Geobrugg GBE-500A-R, Maintenance Manual

Page 1: ...R GBE 1000A GBE 1000A R GBE 2000A GBE 3000A RXE 500 RXE 500 LA RXE 1000 RXE 2000 RXE 3000 RXE 5000 RXE 8000 RXE 10000 ATT 20 ATT 40 ATT 60 ATT 80 Date 01 01 2019 Issue 10 Geobrugg AG 8590 Romanshorn Maintenance Manual RXE GBE and ATT series ...

Page 2: ...it is recommended that technical advice is obtained from the manufacturer This maintenance manual consists of the following sections Lifespan Inspections Criteria for repairs and replacement Emptying and clearing of barriers Repairing and replacing components Inspection checklist ISO 9001 certificates No claims are made that this document is complete It is designed for general standard application...

Page 3: ...S 1216 RXE 1000 1000 kJ System drawing GS 1142 RXE 2000 2000 kJ System drawing GS 1150 RXE 3000 3000 kJ System drawing GS 1157 RXE 5000 5000 kJ System drawing GS 1125 RXE 8000 8000 kJ System drawing GS 1138 RXE 10000 10000 kJ System drawing GS 1552 ATT 20 System drawing GS 1556 ATT 40 System drawing GS 1567 ATT 60 System drawing GS 1568 ATT 80 System drawing GS 1569 II QUALITY OF THE SYSTEM COMPON...

Page 4: ... ings etc for example or forces beyond human control weather earthquakes etc The multiplicity of factors that may trigger such events means that guaranteeing the safety of persons and property is not an exact science However the risks of injury and loss of property can be substantially reduced by appropriate calculations that apply good engineering practices and by using predictable parameters alo...

Page 5: ...bility 9 4 CRITERIA FOR REPAIR AND REPLACEMENT 10 4 1 Debris in the barrier 10 4 2 Remaining usable height following an incident 10 4 3 U brake 10 4 4 Meshes and nets 10 4 4 1 TECCO 10 4 4 2 SPIDER 10 4 4 3 ROCCO 10 4 4 4 Wire mesh 11 4 5 Ropes as per the rope assembling drawings 11 4 5 1 Corrosion 11 4 5 2 Mechanical damage 11 4 6 Posts 11 4 7 Hinge bolt between post and base plate 11 4 8 Base pl...

Page 6: ...et areas 21 8 5 3 ROCCO repairing smaller net areas 21 8 5 4 Wire mesh repairing smaller mesh areas 21 8 6 Replacing nets and meshes 22 8 6 1 TECCO replacing a mesh field 22 8 6 2 SPIDER replacing a net field 23 8 6 3 ROCCO replacing individual rings 26 8 6 4 ROCCO replacing a net field 27 8 6 5 Wire mesh replacing a length of mesh 28 8 7 Repairing ropes 28 8 8 Replacing ropes 28 8 9 Replacing pos...

Page 7: ... recommended Upslope Downslope 1 HAZARD NOTES QUALIFICATION OF THE GROUP LEADER Only a qualified group leader may be put in charge of the maintenance TENSIONED ROPES Ropes will be tensioned When installing and pretensioning ropes ensure that there are no persons within in the danger area RELEASING TENSIONED PARTS Releasing or separating tensioned parts should be avoided wherever possible If this i...

Page 8: ...or the U brake bolts etc 2 1 2 Assemblies The lifespan of an assembly is defined by its load bearing capacity as well as by its mechanical functional efficiency Typical assemblies include e g the installed barrier itself the U brakes and the running wheel groups 2 1 3 Safety factors If the functional efficiency or load bearing capacity of the components is reduced as a result of damage or corrosio...

Page 9: ...mum number of inspections Under normal environmental conditions two checks a year are sufficient If frequent rockfall occur more inspections are appropriate These should be carried out before the start of winter and after winter has ended A useful aid for the systematic checking of the barrier is the Barrier Inspection checklist in the Annex 3 2 Inspection following incidents An inspection must be...

Page 10: ...h may need to be replaced 4 3 U brake In the course of the EOTA certification tests depending on their installation position the U brakes became elongated to varying degrees Accordingly following several minor incidents their energy absorption capacity for a subsequent maximum incident varies Type Maximum Elongation U 150 30 cm U 300 60 cm U 400 80 cm If the initial elongation exceeds this value t...

Page 11: ...to an angle of 15 do not need to be replaced 4 7 Hinge bolt between post and base plate In the event of impacts into the post the hinge bolt between the post and the base plate may be bent or broken predetermined breaking point in order to avoid damage to the base plates and anchors Bent or broken hinge bolts must be replaced 4 8 Base plate Plastic deformations to the base plate do not impair the ...

Page 12: ... taken that the net is not damaged and it must be ensured that stones rolling down the slope do not cause any damage see illustration below Dug channels or large plastic pipes are useful for directing stones debris and rubble safely towards the valley Lowering stones safely secured with a rope 5 1 Breaking stones down Large blocks that cannot be lifted out or transported away must be broken down D...

Page 13: ...Maintenance manual RXE GBE 09 Breaking a block down using explosives If a crane is available the stones can be fitted with a haulage anchor and brought down to the valley safely Fitting the block with haulage hooks Lifting the block out with the aid of a crane ...

Page 14: ... Two cable winch hoist with 7 5 kN tensile strength e g LUG ALL Various slings each 1 meter in length Shackles according the barrier type Torque wrench range 25 400 Nm see tightening torque required for wire rope clips and base plate fastening nuts Socket wrench set with ratchet or open ended wrench set Hammer flat nose pliers roll of adhesive tape Auxiliary ropes 30 50 m measuring tape Inclinomet...

Page 15: ... is the width of the clamping jaws If you are using a thimble in the loop structure the first wire rope clip must be attached directly to the thimble The clamping brackets U brackets must always be fitted to the unstressed end of the rope and the clamping jaws saddle must always be fitted to the stressed rope never saddle a dead horse Nominal size mm Distance e mm Required tightening torque Nm Req...

Page 16: ...s 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 If you are using a thimble in the loop structure the first wire rope clip must be attached directly next to the thimble For loops without a thimble the length h between the first wire rope clip and the point of load ...

Page 17: ...22 14 15 9 16 3 50 150 24 16 5 8 3 90 170 24 18 20 3 4 4 90 180 27 22 7 8 4 150 330 32 22 GEOBINEX 7 8 5 150 330 32 A visible contusion of the wire ropes positively indicates that the wire rope clips have been tightened to the required tightening torque Undamaged wire rope clips could be reused Especially the threads and clamping jaw have to be checked Wire rope clips always have to be installed a...

Page 18: ...onents When carrying out repairs the geometrical condition of the barrier must be restored to match that on ini tial acceptance If this is no longer possible a technically acceptable solution must be agreed with Geo brugg The correct geometrical arrangement of the individual components can be found in the product manual 8 2 Tightening sagging ropes 02 01 03 04 05 ...

Page 19: ... wire rope clips of the rope with the required tightening torque 06 Detach the cable pulley device 8 3 Replacing ropes Fit the clips of the cable pulley device to the post e g with the auxiliary strap 01 and to the fastening of the U brake e g rope anchor 02 Carry out the remaining steps as described in section 8 2 Actuate the cable pulley device until the rope that is to be replaced is loose Rele...

Page 20: ...the rope of the U brake 01 and the fastening of the U brake e g rope anchor 02 Carry out the remaining steps as described in section 8 28 1 Actuate the cable pulley device until the entire tensile force is on the cable pulley device Remove the shackle of the U brake from the loop of the rope Replace the U brake and return the shackle to the loop Release the cable pulley device so that the tensile ...

Page 21: ...thy a correspondingly small net can be laid over the damaged area and fastened to the intact mesh loops with shackles Care must be taken to ensure that the mesh loops are aligned horizontally as they are for intact meshes 8 5 3 ROCCO repairing smaller net areas If the rings of a smaller net area have been pulled along in sympathy a correspondingly small net can be laid over the damaged area and fa...

Page 22: ...most spiral of the damaged area b Open up the eyelet connection of the outermost spiral c Unscrew the outermost spiral A separation is produced in the mesh area d Cut open the mesh loops of the damaged mesh along the support rope and remove the damaged mesh e Fasten the mesh loops of the new mesh to the support ropes with HELIX spirals or shackles f Connect the new mesh to the intact adjacent mesh...

Page 23: ...a net field The SPIDER net is replaced by unscrewing the outermost spirals of the damaged area inserting the new net and joining this to the intact nets with two new spirals or with shackles a Relieve the strain on the outermost spiral of the damaged area b Cut open the eyelet connection of the outermost spiral ...

Page 24: ...termost spiral A separation is produced in the net area d Cut open the mesh loops of the damaged net along the support rope and remove the damaged net e Fasten the mesh loops of the new net to the support ropes with shackles f Connect the new net to the intact adjacent nets with a spiral or with shackles ...

Page 25: ...Page 25 32 Geobrugg Gruppe CH 8590 Romanshorn Switzerland Maintenance manual RXE GBE 09 g Connect the eyelets of the two spirals with a shackle and remove the strain relief ...

Page 26: ...meter of 4 8 mm through the 4 rings adjacent to the damaged ring and tighten it such that its diameter becomes smaller than that of the ring that is to be replaced b Secure the piece of rope that has been threaded through with a wire rope clip 01 c Guide a piece of wire with a diameter of 3 mm and a tensile strength of at least 1770 N mm2 along the piece of rope that was threaded through and throu...

Page 27: ...posts 01 pull it through the rings in the second row of the replacement net 02 and guide it through a second shackle 03 on the top support rope next to the other post to the cable pulley device 04 Tighten the rope until the first row of rings of the net is at the same height as the top support rope Whilst pulling up gradually cut open the tied up rows of rings of the net e Pull up the net like a c...

Page 28: ...ty post with auxiliary ropes e Dismount the shackle with the running wheel on the post head f Remove the hinge bolt of the post g Lift the post out of the base plate using a winch and place it secured on the ground on the mountain side h Transfer the retaining ropes from the faulty post to the new post i Place the post foot into the base plate and fit the hinge bolt j Erect the post in a secured m...

Page 29: ...tom support rope is also dismounted The faulty base plate is then replaced by a new one and the barrier is refitted 8 12 Replacing base plate anchors Replacing base plate anchors requires the base plate and the post to be removed in accordance with section 8 9 8 10 8 11 Depending on the type of damage to the foundation or the anchors it may be necessary to recreate the foundation in a suitable loc...

Page 30: ...left free to the left and right of the posts d Is the net fitted correctly to the support ropes or U Ropes e If support ropes have been separated are the bottom support ropes joined to the corresponding anchor and not to the base plate f Is the number of wire rope clips on the rope end connections correct g Are the wire rope clips fitted correctly h Has the correct tightening torque been applied t...

Page 31: ... paragraph describes the criteria for repair and replacement Location General remarks Impact area Objects in the barrier Leaves soil wood Up to 20 cm Rubble pebbles 20 cm 4 1 Stones Up to 100 kg Stones up to approx 35 cm in size 100 kg 4 1 500 kg 4 1 4 2 Stones over 60 cm in size Visible damage A Support and transmission ropes U brakes B Retaining ropes Deformed rope Yes 4 5 2 Deformed rope Yes 4 ...

Page 32: ...m 4 10 E Mesh net F Wire mesh Compressed mesh loops rings Yes No 4 4 Torn down punctured Yes 4 4 4 Torn wires Yes 4 4 No No G Post base plate Deformed post Yes 4 6 No Hinge bolt Yes 4 7 bent broken No Deformed base plate Yes 4 8 Damaged rod anchor Yes 4 9 No No Rod anchor pulled out of the ground 3 cm 4 9 H Wire rope clips All wire rope clips Yes 7 have the right torque No 7 Remarks Notes Sketches...