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.
Rockfall barrier RMC 050/A – 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 compromising 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; the maximum height difference between two adjacent base plates shall be less than 0.5 m measured along the post. Please contact the manufacturer in case such differences are higher than those allowed. Install the posts at 10.00 m intervals. Upslope anchors shall be installed along a straight horizontal line situated on the upslope side and parallel to the alignment of the base plates. The position of the upslope anchors shall be aligned with the mid point of the spans (refer to drawings). Lateral anchors shall be installed at a proper distance (always not lower than 4.0 m; refer to drawings) from the last post, with an offset of 1.0 m distance downslope of the alignment connecting the last base plate and the adjacent one. If the slope geometry produces an offset in the barrier alignment, causing an upslope angle lower than 180°, a downslope anchor will be required. Downslope anchor shall be aligned along the angle bisector, and located at a distance not lower than 3.0 m from the relating base plate. In case of alignment deviation, the manufacturer shall be informed in order to complete the supply with the additional anchors and downslope bracing cables. It could be convenient, in particular situations, prearranging a concrete plinth underneath the base plate, so that it leans in homogeneous way to the substratum of the underlying soil. The plinth does not have any bearing purpose, because it is assumed that the forces are transferred to the ground through steel bars or by micro-piles only. Its dimensions, having a levelling function only, can be variables depending on the slope morphology. Each plinth must be designed in a way that the base plates will be perfectly aligned and horizontal. The prepared concrete base (foundation), on which the base plate will be installed, must be level with the surrounding ground, and not raised above the soil profile, since the longitudinal cables must be close to the ground surface. PREARRANGEMENT OF THE POST ON THE GROUND Place the posts folded down straightway upslope the base plates. Insert the M30x100 bolt in the proper prearranged base plate hole and in the flask slot at the base of the post and then secure it with the proper nut. In this way the hinged joint is realized. CONNECTION OF THE BRACING CABLES TO THE LATERAL POSTS
1. Insert the loop of lateral bracing cable on the top of the post. 2. Insert the loop of upslope bracing cables on the top of the post. 3. Insert the loop of lateral junction cable on the top of the post
Rockfall barrier RMC 050/A – Installation manual
BRACING CABLES CONNECTION TO THE INTERMEDIATE POSTS 1. Insert the loop of upslope bracing cables on the top of the post 2. in case of alignment deviation, insert the loop of dowslope bracing cable on the top
of the post
LIFTING AND INSTALLATION OF THE POSTS Connect the upslope bracing cables to the relating anchors. Straighten the post and tilt it downslope a little bit, inserting the M16x80 bolt or the M18x80 bolt or the M20x80 bolt (limiting bolts) in the proper hole in the base plate, depending on the desired inclination, and stretch the upslope bracing cables (and the downslope bracing cable, if any) with a moderate tension.
M16x80 bolt and nut= Vertical post 0° M18x80 bolt and nut = Post tilted 6°dowslope M20x80 bolt and nut = Post tilted 12°dowslope
To achieve alternative inclinations than those indicated, please act on the inclination of the base plates. INSTALLATION OF THE UPPER AND LOWER LONGITUDINAL CABLES For the correct placement of the longitudinal cables, please refer to the following drawings. NET PANELS INSTALLATION The net panels will be connected to the upper and lower longitudinal cables, using segments of steel cables ø 7 mm. These segments will be connected each other using shackles 10 mm, as shown in the following drawings (see drawing n. 29). The adjacent panels are joined together with a minimum overlap of 0.5 m. The connection of adjacent panels has always to be carried out next to the post. The “panel-to-panel” connection shall be completed connecting a couple of segments of vertical cables ø 7 mm, inserted into the hexagonal meshes, with the edges of the net panels (excluding the longitudinal cables) by means of shackles 10 mm, as shown in the drawings n. 27 and 28. The net panels shall be connected to the lateral posts by means of a minimum folding length of 0.5 m. The folding next to the lateral posts shall be completed connecting a segment of vertical cable ø 7 mm, inserted into the hexagonal meshes, with the edges of the net panels (excluding the longitudinal cables) by means of shackles 10 mm, as shown in the drawings n. 25 and 26. The lateral junction cable runs through the folding of the net panel and the fairlead of the lateral base plate (as shown in the drawings), and it is connected to the lateral anchors using clamps.
Rockfall barrier RMC 050/A – Installation manual
INSTALLATION OF THE VERTICAL JOINT CABLES – ADDITIONAL ELEMENT OF THE NET
The vertical joint cables shall be installed at a regular distance of 1.66 m, with reference to the axis of the posts. Each cable is installed vertically and inserted through the net panel, alternating the crossing of the cable on the upslope side and the downslope side of the barrier, every n. 4 hexagonal mesh of the net panel. Each vertical joint cable shall be installed in the opposite way of the adjacent one, for what concern the pattern of the crossing of the cable on the upslope and downslope side of the barrier (see drawings n. 30, 31 and 32). The vertical joint cables shall be connected with the upper and lower longitudinal cables using shackles 10 mm. The vertical joint cables shall not be installed next to the lateral posts of the barrier and/or next to a possible “panel-to-panel” connection (where there is already a couple of vertical segments of cable Ø 7 mm). CORRECT CLAMPS PLACEMENT AND TIGHTENING
Clamps Clamp-to-clamp distance (mm)
Length of end section of rope (mm)
Tightening torque (N·m)
Number of clamps
for cables Ø 7 40 320 6 4 for cables Ø 14 70 448 33 4 for cables Ø 16 70 512 49 4
The tightening torque of the nuts of the base plate anchors must be equal to 150 N·m. In order to properly install the rockfall barrier, all the nuts have to be fully tightened. USE OF SHACKLE 10 mm:
for joining the segments of cable Ø 7 mm each other, used for connecting the net panel with the longitudinal cables;
for connecting the segments of cable Ø 7 mm with the edges of the panel, used for the connection of the net panel to the lateral posts;
for connecting the segments of cable Ø 7 mm with the edges of the panel, used for the “panel-to-panel” connection;
for connecting the vertical joint cable Ø 7 mm with the longitudinal cables; USE OF SHACKLE 16 mm:
for connecting the loop fixed with ferrule of the lateral junction cable with the upper longitudinal cable;
Rockfall barrier RMC 050/A – Installation manual
SUGGESTED TOOLS
Level (clinometer) and goniometer Ratchet wrench with compass n.10, 13, 17, 19, 21, 22 and 30 Wrench n.30, 32, 36, 45 and 60 Traction jaws for Ø 14 and Ø 16 mm cables Nippers Uphand hammer and sledge hammer Tirvit (cable turnbuckle) Torque wrench Wire cable cutter (type Felco) Shear Tirfor (traction and lifting device) Pipe wrench Cable tackle Lever (crowbar) Ladders
