installation manual rb 1500_rev.3
DESCRIPTION
Installation Manual RB 1500TRANSCRIPT
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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
SIGNATURE
SIGNATURE
DRAWN CHECKED ON APPROVED SCALE
SHEET
DATE ID NUMBER
SIGNATURE
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Rockfall barrier RB 1500 Installation Manual
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.
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Rockfall barrier RB 1500 Installation Manual
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.
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Rockfall barrier RB 1500 Installation Manual
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
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Rockfall barrier RB 1500 Installation Manual
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
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Rockfall barrier RB 1500 Installation Manual
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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