Date: 01.01.2019
Edition: 01
© Geobrugg AG
8590 Romanshorn
Product Manual
ATT-40
ATTENUATOR SYSTEM
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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
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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
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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
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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.
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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
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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
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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
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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
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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°
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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
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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
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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
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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
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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°
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Drilling
On request, an installation template can be supplied.
Drilling dimension base plate type 1
Drilling dimension base plate type 2
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7 Installing the rope anchor
Foundation example for the rope anchor
< 30° > 15°
δ
δ/2
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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.
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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).
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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.
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Step 6: Edge ropes
If provided, install the vertical and/or the bottom rope.
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10 Assembly details
Detail 1: Border post (left)
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Detail 2: Middle post
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Detail 3: Upslope anchor ropes
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Detail 4: Lateral anchoring
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Detail 5: Connecting mesh panels to top support rope
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Detail 6: Connecting mesh panel to mesh panel horizontally
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Detail 7: Mesh connection vertical with seam rope
312: cut it to length of max. 25 m.
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Detail 8: Mesh connection vertical with shackles or T3-clips
Overlapping: At least 3 meshes.
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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.
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12 System drawings
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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“
95 Wire rope clip 5/8“
96 Wire rope clip 3/4“
312 Seam rope