE CHANGE IN DIRECTION FROM 5° TO 15°

Lengths and angle Anchor point

e: see Table 3 D: Upslope anchor rope

x: Distance between posts T: Downslope anchoring

y: Angle of change in direction

DOWNSLOPE ANCHORING DUE TO UPSLOPE CHANGE IN DIRECTION LARGER 15°

In case of an upslope change in direction larger than 15° the forces in the downslope anchoring, upslope

anchor ropes, post and base plate increase continuously.

For example in case of a change in direction of 35° the forces are 2.3 times higher than for 15°.

Consultation with Geobrugg is recommended

Page 18/41

STAKING OUT WITH A CHANGE IN DIRECTION TOWARDS THE DOWNSLOPE BETWEEN 30°

AND 40°

Lengths Anchor points

x: Distance between posts D: Upslope anchor rope

d: see Table 3

With a change in direction towards the downslope with an angle of 30° - 40° an additional upslope anchor rope is

needed in distance d. The maximum change in direction toward the downslope of 40° must not be exceeded.

Page 19/41

6 INSTALLING THE ROPE ANCHOR

Angle at the post

: The angle between the posts and the perpendicular depends on the terrain slope , see Table 5.

: An angle of between 60° and 85° must be maintained between the upslope anchor rope and the post.

: The default angle between the terrain and the post is 75°.

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.

Depending on the terrain conditions but in any case, if terrain slope angle > 45° it is recommended to

use bavettes (additional mesh between the terrain and bottom part of the mesh).

The anchor holes are drilled in the pulling direction, with a minimum angle of > 15° to the horizontal.







=75

>15°

>35°

0°-30°

15°

32°

17°

34°

19°

36°

21°

38°

23°

40°

25°

42°

27°

44°

29°

45°

30°

Table 4

Page 20/41

7 ANCHORING THE BASE PLATE

STANDARD BASE PLATE (TYPE 1)

LOOSE GROUND:

•Permitted installation position of the base plate 29: Inclined 0 –30°

to the horizontal

•Drill hole for the main anchor 05

•Prepare the concrete foundation 111; the concrete foundation is di-

mensioned and reinforced in accordance with the information from

the project engineer (Geobrugg recommendation: 0.6 x 0.4 x 0.15 m)

•Insert the anchor 05, spacers 09, and fastening nuts 10; the project

engineer calculates the lengths of the anchors

•Optional: stabilization tube 04 for vertical anchor

•Important: Spacers and fastening nuts must be fixed on both

sides of the base plate 29

•Mortar the main anchor 05 in the loose ground 110

•Drill and install securing anchor 06 by using the base plate as tem-

plate. Length min. 1.0 m

•Fill in the concrete foundation 111

•Tighten the fastening nuts 10 to

approx. 30 kN pretensioning force

CONCRETE:

•Can be used for all types of soil and rock

•Dig a hole for the concrete foundation 111

•Drill the rear anchoring 07; the project engineer calculates the

lengths of the anchors

•Prepare the concrete foundation 111; the concrete foundation is di-

mensioned and reinforced in accordance with the information from

the project engineer

•Mortar in the rear anchoring 07 with the fastening nuts 10 and spac-

ers 09

•Install both anchors 08 with the help of the base plate 29. Spacers

09 and fastening nuts 10 must be fixed on both sides of the

base plate;

length of anchor 08 L = 0.5 m

•Fill in the concrete foundation 111

•Tighten the fastening nuts 10 to approx. 30 kN pretensioning force

09,10

111

04,05

09,10

110

0.15 m

0.4 m

0.6 m

111

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