installation manual rb 1500_rev.3

Rockfall barrier RB 1500 Installation Manual

Via Kennedy, 10

40069 Zola Predosa (BO) ITALY Tel: +39 051 6436000 Fax: +39 051 6436201

Web Site: www.officinemaccaferri.com

HIGH RESISTANCE ROCKFALL BARRIER

(1500kJ) RB 1500

INSTALLATION MANUAL

UPDATE / REVISION No. CHANGES / REVISION DESCRIPTION DATE / SIGNATURE

Rev. 0 April 10th 2012 Rev. 1 December 12th 2013 Rev. 2 February 25th 2013 Rev. 3 April 17th 2013

First issue Second issue (addition of supplementary installation drawings) Third issue (amendments of some drawings) Forth issue (addition of supplementary installation drawings)

REPLACES

DATE

REPLACED BY

DATE

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DRAWN CHECKED ON APPROVED SCALE

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OFFICINE MACCAFERRI LIMITS OF LIABILITY This Installation Manual is realized to show how the different components of the assembly kit have to be assembled to make the Rockfall Barrier. The company may supplement, integrate or improve the document, without entailing any reason to believe this document inappropriate. The company disclaims any liability for:

injuries or accidents due to the inappropriate use of the elements of the assembly kit;

injuries or accidents during the Rockfall Barrier installation; incorrect installation, incorrect compliance of the instruction contained in this

Manual; changes unauthorized by Officine Maccaferri; work done by untrained or unsuitable workers.

The Rockfall Barrier efficiency depends also on the painstaking observance of the manual, which has to be read before the lay-out and the installation of the barrier. The configurations of the geometry and of the barrier elements shown in this Manual are the only admitted, any changes must first be arranged with Officine Maccaferri.


FOREWORD The following document refers to the standard barrier installation, and is intended as a

guide for an easy and quick assembly and installation of the rockfall barrier. Modifications

to the barrier are possible without compromise the barrier functionality, but only in special

cases, and after obtaining approval from the manufacturer.

BARRIER LAYOUT The rockfall barrier must allow a straight horizontal line.

Install the posts at 10.00m intervals (*).

Upslope foundations shall be located along a line on the upslope side and parallel to the

alignment of the posts, orthogonally to the intermediate point of the spans (modules), and

at a distance as indicated in the attached drawings.

Lateral foundations A will be aligned along the line joining the lateral post with the contiguous one, and they will be placed at a distance as indicated in the attached

drawings.

Lateral foundations B will be located at 1,50 m distance downslope from the lateral foundations A.

If the natural site morphology produces an offset in the barrier alignment with an upslope

angle, a downslope anchor will be required. The downslope anchor will be aligned along

the angle bisector, and located at a distance not lower than 3 m from the base plate of the

correspondent post.

It could be convenient, in particular situations, to prearrange a concrete plinth underneath

the base plate, so that it lean in homogeneous way to the substratum of the underlying

soil.

The plinth does not have any bearing purpose, given that the forces are transferred to the

ground through steel bars or micropiles only. Its dimensions, having a levelling function

only, may be variables depending to the ground morphology. The plinths of the posts must

be completely underground to avoid that the lower longitudinal cables remain risen from

the ground.

(*) If for local reason of the natural site it is necessary to have a different geometry from the test site geometry a specific design shall be provided. Forces acting in the structure should be evaluated to demonstrate the fitness for use of the falling rock protection kit. The producer, under its own responsibility, shall provide geometric tolerances in the installation book with special references to the spacing of the posts and the inclination of the main ropes. (ETAG 027 - cl. 4.3).

INSTALLATION OF THE BASE PLATES The base plates has to be connected to the foundations previously made.

The nuts of the rod bars shall be screwed by applying a tightening torque of 150 Nm.


PREARRANGEMENT OF THE POSTS ON THE GROUND Place the posts on the ground straightway upslope and aligned with the base plates.

Insert the M30x100 bolt in the proper prearranged base plate holes and in the slot at the

base of the post and then secure it with the proper M30 nut. In this way the hinged joint is

realized.

INSTALLATION OF UPSTREAM CABLES, SIDE CABLE AND LATERAL JUNCTION CABLE ON THE LATERAL POSTS

1. Insert the loop (fixed with ferrule) of the lateral junction cable in the proper slot on

the top of the post.

2. Insert the loop (fixed with ferrule) of the side cable in the proper slot on the top of

the post.

3. Insert the loop (fixed with ferrule) of the upstream cables in the proper slot on the

top of the post (n. 2 upstream cable per post).

4. Close the proper slot for the loops of upstream cables, side cable and lateral

junction cable, using the bolt M20x150 and the nut M20.

INSTALLATION OF THE UPSTREAM CABLES ON THE INTERMEDIATE POSTS 1. Insert the loop (fixed with ferrule) of the upstream cables in the proper slot on the

top of the post (n. 2 upstream cable per post).

2. Close the proper slot for the loops of the upstream cables, using the bolt M20x150

and the nut M20.

DEFINITIVE ASSEMBLING OF THE POST 1. Connect the upstream cables with the upslope foundations.

2. Lift the post and tilt it downslope a little bit. Install the post with the desired

inclination, by inserting the limiting bolt M16x100 or M18x100 or M20x100 or

M22x100 in the proper holes on the base plate, and stretch the upstream cables

with a moderate tension.

The inclination of the post can be set using the limiting bolts that allow the following

inclinations:

M16x100 bolt and nut Vertical post 0 M18x100 bolt and nut Post tilted 6 dowslope M20x100 bolt and nut Post tilted 12 dowslope M22x100 bolt and nut Post tilted 18 dowslope


INSTALLATION OF THE UPPER AND LOWER CABLES See the attached drawings for the installation of the above cables.

INSTALLATION OF THE RING NET PANELS The connection between the ring net panels and the upper and lower cables will be carried

out, by inserting the above mentioned cables in the edge rings on the upper and lower side

of the panels.

In particular, the upper cable shall be inserted first into the red ring and then into the other

edge rings of the upper side of the panel (please refer to the attached drawings). This

procedure has to be repeated for each module (span) of the barrier. The installation of the

ring net panel shall be carried out by placing the green ring next to the red ring of the

adjacent ring net panel (please refer to the attached drawings).

The connection between adjacent ring net panels will be carried out using shackles size 16

mm. The ring net panels will be connected at the lateral posts through the lateral junction

cables which go inside the rings (please refer to the attached drawings).

INSTALLATION OF THE HEXAGONAL DOUBLE TWISTED WIRE MESH The double twisted wire mesh shall be installed on the upslope side of the ring net panels, and it will be fastened to the panels and to the longitudinal cables, using

galvanized steel wire having a diameter of 2,20 mm with ~ 50 cm x 50 cm mesh pattern.

INSTALLATION AND TIGHTENING OF THE U-BOLT WIRE ROPE GRIPS (CLAMPS)

Clamp size Cable diameter

(mm)

Clamps

(number)

Clap-to-clamp

distance (cm)

Tightening torque

(Nm)

19 18 5 ~ 7 68

22 20 5 ~ 7 107

SHACKLES FOR THE CONNECTION BETWEEN ADJACENT RING NET PANELS

Schackle size

16 mm

SUGGESTED TOOLS

Level (clinometer) Ratchet wrench with compass n. 17, n.19, n.22, n.24, n.27, n.30, n.32 and n.36 Wrench n.17, n.19, n.22, n.24, n.27, n.30, n.32, n.36 and n.46 Nippers


Uphand hammer Sledge hammer Wire cable cutter Felco type Shear Tirfor (traction and lifting device) Pipe wrench Rope tackle Lever Traction jaws for 18mm cable Tirvit (cable turnbuckle) Dynamometric key Goniometer - Clinometer Ladders

Clarifications Since the foundations are not considered part of the kit, their design is in the

responsibility of the designer, taking into account national provisions (ETAG 027, cl.

1.1).

The provisions and the verification and assessment methods of the performance characteristics of the rockfall barriers included or referred to in the Guideline ETAG

027 are based upon the assumed working life of the falling rock protection kit for the

intended use of 25 years, provided that the falling rock protection kit is subject to

appropriate installation, use and maintenance (ETAG 027, cl. 1.3). This working life

is intended to be assumed without any rock impact and under normal environmental

conditions. After each impact, the barrier should be checked and, eventually,

subject to maintenance or substituted (ETAG 027, cl. 1.3).

In environmental aggressive conditions, the assumed working life shall be at least 10 years with appropriate maintenance (ETAG 027, cl. 1.3).

The indications given as to the working life of the falling rock protection kit cannot be interpreted as a guarantee given by the manufacturer or his representative or the

approval body issuing the ETA, but are regarded only as a means for choosing the

appropriate products in relation to the expected economically reasonable working

life of the works (ETAG 027, cl. 1.3).

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installation manual rb 1500_rev.3

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