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Geobrugg RXE-2000 Product Manual

Rockfall barrier
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European Technical
Assessment: ETA 13/1047
Date: 28.02.2019
Edition: 11
© Geobrugg AG
8590 Romanshorn,
Switzerland
Product Manual
RXE-2000
ROCKFALL BARRIER

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Summary of Contents for Geobrugg RXE-2000

  • Page 1 Product Manual RXE-2000 European Technical ROCKFALL BARRIER Assessment: ETA 13/1047 Date: 28.02.2019 Edition: 11 © Geobrugg AG 8590 Romanshorn, Switzerland...
  • Page 2 This document does not claim to be exhaustive. It is designed for general, standard applications and does not take any project-specific parameters into account. Geobrugg cannot be held liable for any additional costs which, may arise in special cases. If anything is unclear, please contact the manufacturer. Geobrugg AG's general terms and conditions apply.
  • Page 3 European approval, known as ETA (European Technical Assessment), as well as a Swiss inspection certif- icate from the Federal Office for the Environment (FOEN). The current system, RXE-2000, has the assessment no. ETA – 13/1047 and the test certificate no. S 13-2.
  • Page 4 Geobrugg can provide assistance when you are assessing the influence of significant anomalies and special situ- ations and offer suggestions for feasible solutions. However, Geobrugg cannot guarantee consistent performance of the type demonstrated in the rockfall tests under real-life conditions.

  • Page 5: Table Of Contents

    CRANE OR HELICOPTER ASSEMBLY ................26 SUPERSTRUCTURE INSTALLATION STEPS ..............27 ASSEMBLY DETAILS ....................... 33 SUPPORT ROPE SEPARATION WITH INTERMEDIATE ANCHORING ......49 SPECIAL SOLUTIONS IN ADDITION TO THE STANDARD SOLUTION......56 FINAL CHECK ........................57 Page 5/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 6: Hazard Notes

    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 HAZARD NOTES QUALIFICATION OF THE GROUP LEADER Only a qualified group leader may be put in charge of the installation.

  • Page 7: Tools For Installing Rockfall Barriers

    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 Page 7/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 8: 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 9 Undamaged wire rope clips may be reused. The threads and clamping jaw have to be checked thorough- Wire rope clips must always be installed and used with the required tensioning torque. Page 9/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 10: Staking-Out In Accordance With The Terrain

    The base plate must be positioned in such a way that the bottom support rope passes by it and is not damaged by the edges of the foundation. Page 10/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 11 > 1.50 m > 2.00 m Net must be adjusted In the event of a height difference that is greater than what is specified in Tab. 2, contact Geobrugg so that the correct net length can be determined Page 11/60 ©...

  • Page 12: Staking-Out Geometry

    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 an adapted solution quickly. Page 12/60 ©...
  • Page 13 Downslope rope If the terrain slope is less than 30°, the distance of the upslope anchor ropes must be adapted and the length of the upslope an- chor ropes must be checked. Page 13/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 14 In the case of changes in direction toward the upslope with an an- gle of more than 15°, an intermediate suspension is required; there is no downslope anchoring in this case. Page 14/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 15 In the case of changes in direction toward the downslope with an angle of more than 30°, an additional upslope anchor rope (D) is installed on the post (three upslope anchor ropes instead of two). The maximum change in di- rection toward the downslope is 40°. Page 15/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 16: Installing The Rope Anchor

    The anchor bore holes are drilled in the direction of movement with a minimum incline of ≥ 15° to the horizontal. Page 16/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 17 Page 17/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 18: Anchoring The Base Plate

     Prepare the concrete foundation 111; the concrete foundation 111 is dimensioned and reinforced in accordance with the in- 0.2 m formation from the project engineer (Geobrugg recommenda- tion: 0.6 x 0.5 x 0.2 m) 0.6 m 0.5 m ...
  • Page 19 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 19/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 20: Preparing 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 on the left side of the posts. Page 20/60 ©...
  • Page 21 Marking for the various rows for control structure height h = 7 m: Row no. (1) (11) (21) (31) Marking for the various rows for control structure height h = 7.5 m: Row no. (1) (11) (23) (33) Page 21/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 22 5 spare rings through which the transmission ropes are not guided. The rings are bundled for delivery. Half nets: If the length of the nets is half as long as the distance between posts, one side of the net does not have rings marked in blue. Page 22/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 23 5 spare rings through which the transmission ropes are not guided. The rings are bundled for delivery. c) 5 spare rings through which the RUNTOP ropes are guided. The rings are bundled and fixed to the adjacent in- termediate rings for delivery. Page 23/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 24 1 pc.. Ringnet 16/3/350 1 pc.. Hex bolt M30x240 2 pcs.. Hex bolt M30 2 pcs.. Retaining rope 1 pc.. Lateral anchor rope 2 pcs.. Shackle 1" 2 pcs.. Shackle 1 1/4" Page 24/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 25 The top strap is fixed after the second row of rings 205 in such a way that the two upper ring bundles can be swiveled away from the post in a subsequent installation step 206, allowing the support ropes to be fed through the rings and the running wheels. Page 25/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 26: Crane Or Helicopter Assembly

    To lift the edge posts, use the middle 1 1/4" shackle 89 on the post head. To lift the middle posts, use the 1" shackle 86 of the U-Brakes which are yet to be installed. Do not use the rungs 208 under any circumstances! Page 26/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 27: Superstructure Installation Steps

    The utmost caution must be exercised in danger areas while the posts are still able to tilt forward, back- ward, or to one side. Page 27/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 28 The support ropes must be installed before the U-Rope to prevent the ropes from crossing over one another. The ring net is fitted later, after the transmission ropes have been added (see later steps). Page 28/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 29 Guide the lower U-Rope from one of the U-Brakes to the other U-Brake through the holes on the post base and the main rings marked in blue on the net bundle, but do not tension them yet. Page 29/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 30 Open, fit, and connect the ring net bundles under one another, and shackle to the other vertical rope. When opening the ring net bundles, lift the transmission ropes to their final height. Do not connect the nets to one another at the post heads. Page 30/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 31 Tension the top U-rope, bottom support ropes, lower U-rope, and the transmission ropes.  Feed vertical ropes F2 into the two edge nets.  Fix the secondary mesh strips upslope on the ring net. Page 31/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 32 Page 32/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 33: Assembly Details

    Install the overturn securing rope 68 so that the posts can be installed safely. 64, 65 Hex bolt M22 Washer for M22 83 for middle posts Overturn securing rope 86 for border posts Shackle 5/8" Shackle 1" Page 33/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 34 M20 hex head nut Retaining rope 53/55 Lateral rope Overturn securing rope Top support rope Bottom support rope 78.1 1x Upper U-Rope 56/57/58 78.2 1x Lower U-Rope Shackle 1" Shackle 1 1/4" Page 34/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 35 67, insert vertical rope F 69 around the shackle bolt and position the loop halfway up the post 211. Lateral rope Vertical rope F1 Vertical rope F2 Wire rope clip 5/8” Page 35/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 36 Washer for M20 Hex nut M20 Upslope anchor rope 33/35/53/55 Overturn securing rope Top support rope Bottom support rope 78.1 1x Upper U-Rope 78.2 1x Lower U-Rope 5/8" Shackle 1" Shackle Page 36/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 37 UPSLOPE ANCHOR ROPES ON ROPE ANCHOR Spiral rope anchor Retaining rope Wire rope clips 7/8”, for each rope Page 37/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 38 LATERAL ANCHORING ON LEFT ROPE ANCHOR Lateral rope Wire rope clip 7/8”, per rope Page 38/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 39 TOP SUPPORT ROPES, UPPER U-ROPE, AND UPPER TRANSMISSION ROPE ON ROPE AN- CHOR 71/97 78.1/97 73.1/97 U-Brake U-300-R20 Top support rope 73.1 1x Upper transmission rope 78.1 1x Upper U-Rope Shackle 1“ Shackle 1 1/4“ Wire rope clips 7/8”, for each rope Page 39/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 40 ROPE ANCHOR 73.2/97 78.2/97 73.2/89 72/97 U-Brake U-300-R20 Bottom support rope 73.2 1x Lower transmission rope 78.2 1x Lower U-Rope Shackle 1" Shackle 1 1/4" Wire rope clip 7/8”, for each rope Page 40/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 41 The 5 rings marked in blue are left free. In the case of the nets on the middle posts 31, the transmission ropes are guided through the rings marked in red. Every ring is accounted for. Page 41/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 42 MIDDLE POSTS: FINAL POSITION OF THE TRANSMISSION ROPES IN THE RING NET The transmission ropes 73.1 and 73.2 are guided through the corresponding ring row (red) without interruption. The transmission ropes are not connected to the posts. 73.1 73.2 Page 42/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 43 Furthermore, the intermediate ring between the red and blue edge rings is fixed to both support ropes 72 with a 3/4" shackle 84. The main rings 215 on the edge of the net are fixed to the unrestricted rope line of the vertical rope F1 69 with 1/2" shackles 82. Page 43/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 44 In addition, the blue colored intermediate rings in the corners of the net are fixed to both U-Ropes 78 with 5/8" shackles 83. Furthermore, the intermediate ring between the red and blue edge rings is fixed to both support ropes 72 with a 3/4" shackle 84. Page 44/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 45 4 neighboring rings (step 2). Details how to connect the ring net in the upper area of the middle post see next page. Step 1 Step 2 Page 45/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 46 Die ersten 3 Ringe (pink) sind freigelassen, die folgenden 4 Ringe (schwarz) sind in einem Winkel von ca. 45° durchstossen, danach sind die Seile vertikal durch die verblei- benden Ringe (X) geführt. Page 46/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 47 The wire mesh 221 is fixed to the ring net 220 with a double wire connector 222. Fastening takes place at each ROCCO-Ring. The wire mesh strips overlap one another by 10 cm. Page 47/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 48 INTERMEDIATE ROPE SUSPENSION DOWNSLOPE ANCHOR Downslope rope 1“ Shackle 7/8” Wire rope clips Page 48/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 49: Support Rope Separation With Intermediate Anchoring

    Upper U-Rope sec. right 74.1 Upper RUNTOP rope 78.2 R 1x Lower U-Rope sec. right 74.2 Lower RUNTOP rope 78.1 L 1x Upper U-Rope section left 78.2 L 1x Lower U-Rope section left Page 49/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 50 NET RINGS AT RUNTOP ROPE AND RELEASED RINGS OF THE TRANSMISSION ROPES 97/213/214 97/213/214 71 R 71 L 74.1/212 73.1 R 73.1 L 73.2 L 73.2 R Page 50/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 51 The transmission rope 73.1L and 73.1R release the blue colored rings and will be fixed to each U-Brake on the upslope side of the net. (5 rings on the left and 5 rings on the right) Page 51/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 52 TOP SUPPORT ROPE, UPPER U-ROPE AND UPPER TRANSMISSION ROPE ON ROPE ANCHOR 73.2 78.2 U-Brake U-300-R20 Bottom support rope 73.2 1x Lower transmission rope 78.2 1x Lower U-Rope Shackle 1“, per Brake Shackle 1 1/4", per Brake Page 52/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 53 RUNTOP rope through the blue colored rings. Then fix the RUNTOP rope to the support rope with a wire rope clip. Torque 50 Nm; Attach the clamping jaw to the top support rope. Page 53/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 54 RUNTOP rope through the blue colored rings. Then fix the RUNTOP rope to the support rope with a wire rope clip. Torque 50 Nm; Attach the clamping jaw to the top support rope. Page 54/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 55 The RUNTOP rope is guided through 5 blue rings on each side. Then fix the RUNTOP rope to the bottom support ropes with a wire rope clip and tension the RUNTOP rope. Tightening torque 50 Nm (lubricated); attach the clamping jaw to the RUNTOP rope to simplify the installation Page 55/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

  • Page 56: Special Solutions In Addition To The Standard Solution

    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 56/60 © Geobrugg AG, Switzerland...

  • Page 57: Final Check

    Are the nets connected to one another correctly? Are the edge nets fastened to the vertical ropes correctly? Is the sagging of the top support rope less than 3% of the distance between posts? Page 57/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 58 Page 58/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 59 Page 59/60 © Geobrugg AG, Switzerland RXE-2000 / 11...
  • Page 60 Page 60/60 © Geobrugg AG, Switzerland RXE-2000 / 11...

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