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Geobrugg RXE-1000 Product Manual

Rockfall barrier
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European Technical
Approval
ETA–13/0225
ETAG 027: Category A
Energy class 3: 1000 kJ
Height: 4 - 5m
Testing certificate S 13-1
Federal office of environmental
Switzerland
Test institute
Federal Research Institute WSL
Birmensdorf, Switzerland
Date: 08.10.2018
Edition: 17
© Geobrugg AG
CH-8590 Romanshorn
Product Manual
RXE-1000
ROCKFALL BARRIER

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  • Page 1 Energy class 3: 1000 kJ Height: 4 - 5m Testing certificate S 13-1 Federal office of environmental Switzerland Test institute Federal Research Institute WSL Birmensdorf, Switzerland Product Manual RXE-1000 ROCKFALL BARRIER Date: 08.10.2018 Edition: 17 © Geobrugg AG CH-8590 Romanshorn...
  • Page 2 Page 2/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 3 Page 3/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 4 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.
  • Page 5 • Anchorage 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.
  • Page 6 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.

  • Page 7: Table Of Contents

    INSTALLING THE SUPERSTRUCTURE ................28 ASSEMBLY DETAILS ....................... 33 SUPPORT ROPE SEPARATION WITH INTERMEDIATE SUSPENSION ......46 SPECIAL SOLUTION ADDITIONAL TO THE STANDRAD ..........50 FINAL INSPECTION ......................51 Page 7/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 8: Hazard Statement

    EXPLANATION OF USED SYMBOLS Safety indication: essential to follow Note / Reminder that the system is correctly installed easily A consultation with Geobrugg is recommended Upslope Downslope HAZARD STATEMENT QUALIFICATION OF THE GROUP LEADER The management of installation may only be done by a qualified group leader.

  • Page 9: Installation Tools

    • 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 Page 9/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 10: Using The Wire Rope Clips

    , where t is 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.
  • Page 11 Undamaged wire rope clips could be reused. Especially the threads and clamping jaw have to be checked. Wire rope clips always have to be installed and used with the required tensioning torque. Page 11/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 12: Staking Out Depending On The Terrain

    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. Page 12/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 13 > 1.00 m > 1.50 m 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. Page 13/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland...

  • Page 14: Staking Out Geometry

    Depending on the terrain the standard staking cannot be kept. To ensure the proper functioning of the barrier of- ten small adjustments in cross section or length of the nets, ropes, posts are sufficient. If Geobrugg is informed of the discrepancies can be found a customized solution together. Page 14/55 ©...
  • Page 15 Tab.3 Anchor point retaining rope 0°- 29° anchor downslope rope In a ground slope of less than 30°, the distance between post and retaing rope anchor is modified. Page 15/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 16 Anchor position intermediate suspension If the barrier line changes upslope more than 15° an intermediate anchor rope is required. In this case the downslope anchor rope is no longer necessary. Page 16/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 17 For a downslope change in direction of more than 30° an additional retaining rope (D) is mounted on the post head (three ropes instead of two). The maximum angle for a downslope change in direction is 40°. Page 17/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 18: Rope Anchor - Placement

    The anchor holes are drilled in the pulling direction, with a minimum angle of > 15° to the horizontal. Page 18/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 19: Anchoring The Base Plate

    • Prepare the concrete foundation 111; the concrete foundation 0.2 m 111 is dimensioned and reinforced in accordance with the in- formation from the project engineer (Geobrugg recommenda- 0.6 m tion: 0.6 x 0.5 x 0.2 m) 0.5 m •...
  • Page 20 You can find more information about anchoring the base plate in the anchor data sheet. The forces that may occur in the event of a rockfall event must not be underestimated. Civil engineering and installation work must therefore be carried out by experts. Page 20/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 21: Preparation Of The Nets And Posts

    X: In the event of significant height differences, it is easier to pull the net down from the higher post to the lower post. If specified in the order instructions, Geobrugg will supply the bundles according to the customer’s re- quest.
  • Page 22 Row-No. (1) (9) (17) (25) Marking the different rows for barrier height h = 6 m: Row-No. (1) (11) (19) (29) h = 5 m h = 6 m Page 22/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 23 RXE-1000: MARKING OF THE RINGS WITHOUT A SUPPORT ROPE SEPARATION Border net 1 Middle net Middle net Border net N  red colored rings: Ring passes through the support ropes and transmission ropes.  Blue colored rings of border nets: 2 rings on top and bottom are shackled to the U-rope.
  • Page 24 RXE-1000: MARKING OF THE RINGS WITH A SUPPORT ROPE SEPARATION (SRS) Middle net SRS net left … … … SRS net right Middle net … … …  red colored rings: Ring passes through the support ropes and transmission ropes.
  • Page 25 1 Stk. 6kt bolt M30x180 53 / 55 2 Stk. 6kt nut M30 2 Stk. Retaining rope 1 Stk. Lateral rope 2 Stk. Shackle 7/8" 1 Stk. Shackle 1" Page 25/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 26 The top strap is attached to the second row 205, so that in a subsequent assembly step, the two upper ring panel be turned away from the support rope to pass through the rings and the running wheel. Page 26/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 27: Crane And Helicopter Installation

    CRANE AND HELICOPTER INSTALLATION Fix the net panels with straps 207 flight safely. Use the middle post head shackle1“ 86 to lift the assembly. Never use the climbing steps 208! Page 27/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 28: Installing The Superstructure

    • Install the well prepared posts to the ground plates and secure them with the securing overturn ropes and the retaining ropes. Exercise extremely caution in the danger area around the posts as long the posts could topple backwards, forwards or to the lateral side Page 28/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 29 To avoid crossing ropes do not install the U-rope before the top support rope. The ring net will be opened later on after the installation of the transmission ropes. Page 29/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 30 To avoid crossing ropes do not install the U-rope before the bottom support rope. • Guide the bottom U-rope from the left U-brake through the clevises on the ground plate to the U-brake at the right. Do not tension the bottom U-rope. Page 30/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 31 • Open the net panels, connect them to each other and fix the border rings of the last net to the vertical rope at the right. During opening the net panels the transmission ropes will be lifted to its final height. Page 31/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 32 • Tension the top U-rope, bottom support rope, bottom U-rope and transmission ropes • Shackle colored rings to U-rope • Attach the secondary mesh to the ring net at mountain side Page 32/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 33: Assembly Details

    2 pcs. 6kt nut M22 1 pcs. washer M22 1 pcs. Overturn securing rope 1 pcs. Shackle 5/8“ Overturn securing rope 68 mount for secure mounting of the posts. Page 33/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 34 78.1 1 pcs. Top U-Rope 78.2 1 pcs. Bottom U-rope 4 pcs. Shackle 7/8" 1 pcs. Shackle 1" 3 pcs. Wire rope clips 5/8” 53, 55 56, 57, 58 78.2 Page 34/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 35 Before tensioning the lateral rope 67 the vertical rope 69 shackle with the ground plate and bolt of the shackle on the post head then position the loop 211at half of the post. Page 35/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 36 1 pcs. Top support rope 78.1 1 pcs. Top U-rope 53, 55, 35, 37, 33 78.2 1 pcs. Bottom U-rope 56, 57, 58 1 pcs. Shackle 5/8" 3 pcs. Shackle 7/8" 78.2 Page 36/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 37 7/8” 4 pcs LATERAL ROPE ON THE ROPE ANCHOR 1 pcs spirale rope anchor 1 pcs lateral rope wire rope clip 5/8” per rope 3 pcs Page 37/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 38 73.1 1 pcs top transmission rope 78.1 1 pcs top U-Rope shackle 1“ 4 pcs wire rope clip 5/8” 3 pcs wire rope clip 7/8” 4 pcs Page 38/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 39 73.2 1 pcs bottom transmission rope 78.2 1 pcs bottom U-Rope shackle1“ 4 pcs wire rope clip 5/8“ 3 pcs wire rope clip 7/8“ 4 pcs 78.2 73.2 Page 39/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 40 U-rope 78.x by shackles1/2”82. The main rings 215 on the border are fixed to the vertical rope string 69 which is not fixed with wire rope clips. The shackles are ½” 82. Page 40/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 41 MIDDLE POST: INSTALLATION OF THE TRANSMISSION ROPES The transmission ropes 73.1 and 73.2 are guided without interruption by the corresponding ring series (red). The transmission ropes are not connected to the post. 73.1 73.2 Page 41/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 42 (blue) are not fixed to the support rope. The colored rings (blue) are fixed to the U- rope 78.x by shackles ½” 82. Page 42/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 43 (step 1). In next step, the lower main ring is fixed to the upper main ring of the other net by shackle ½”. Step 1 Step 2 Page 43/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 44 The wire mesh 221 is fixed with double wire ties 222 on the ring net 220. The wire tie is attached to each ROCCO ring in any intermediate series. The wire mesh strips overlap each other 10cm. Page 44/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 45 INTERMEDIATE ROPE SUSPENSION DOWNSLOPE ANCHOR 1 pcs Spiral rope anchor 1 pcs Downslope anchor rope 1 pcs Shackle7/8“ Wire rope clip 5/8” 3 pcs Page 45/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 46: Support Rope Separation With Intermediate Suspension

    The blue colored rings are released by the transmission ropes and are guided to the U-Brakes on post head and bottom support anchor. 5 rings left and 5 rings right of the post are free. Page 46/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 47 Bring the bypass rope with the round clip on the shackle in height. Guide both ends of the bypass rope through the blue colored rings. Then fix the bypass rope to the support rope with a wire rope clip. Torque 50 Nm Page 47/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 48 Bring the bypass rope with the round clip on the shackle in height. Guide both ends of the bypass rope through the blue colored rings. Then fix the bypass rope to the support rope with a wire rope clip. Torque 50 Nm Page 48/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 49 Torque 50 Nm correct position of the wire rope clip. The sattle is fixed to the bypass rope because of an easy pretension of the wire rope clips. Page 49/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

  • Page 50: Special Solution Additional To The Standrad

    GAP-FILLING SOLUTION On steep slopes with torrent channels, there may be large gaps between the ground and the bottom sup- port rope. In these cases, individual gap-filling solutions can be developed in consultation with Geobrugg Page 50/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland...

  • Page 51: Final Inspection

    Are the nets connected correctly? Are the end nets correctly fastened to the vertical ropes? Is the sag of the top support rope less than 3% of the distance between the posts? Page 51/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 52 Page 52/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 53 Page 53/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 54 Page 54/55 © Geobrugg Gruppe, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...
  • Page 55 EXTRACT FROM THE FOEN TEST CERTIFICATE NO. 13-1 Page 55/55 © Geobrugg AG, CH-8590 Romanshorn, Switzerland RXE-1000 / 17...

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