att-40 attenuator system

Date: 01.01.2019

Edition: 01

© Geobrugg AG

8590 Romanshorn

Product Manual

ATT-40

ATTENUATOR SYSTEM

2/36 © Geobrugg AG, Switzerland L2_ATT-40 en Product Manual 01_190101.doc

Intended application/Purpose

This handbook serves as a construction manual for the standard application of the frontal protection

barrier named. It makes no claims to be complete, it may be changed by Geobrugg at any time and is not

subject to any notification requirement.

Target group

Only trained persons or persons authorized by the construction firm may install the protection barrier.

These must have read and understood the handbook prior to installation in order to guarantee the safe

and proper erection of the barrier. Please contact us if you have any questions or if anything is unclear.

Afterwards, keep this product manual ready.

Liability and limitation of liability

It is not permitted to alter or reconstruct Geobrugg products without approval. In case of any deviation

from this manual, or changes or omissions of operational steps, Geobrugg AG cannot guarantee any

safe or long service life and cannot be made liable.

Otherwise the general terms and conditions of Geobrugg AG apply (see www.geobrugg.com).

Geobrugg AG

Symbols used

Safety note: Must be followed

Information for a simple and correct installation

Contact us

Upslope

Downslope

correct

wrong


Content

Intended application/Purpose .............................................................................................................. 2

Target group ........................................................................................................................................ 2

Liability and limitation of liability .......................................................................................................... 2

Symbols used ...................................................................................................................................... 2

1 Important information ....................................................................................................................... 6

Qualification of the group leader .............................................................................................. 6

Tensioned ropes ...................................................................................................................... 6

2 General information .......................................................................................................................... 6

Key ........................................................................................................................................... 6

System drawings ...................................................................................................................... 6

View of the drawings ................................................................................................................ 6

3 Tools ................................................................................................................................................... 7

Staking-out ............................................................................................................................... 7

Installation ................................................................................................................................ 7

4 Using the wire rope clips .................................................................................................................. 8

Step 1 Lubricate threads .......................................................................................................... 8

Step 2: Install the wire rope clips ............................................................................................. 8

Step 3: Tighten the wire rope clips .......................................................................................... 9

5 Staking-out ....................................................................................................................................... 10

General principles for staking-out .......................................................................................... 10

Position of the barrier ............................................................................................................. 10

Ideal barrier line ..................................................................................................................... 10

Orientation of the foundations and base plates ..................................................................... 11

Post inclination ....................................................................................................................... 11

Staking-out for straight barrier line ......................................................................................... 12

Staking-out with an upslope change in direction ................................................................... 12

Staking-out with a change in direction towards the downslope ............................................. 13

Staking-out with support rope separation with intermediate suspension .............................. 14

Staking-out with support rope separation with intermediate suspension straight .................. 15

6 Base plate ........................................................................................................................................ 16

Inclination ............................................................................................................................... 16

Anchoring ............................................................................................................................... 16

Drilling .................................................................................................................................... 17

7 Installing the rope anchor .............................................................................................................. 18

Foundation example for the rope anchor ............................................................................... 18

8 Preparing the posts......................................................................................................................... 19


9 Installation steps for the superstructure ...................................................................................... 20

Step 1: Install overturn securing ropes .................................................................................. 20

Step 2: Erect the posts ........................................................................................................... 20

Step 3: Fix lateral anchoring .................................................................................................. 20

Step 4: Top support ropes ..................................................................................................... 21

Step 5: Attach the net ............................................................................................................ 21

Step 6: Edge ropes ................................................................................................................ 22

10 Assembly details ............................................................................................................................. 24

Detail 1: Border post (left) ...................................................................................................... 24

Detail 2: Middle post .............................................................................................................. 25

Detail 3: Upslope anchor ropes ............................................................................................. 26

Detail 4: Lateral anchoring ..................................................................................................... 27

Detail 5: Connecting mesh panels to top support rope .......................................................... 28

Detail 6: Connecting mesh panel to mesh panel horizontally ................................................ 29

Detail 7: Mesh connection vertical with seam rope ............................................................... 30

Detail 8: Mesh connection vertical with shackles or T3-clips ................................................. 31

11 Final check ....................................................................................................................................... 33

12 System drawings ............................................................................................................................. 34

13 Key ................................................................................................................................................... 36


1 Important information

If safety instructions are ignored, there is a risk of death, serious injury and/or property damage!

Qualification of the group leader

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

maintenance and repair of protective barriers, potentially dangerous situations cannot be avoided.

This work may only be carried out by suitably trained specialist personnel in compliance with local,

country-specific safety regulations and laws.

Appropriate safety precautions must be taken

Tensioned ropes

During erection and tensioning the cables, no persons are allowed to be present in the danger area.

Avoid releasing or separating construction components that are under tension.

2 General information

Key

Note the key on the last page. It contains information necessary for a correct understanding of the

drawings.

System drawings

Please also refer to the system drawings for a better understanding.

View of the drawings

Unless otherwise indicated, all drawings are shown with view in the direction towards the mountain.


3 Tools

Staking-out

- Measuring tape

- Folding meter stick

- Marker spray

- Wooden peg or iron peg

- Hammer

- Manual

Installation

- Set of open-ended or ring wrench 22 – 32 mm

- Socket wrench set with ratchet

- Torque wrench, range 25 – 330 Nm

- Open-ended wrench (for anchor nut)

- Motor cutting disc or hammer wire cutter; 28 mm cutting capacity

- Roll of adhesive tape

- Rope clamp, small 8 – 16 mm/large 14 – 26 mm (min. 2x)

- Chain hoist or rope hoist (min. 1.5 t / 15 kN)

- Multipurpose lubricant spray (e.g. Panolin CL 60)

- Manual


4 Using the wire rope clips

Step 1 Lubricate threads

Wire rope clip FF-C-450-type 1 class 1

E.g. with Panolin CL 60 multipurpose-lubricant spray

Step 2: Install the wire rope clips

d

t > 10 x d > 10 x d

e = 1 … 2 x t


Step 3: Tighten the wire rope clips

Tighten all nuts evenly and alternately up to the required torque given in table 1.

Table 1: valid for wire rope clips FF-C-450 type 1 class 1 (similar EN 13411-5 type 2)

Tightening torque

[mm] [Size] [Quantity] [Nm] [Nm] [mm] [mm]

3 – 4 1/8” 2 4 8 10 20

6 – 7 1/4” 2 10 25 15 30

8 5/16” 3 20 50 18 33

9 – 10 3/8” 3 30 75 19 40

11 – 12 7/16” 3 40 110 22 48

14 – 15 9/16” 3 50 150 24 53

16 5/8” 3 90 170 24 53

18 – 20 3/4” 4 90 180 27 57

22 7/8” 4 150 330 32 62

22 GEOBINEX 7/8” 5 150 330 32 62


5 Staking-out

General principles for staking-out

The following specifications are valid for standard topographical conditions and ensure an ideal

installation and functionality of the barrier.

Position of the barrier

Differences in height greater than 1.0 m must be considered when calculating the net length.

Ideal barrier line

x

x

x


Orientation of the foundations and base plates

Post inclination

On account of the risk of tipping, it is imperative to observe that Ω is always > 15°!

: 60° - 85°

: 75° (if ∢ ß > 30°)

d: see table 2

∢ ß ∢ Ω

< 30°

35° 17°

40° 25°

45° 30°

> 45°


Staking-out for straight barrier line

a, c & d: see table 2

Staking-out with an upslope change in direction

φ: 5° - 15°

e: see table 2

D

A,C

D

A

T


Staking-out with a change in direction towards the downslope

φ: 30° - 40°

d: see table 2

Table 2: ∢ ß = 30° - 90°. +/- 0.2 [m]

h

[m]

a

[m]

c

[m]

d

[m]

e

[m]

3.00 4.50 1.00 5.10 1.50

3.50 5.30 1.15 6.00 1.75

4.00 6.00 1.30 6.80 2.00

4.50 6.75 1.45 7.60 2.25

5.00 7.50 1.65 8.50 2.50

6.00 9.00 2.00 10.20 3.00

7.00 10.50 2.35 11.90 3.50

8.00 12.00 2.65 13.60 4.00

D

A

D


Staking-out with support rope separation with intermediate suspension

For rockfall protection barriers, a support rope separation is recommended every 60 - 100 m.

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

φ: 15° < φ < 25°

a & c: see table 2

D

Z

A


Staking-out with support rope separation with intermediate suspension straight

a & c: see table 2

Table 2: ∢ ß = 30° - 90°. +/- 0.2 [m]

h

[m]

a

[m]

c

[m]

d

[m]

e

[m]

3.00 4.50 1.00 5.10 1.50

3.50 5.30 1.15 6.00 1.75

4.00 6.00 1.30 6.80 2.00

4.50 6.75 1.45 7.60 2.25

5.00 7.50 1.65 8.50 2.50

6.00 9.00 2.00 10.20 3.00

7.00 10.50 2.35 11.90 3.50

8.00 12.00 2.65 13.60 4.00

D

Z

A


6 Base plate

Foundations sizes and anchor lengths according to specifications given by the project engineer. You

must use mortar that is resistant to both frost and de-icing salt. If desired, a stabilization tube can be

supplied for the vertical anchor. You will find more information in the anchor data sheet.

Inclination

Anchoring

Anchoring in rock Anchoring in soil

90°

> 60°

> 60°


Drilling

On request, an installation template can be supplied.

Drilling dimension base plate type 1

Drilling dimension base plate type 2


7 Installing the rope anchor

Foundation example for the rope anchor

< 30° > 15°

δ

δ/2


8 Preparing the posts

Preattach all shackles, upslope and lateral anchor ropes.

To lift the posts, use nothing else then the middle 5/8“ shackle.


9 Installation steps for the superstructure

Prior to the start of step 1, drill the anchor and prepare the foundations.

Extreme caution is advised as long as the posts have not been fixed. There is a risk of death, serious

injury and/or property damage.

Step 1: Install overturn securing ropes

Install the overturn securing ropes on the base plates.

Step 2: Erect the posts

Erect the posts using upslope anchor ropes and the overturn securing ropes.

Step 3: Fix lateral anchoring

Install the lateral anchor ropes (and if required, the intermediate anchor ropes).


Step 4: Top support ropes

Install the top support rope.

Step 5: Attach the net

Attach the nets to the top support rope and install all other nets and connect them to each other.


Step 6: Edge ropes

If provided, install the vertical and/or the bottom rope.


10 Assembly details

Detail 1: Border post (left)


Detail 2: Middle post


Detail 3: Upslope anchor ropes


Detail 4: Lateral anchoring


Detail 5: Connecting mesh panels to top support rope


Detail 6: Connecting mesh panel to mesh panel horizontally


Detail 7: Mesh connection vertical with seam rope

312: cut it to length of max. 25 m.


Detail 8: Mesh connection vertical with shackles or T3-clips

Overlapping: At least 3 meshes.


11 Final check

When installation is complete, it is particularly important to check the following points:

a) Are all ropes guided to the correct anchors

b) Have the ropes been guided correctly on the post head?

c) Is the mesh fixed correctly to the support ropes?

d) Is the number of wire rope clips at the rope end connections correct?

e) Are the wire rope clips fitted correctly?

f) Has the right amount of tightening torque been applied to the wire rope clips?

g) Are the meshes connected to one another correctly

h) Are the edge meshes connected to the vertical ropes correctly?

i) Is he sagging of the top support rope less than 3% of the distance between posts?

Pay attention to the maintenance handbook.


12 System drawings


13 Key

A Top support rope x Post spacing

C Lateral anchor rope ∢ ß Fall of ground

D Upslope anchor rope

T Downslope anchor rope

Z Intermediate suspension

01 Spiral wire rope 80 Shackle 3/8“

33 Running wheel 81 Shackle 7/16“

56 Hexagonal bolt M20x110 82 Shackle 1/2“

57 Washer for M20 83 Shackle 5/8“

58 Hexagonal Nut M20 84 Shackle 3/4“

68 Overturn securing rope 87 Shackle 1“ straight

90 Wire rope clip 1/4“



312 Seam rope

att-40 attenuator system

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