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

(500 kJ)

RMC 050/A

INSTALLATION MANUAL
UPDATE / REVISION No.

CHANGES / REVISION DESCRIPTION

DATE / SIGNATURE

Rev. 5 - August 5th 2013

DATE
REPLACES

DATE
REPLACED BY

SIGNATURE
DRAWN

CHECKED ON

SIGNATURE
APPROVED

DATE

SCALE

SHEET
ID NUMBER

SIGNATURE

Rockfall barrier RMC 050/A 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 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=
M18x80 bolt and nut =
M20x80 bolt and nut =

Vertical post 0
Post tilted 6dowslope
Post tilted 12dowslope

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 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 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 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 7 mm).

CORRECT CLAMPS PLACEMENT AND TIGHTENING

Clamps

Clamp-to-clamp
distance (mm)

Length of end section

of rope (mm)

Tightening
torque (Nm)

Number of
clamps

for cables 7
for cables 14
for cables 16

40
70
70

320
448
512

6
33
49

4
4
4

The tightening torque of the nuts of the base plate anchors must be equal to 150
Nm.
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 7 mm each other, used for connecting the net
panel with the longitudinal cables;
for connecting the segments of cable 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 7 mm with the edges of the panel, used for
the panel-to-panel connection;
for connecting the vertical joint cable 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 14 and 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

Rockfall barrier RMC 050/A Installation manual

Lateral bracing cable

Upper longitudinal cable

DOWNSLOPE

ROCKFALL BARRIER RMC 050/A

PERSPECTIVE VIEW

Energy
dissipator

Lateral junction cable

Steel tubular posts

Lower longitudinal cable

UPSLOPE

Interception panel

Lateral bracing cable

Energy
dissipator

Lateral junction cable

Upslope bracing cables

Rockfall barrier RMC 050/A

Installation manual - Drawing 1