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

(750kJ)

RB 750

INSTALLATION MANUAL
UPDATE / REVISION No.
th

Rev. 0 August 8 2013

Rev. 1 February 2nd 2014
th
Rev. 2 June 19 2014

CHANGES / REVISION DESCRIPTION

DATE / SIGNATURE

First issue
Second issue (addition of supplementary installation drawings)
Third issue (amendments on drawings n. 21 and 22)

DATE
REPLACES

DATE
REPLACED BY

SIGNATURE
DRAWN

CHECKED ON

SIGNATURE
APPROVED

DATE

SCALE

SHEET
ID NUMBER

SIGNATURE

Rockfall barrier RB 750 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.

Rockfall barrier RB 750 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.
Place the base plates depending on the post-to-post spacing, i.e. on the span length (*).
Upslope foundations shall be located along a line on the upslope side and parallel to the
alignment of the base plates, orthogonally to the intermediate point of the spans
(modules), and at a distance as indicated in the attached drawings.
Lateral foundations will be located at 1,00 m distance downslope from the alignment of the
line joining the lateral base plate with the contiguous one, and they will be placed at a
distance depending on the height of the barrier (as indicated in the attached drawings) but
in any case not lower than 4,50 m (if this is not feasible for local reason of the natural site,
please contact the manufacturer).
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. In case of deviation of the alignment, the manufacturer have to be
informed in order to complete the supply with downslope anchors and bracing cables.
It could be convenient, in particular situations, to prearrange a reinforced 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 variable depending to the ground morphology. The plinths
of the posts must be completely underground to avoid that the lower longitudinal cables
remain raised 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 with the foundations previously realized.
The nuts of the rod bars shall be screwed by applying a tightening torque of 150 Nm.
Rockfall barrier RB 750 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 side cable in the proper slot at the top of the
post.
2. Insert the loop (fixed with ferrule) of the upstream cables in the proper slot at the top
of the post.
3. Insert the loop (fixed with ferrule) of the lateral junction cable in the proper slot at
the top of the post.
INSTALLATION OF THE UPSTREAM CABLES ON THE INTERMEDIATE POSTS
1. Insert the loop (fixed with ferrule) of the upstream cables in the proper slot at the top
of the post.
2. In case of deviation of the alignment of the rockfall barrier, insert the loop (fixed with
ferrule) of the downslope bracing cable on the proper slot at the top of the post.
DEFINITIVE ASSEMBLING OF THE POST
Connect the upstream cables with the upslope foundations.
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 which allow the following
inclinations (with reference to the vertical to base plate):
M16x100 bolt and nut
M18x100 bolt and nut
M20x100 bolt and nut
M22x100 bolt and nut

Vertical post 0
Post tilted 6 dowslope
Post tilted 12 dowslope
Post tilted 18 dowslope

In order to achieve alternative inclinations than those indicated, please act on the
inclination of the base plate.

Rockfall barrier RB 750 Installation Manual

INSTALLATION OF THE UPPER AND LOWER CABLES

See the attached drawings for the installation of the upper and lower cables.
INSTALLATION OF THE RING NET PANELS
The connection between the cable net panels and the upper and lower cables will be
carried out, by inserting the above mentioned cables in the edge meshes on the upper and
lower side of the panels (please refer to the attached drawings).
The connection between adjacent cable net panels will be carried out using shackles size
12 mm (please refer to the attached drawings).
The cable net panels will be connected at the lateral posts through the lateral junction
cables which go inside the edge meshes on the vertical side of the panel and inside the
loop with thimble fixed with ferrule of the intermediate side cable, placed at a level
approximately corresponding to the half of the height of the barrier (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 cable 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 approximately 50 cm x 50 cm
mesh pattern.
INSTALLATION AND TIGHTENING OF THE U-BOLT WIRE ROPE GRIPS (CLAMPS)
Clamp size

Cable diameter

Clamps

Clap-to-clamp

Tightening torque

(mm)

(number)

distance (cm)

(Nm)

16

16

~7

49

19

18

~7

68

SHACKLES FOR THE CONNECTION BETWEEN ADJACENT CABLE NET PANELS

Schackle size
12 mm

SUGGESTED TOOLS

Level (clinometer)
Ratchet wrench with compass n.10, n.13, n.17, n.19, n.21, n.22 e n.30
Wrench n.30, n.32, n.36, n.45 e n.60
Nippers
Uphand hammer
Rockfall barrier RB 750 Installation Manual

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).

Rockfall barrier RB 750 Installation Manual