100-8000kJ

European Technical Approval

www.eota.eu

GBE rockfall protection barriers:The most economic solution to your safety problems.

Tested under the most rigorous conditions in vertical drop according to European ETAG 027 guidelines and under the scrutiny of the Swiss Federal Institute WSL; with ETA approval and CE marking.

The Geobrugg GBE rockfall

protection barriers offer

- protection against impact

energies up to 8,000 kJ

- maximum residual useful

height in ETAG 027 category A

- low anchor forces, short

anchors, shorter drilling times

- short installation times thanks

to modular construction and

lightweight components

2

GBE-100A-R to GBE-1000A-R.

We provide A-R barriers wherever rockfall protection

barriers need to be installed in front of a service road or

on retaining walls. Fitted with special posts, the A-R

barriers do not need any retaining ropes.

GBE-500A to GBE-1000A rockfall

protection barriers.

TECCO® mesh is used for rockfall events of 500 and

1,000 kJ. The small opening of TECCO® mesh stops even

small stones.

Overview of the GBE barrier series.

In development of the GBE barrier series in accordance

with ETAG 027 – the Guideline for European Technical

Approval of Falling Rock Protection Kits – our engineers

left nothing to chance, neither functionally nor mechani-

cally. With very simple installation and maximum protec-

tion in mind, we are setting a new standard in rockfall

protection barriers.

GBE barriers up to 3,000 kJ are pre-assembled as stan-

dard and delivered to construction sites with net packs

folded on the posts (see pages 6/7). Depending on the

height and weight of the posts, GBE high-energy barriers

up to 8,000 kJ can be pre-assembled on the construction

site prior to installation (see page 10).

The GBE barrier series:protection against impact energies from 100– 8,000 kJ.

3

GBE-3000A rockfall protection

barrier.

For rockfall events of 3,000 kJ, the SPIDER® spiral rope

net is reinforced with TECCO® mesh, which retains smaller

stones.

GBE-2000A rockfall protection

barrier.

The SPIDER® spiral rope net is used for rockfall events

of 2,000 kJ. An additional secondary mesh holds back

smaller stones.

GBE-5000A and GBE-8000A

rockfall protection barriers.

For the most serious rockfall events of 5,000 and 8,000 kJ,

we deploy ROCCO® ring nets with 16 and 19 wire coils

respectively. An additional secondary mesh is fitted to

retain even small stones.

4

The GBE system:Easy-to-install components that work as an integrated system.

The TECCO® mesh.

TECCO® mesh, which is used in the GBE barriers for impact

energies of 100, 500 and 1,000 kJ, is made from robust,

high-tensile steel wire with a diameter of 4 mm and

nominal tensile strength of 1,770 N/mm2. (Conventional

meshes have a strength of only 500 N/mm2.) Thanks to the

small opening size of 80 mm, no secondary mesh is neces-

sary: a considerable benefit for a simplified installation.

The SPIDER® spiral rope net.

SPIDER® S4/130 spiral rope nets are used as the main

net in the GBE barriers for impact energies of 2,000

and 3,000 kJ. Like TECCO® mesh, it is made from robust

strand of high-tensile steel wire with a diameter of 4 mm

and nominal tensile strength of 1,770 N/mm2. The

3,000 kJ barrier is further reinforced with TECCO® mesh.

The ROCCO® ring net.

ROCCO® ring nets are used in the GBE barriers for impact

energies of 5,000 and 8,000 kJ. They are made from steel

wire with a diameter of 3 mm and nominal tensile

strength of at least 1,770 N/mm2. Depending on the

amount of energy to be absorbed, between 16 and 19

wire coils are bundled in each ring. Here too, a secondary

mesh provides additional protection.

5

The posts.

HEA profile posts contribute to low installation and

transport weights. The post head is fitted with holes for

guiding the support rope and the retaining rope as well

as for a shackle, permitting transport by helicopter or

crane together with the pre-assembled mesh or net.

In the event of an impact, the bars or rods are drawn

around the mandrel, absorbing energy and also releasing

some of the rope. This enables a very uniform, non-

increasing force-path characteristic, permitting more

lightweight system components to be used and keeping

anchor forces low.

The baseplate.

Regardless of whether installing into loose rock, concrete

foundation or solid rock: the baseplates are easily and

quickly installed using two or, at most, three conventional

anchors. The posts are hinged on the plate. The bolts

between the baseplate and the post have been designed

with a predetermined breaking point.

The running wheel.

The support ropes are directed to the post heads and

baseplates through running wheels, whose function is

similar to rope pulleys. The running wheels always

align in the direction of the rope, giving it a larger sup-

porting surface. Because they are rotating with the rope,

the wheels allow the support rope to slide practically

friction-free through the suspension in case of an impact.

This conserves the supporting ropes and prevents wire

breakages.

The rope anchorage.

Rope anchorages can be made from our proven spiral

rope anchors, the new DSA wire loop anchors or standard

self-drilling anchors with the Geobrugg FLEX head. These

types of anchorages are suitable because they permit an

anchor head deflection of up to 30° while still being able

to bear the full tensile load. Thanks to the U-brake,

anchor forces can be kept very low. For this reason only

very short drilling lengths are necessary.

The U-brake.

Only four U-brakes are used per section in the case of

barriers for up to 3,000 kJ. They are mounted laterally at

the ends of the support ropes, greatly simplifying both

the installation and any necessary maintenance. A visual

check of brake condition can be carried out at any time.

The main component of the U-brake is made from either

a flat steel bar, bent around a mandrel, or from two steel

rods (see picture).

62 3

1

Installing the GBE barrier:Amazingly quick and easy for energy classes up to 3,000 kJ.

Making less work for you.

The time spent installing rockfall protection barriers

plays an extremely significant role in cost calculations.

This is why we compromised on nothing in designing GBE

barriers to be an installation-friendly system.

- Posts are delivered with pre-assembled mesh and

running wheels (picture 1).

- Depending on the barrier type, only one, two or

three anchors suffice to mount the very lightweight

baseplates (picture 2).

- The HEA profile posts are connected to the baseplate

by a bolt (picture 3).

- The lightweight HEA profile posts with pre-assembled

mesh or net can be installed quickly and easily

together with the retaining ropes, either manually

or using a crane or helicopter (pictures 4/5).

- The U-brakes only need to be fitted at the sides and

close to the ground (picture 6).

- The support rope is simply pulled through the folded

mesh or net and tensioned (picture 7).

- The mesh or net can be easily pulled across the

support rope like a curtain (picture 8).

- The mesh and net sections can be quickly connected

with shackles (picture 9).

LINK-TIP – watch GBE moviewww.geobrugg.com/youtube/gbe-en or scan QR code

7

4 5 6

7 98

810 20 50 100 200 500 1000 2‘000 3‘000 5‘000 8‘000 10‘000

Permafrost is thawing.

Rockfall events are becoming

more frequent.

As a result of the changing climate, the risk of landslides,

falling rocks and tumbling blocks in certain areas may be

significantly higher. The increased risk potential can

often exceed the absorption capacity of existing protec-

tive barriers. The result is a growing demand for barriers

that can absorb even higher levels of impact energy than

have been possible to date.

Falling rocks with impact energy

of between 5,000 and 8,000 kJ can

crash through concrete galleries.

The new GBE-5000A and GBE-8000A rockfall barriers,

for impact energies of 5,000 and 8,000 kJ respectively, are

made for very difficult situations: they offer protection

wherever sizeable blocks are expected to break off and

fall from great heights or over large distances. Because

the energy absorption capacity of GBE-5000A and GBE-

8000A barriers is higher than many existing or planned

concrete galleries and retention dams, the two barrier

systems can either supplement intended construction

methods or even replace them entirely. In addition, they

are suitable as an alternative in cases when, for topo-

graphic or esthetic reasons, it is not possible to build a

retention dam.

Fences

Flexible barrierswithout rope retention

Flexible barrierswith rope retention

Galleries

Retention dams

High-performance rockfall protection barriers: withstanding impact energy that would be too much for even concrete galleries to bear.

Applications of rockfall protection systems.

Impact energy properties in kJ.

9

1

2

GBE-5000A and GBE-8000A

rockfall protection barriers.

In making both these high-performance rockfall protec-

tion barriers, we have further developed components

and construction elements that have proven their worth

thousands of times over:

- Baseplates with hinged HEA 220 or RRW 400

posts with a predetermined breaking point.

- Retaining, support and catch ropes, that run

on running wheels with virtually no friction along

the entire protective barrier.

- U-brakes installed on the retaining ropes and

laterally on the support and catch ropes

- ROCCO® ring nets made of rings with 16 or 19

wire coils, that will safely hold back falling rock

even during a maximum-impact event thanks to

excellent elastic-plastic deformation behavior.

10

Pre-assembled posts cut

installation times.

The ring nets for GBE-5000A and GBE-8000A barriers

are supplied in folded packs. In the storage yard on the

construction site, the ring nets, retaining ropes, running

wheels and shackles are fitted to the posts in accordance

with the installation manual. The pre-assembled posts

are then fitted and anchored to the baseplates with the

aid of a crane or helicopter.

Barrier or earth dam?

Comparing the high-energy rockfall protection barrier

with an earth dam for impact energies of up to 8,000 kJ

reveals further benefits: whereas some 100 metric tons

are required for each linear meter of earth dam, the high-

energy GBE-8000A rockfall protection barrier needs only

around one metric ton per linear meter. Opting for a rock-

fall protection barrier significantly reduces the material

and time required and cuts installation costs considerably.

Diagram 1: solution using a retention dam – requires

berm excavation and material filling (gray section).

Diagram 2: solution using a rockfall protection barrier

– no removal or filling required. Diagram 1 Diagram 2

The world record:The GBE-8000A rockfall barrierstops 20 metric tons at 103 km/h.

8,000 kJ rockfall protection

Filling with earth dam

8,000 kJ rockfall protection

GBE-8000A rockfall protection

barrier with retaining rope

11

Tested according to ETAG 027, i.e. under the most rigorous conditions.

Vertical drop tests for maximum

impact energies.

The tests for the certification of the barriers were carried

out according to guideline ETAG 027 of the European

Organization for Technical Approvals EOTA and

monitored by an accredited testing institute. The testing

facility in Walenstadt, accredited to European standards,

allows rockfall protection barriers to be tested under the

toughest possible conditions – vertical drop. The Swiss

Federal Institute for Forest, Snow and Landscape

Research (WSL) serves as the independent institution

responsible for test monitoring, measuring technology

and a neutral assessment.

GBE barriers satisfy the most

stringent requirements of ETAG

027 category A.

All GBE rockfall protection barriers were tested in two so-

called SEL (Service Energy Level) tests: the barriers were

loaded with two hits of 33 % of the nominal energy

without intermediary maintenance. The main MEL

(Maximum Energy Level) test was then performed with

100 % of the nominal energy.

Following this test, a residual useful height of over 50 %

of the original barrier height was measured in the

impact zone. This corresponds to the highest category

available under ETAG 027, category A. You can find more

information about the test procedure at www.eota.eu.

European Technical Approval

(ETA) and CE marking confi rm

conformity with ETAG 027.

All successfully tested GBE rockfall protection barriers are

registered with an official ETA approval number and also

bear a CE marking number, underlining the conformity of

the GBE rockfall protection barriers with the requirements

of the ETAG 027 guideline.

LINK-TIP – watch test moviewww.geobrugg.com/GBE-8000Aor scan QR code

The test results set a new

world record…

On November 29, 2011, a GBE-8000A rockfall protection

barrier, with a construction height of 7 m and post spacings

of 10 m, passed the MEL 100% test under ETAG 027: a

concrete block weighing 20 metric tons smashed into the

ring net of the barrier after free-falling from a height of

43 m at 103 km/h. This corresponds to an impact energy

of 8,000 kJ, a world record for flexible rockfall protection

barriers.

12

8

1

2

3

1

2

3

1500

1250

1000

750

500

250

0

3000

3500

2500

2000

1500

1000

500

0

Corrosion protection: Only the best is good enough – because life span depends on it.

Essentially we supply all steel components (posts, ground

plates and U-brakes) hot-dip galvanized, the TECCO®

mesh, the SPIDER® net as well as the ropes with GEO-

BRUGG SUPERCOATING® or GEOBRUGG ULTRACOATING®,

the 3rd generation of our zinc/aluminium coating. This

considerably improves the corrosion resistance of the wire:

comparison tests with galvanized wires demonstrate a

working life six to ten times longer for wires treated with

ULTRACOATING®, and two or three times longer for those

treated with SUPERCOATING®.

GEOBRUGG ULTRACOATING®:

The intelligent type of coating.

Like with SUPERCOATING®, the wires first run through

a zinc bath and afterwards a zinc/aluminum-bath. The

result is an eutectic alloy with 5% aluminum, 94.5%

zinc and 0.5% of a special add-on. Thanks to this the

smooth surface remains after being attacked by corrosion,

since the corrosion leads to a reduction of the zinc layer

and to formation of an aluminum oxide layer. This latter

guarantees the protected object an economical lifespan

even in corrosive environments (roads, railways, industry,

coastal and volcanic regions).

The coating is applied in a double dip procedure and

final drawn. This results in a very compacted fine surface

which gives a better corrosion protection compared to

standard coated wires.

GEOBRUGG SUPERCOATING® / ULTRACOATING®

conventional galvanizing

GEOBRUGG ULTRACOATING® surpasses even SUPERCOATING®

two- or threefold:

The cross sections illustrated below show a comparison of wires treated with GEOBRUGG SUPERCOATING® and hot-

dip galvanization. The pictures were taken by an electron microscope after the wires had been exposed to environmental

influences for 14 years. GEOBRUGG ULTRACOATING® even surpasses this comparison two- or threefold.

GEOBRUGG SUPERCOATING®

(1) smooth surface (aluminum oxide layer)

(2) homogeneous coating (zinc/aluminum)

(3) wire (Fe)

Hot-dip galvanizing

(1) heterogeneous surface (zinc), partially complete

disintegration and/or already with rust formation

(2) hard zinc layer (iron/zinc)

(3) wire (Fe)

GEOBRUGG ULTRACOATING® in the salt spray test.

In the salt spray test (NaCI) according to EN ISO 9227/DIN 50021/ASTM B117, with ULTRACOATING® it takes six to

ten times longer for 5% dark brown rust to occur than with zinc. In order to achieve the same corrosion protection as

that provided by 150 g/m² ULTRACOATING®, it would be necessary to apply min. 900 g/m² with hot-dip galvanizing.

Expo

sure

in h

ours

until

the o

ccurre

nce o

f 5%

dark

-bro

wn ru

st

2-3x

bette

r

6-10

x bett

er

Requ

ired c

oatin

g (g/

m²)

Behavior in the salt spray testGEOBRUGG ULTRACOATING®

GEOBRUGG SUPERCOATING®

Hot-dip galvanizing

Required coating thicknesses to achieve the same performance for 2900 hours of salt spray test until the occurrence of 5% dark-brown rust

13

What counts for customers, planners and constructors:

Safety certifi cates,

documentation.

- Supervised by an accredited testing institute, all GBE

rockfall protection barriers have passed the approval

test in accordance with the ETAG 027 guidelines laid

down by the European Organization for Technical

Approvals. The test involved a vertical drop at least

25 m/s (90 km/h).

- The maximum deflections were verified by

high- speed cameras and measured data.

- The anchor forces acting during the tests were

documented in detail. They provide the basis for

the project-specific choice of anchors (spiral rope

anchors, self-drilling anchors with concrete

foundation and FLEX head, etc.).

- GBE rockfall protection barriers have a proven

residual useful height that complies with ETAG 027

category A: following the MEL (Maximum Energy

Level) test with 100 % of the nominal energy,

a residual useful height of over 50 % of the original

barrier height was measured in the impact zone.

In the adjacent zones, this figure was almost 100 %.

- All GBE rockfall protection barriers are registered

with an official ETA approval number and bear the

CE conformity marking.

- Approval can be verified at

www.eota.eu>valid ETAs>criteria: ETA number

Environment.

- GBE barriers have a considerably smaller carbon

footprint than concrete galleries or steel

constructions.

- The lightweight, transparent design of the GBE

barriers allows them to blend more easily into

«sensitive» landscapes.

- If desired, entire systems can also be camouflaged

using coloring. This is often done at national parks

in the USA, for example.

Installation and maintenance.

- Shorter construction times thanks to components,

including running wheels and shackles, supplied

pre-assembled, nets prefitted to posts, and post

spacings of up to 12 m

- Maximum deflections of 4.0 to 8.8 m allow barriers

to be installed close to the area being protected

(road, railroad track). This simplifies installation

(e.g. mobile cranes can be used) and maintenance.

- Due to the proven low anchor forces (max. 310 kN),

there is no need to use anchors with high load-

bearing capacity, and hence no need to use large

drilling devices.

- A well-illustrated assembly manual helps the

construction crew with the installation process.

- Our systems can also be installed in regions where

the terrain is very irregular.

- Nets and U-brakes can be repaired with minimum

effort following a rockfall event.

- Our comprehensive service manual describes barrier

clearing and maintenance.

141

1. Ötztal, Tyrol (Austria).

February 2012 – A GBE-1000A rockfall protection barrier

along the L186 highway in the region of Sölden success-

fully held back several snowslides following an unexpected

spell of warm weather.

A proven track record:GBE barriers offer maximum safety.

15

3

4

2

2. Reisseck, Carinthia (Austria).

July 2011 – Along the access road to the Reisseck pumped-

storage plant, a GBE-2000A rockfall protection barrier

stopped a rockslide triggered by heavy rainfall. The

largest slabs measured 2 m by 2 m by 0.5 m.

4. Hidroeléctrico do Baixo Sabor,

Portugal.

March 2011 – The Hidroeléctrico do Baixo Sabor hydro-

power plant was constructing a new dam. A GBE-1000A

rockfall protection barrier set up temporarily to protect

workers successfully stopped a rockfall event. The largest

block was estimated to weigh 14 metric tons.

3. Silz, Tyrol (Austria).

July 2011 – A GBE-2000A rockfall protection barrier

installed along the A12/E60 Inntal highway successfully

held back an avalanche covering some 50 m3 following

heavy rain.

The important facts: Rockfall barriers GBE-100A-R to GBE-8000A.

Geobrugg, a reliable partner.

It is the task of our engineers (and partners) to analyze

the problem together with you in detail and then,

together with local consultants, to present solutions.

Painstaking planning is not the only thing you can expect

from us, however; since we have our own production

plants on four continents, we can offer not only short

delivery paths and times, but also optimal local customer

service. With a view towards a trouble-free execution, we

deliver pre-assembled and clearly identified system

Geobrugg AGGeohazard SolutionsAachstrasse 11 • CH-8590 Romanshorn • Switzerland Phone +41 71 466 81 55 • Fax +41 71 466 81 50www.geobrugg.com • info@geobrugg.com

A company of the BRUGG GroupISO 9001 certifi ed 1.

101.

11.E

N.1

301/

1000

components right to the construction site. There we

provide support, if desired, including technical support

– from installation right on up until acceptance of the

structure.

Product liability.

Rockfall, slides, mudflows and avalanches are natural

events and therefore cannot be calculated. This is why it

is impossible to determine or guarantee absolute safety

for persons and property with scientific methods. This

means that to provide the protection we strive for, it is

imperative to maintain and service protective systems

regularly and appropriately. Moreover, the degree of

protection can be diminished by events that exceed the

absorption capacity of the system as calculated to good

engineering practice, failure to use original parts or

corrosion (i.e., from environmental pollution or other

outside influences).

GBE-5000A

8 (5000 kJ)

ETA-11/0305

1301-CPD-0714

–

–

ROCCO® 16/3/350

3 mm

350 or 300 mm

HEA 220

8 –12 m

20 mm

22 mm

12 x U-300-R20

5 m / 7 m

6 –7 m

>50 % (Cat. A)

GBE-8000A

8 (8000 kJ)

ETA-12/0213

1301-CPD-0803

–

–

ROCCO® 19/3/300

3 mm

300 mm

RRW 400

8 –12 m

22 mm

22 mm Geobinex

48 x various

u-brakes

6 m / 9 m

7– 8 m

>50 % (Cat. A)

Type

Energy class*

Approval no. ETA**

CE number

SPIDER®-spiral rope net

Strand diameter Ø

Mesh type

Wire Ø

Mesh Ø

Post type

Distance between posts

Rope diameter min.

Rope diameter max.

Per 80-100 m structure length:

Brake elements in support rope

Barrier height min./max.

With ETAG 027 approval

residual useful height*

*according to ETAG 027 ** See www.eota.eu>valid ETAs>criteria: ETA number 1 without retaining ropes 2 WSL test according ETAG 027 Right to technical alterations reserved

GBE-500A

2 (500 kJ)

ETA-09/0085

1301-CPD-0572

–

–

TECCO® G80/4

4 mm

80 mm

HEA 120

6 –12 m

14 mm

18 mm

4 x U-150

2 m / 5 m

3 –3.5 m

>50 % (Cat. A)

GBE-3000A

6 (3000 kJ)

ETA-10/0084

1301-CPD-0630

S4-130

8.6 mm

TECCO® G80/4

4 mm

80/130 mm

HEA 200

8 –12 m

20 mm

22 mm Geobinex

4 x U-300-R20

4 m / 6 m

5 –6 m

>50 % (Cat. A)

GBE-1000A

3 (1000 kJ)

ETA-09/0262

1301-CPD-0573

–

–

TECCO® G80/4

4 mm

80 mm

HEA 120

6 –12 m

14 mm

20 mm

4 x U-300

3 m / 5 m

4 –5 m

>50 % (Cat. A)

GBE-2000A

5 (2000 kJ)

ETA-09/0369

1301-CPD-0622

S4-130

8.6 mm

–

–

130 mm

HEA 160

8 –12 m

16 mm

22 mm

4 x U-300-R16

3 m / 5 m

4 –5 m

>50 % (Cat. A)

GBE-500A-R1

2 (500 kJ)

ETA-11/0034

1301-CPD-0695

–

–

TECCO® G80/4

4 mm

80 mm

HEA 140

6 –12 m

14 mm

18 mm

4 x U-150

2 m / 4 m

3 –3.5 m

>50 % (Cat. A)

GBE-100A-R1

0 (100 kJ)

ETA-11/0459

1301-DPD-0756

–

–

TECCO® G80/4

4 mm

80 mm

flanged profile

6–12 m

12 mm

14 mm

–

2 m / 4 m

2–2.5 m

>50 % (Cat. A)

GBE-1000A-R1

3 (1000 kJ)

WSL2

–

–

–

TECCO® G80/4

4 mm

80 mm

HEA 180

6 –12 m

14 mm

20 mm

4 x U-300

3 m / 5 m

4 –5 m

>50 % (Cat. A)

GBE-150A-R1

0 (150 kJ)

WSL2

–

–

–

TECCO® G80/4

4 mm

80 mm

flanged profile

6 –12 m

12 mm

18 mm

–

2 m / 4 m

2–2.5 m

>50 % (Cat. A)