Welded Gabions - Galvanized Welded Wire Gabions - PVC Welded Wire Mesh Basket Gabions

Welded Gabions are rigid mesh basket units for rock filling constructed of welded steel wire mesh galvanized, pvc or Galfan coated finish, available in a variety of wire diameters, dimensions and unit sizes, for gravity retaining wall, architectural cladding and barrier project needs.

Welded Mesh Gabions are filled on site with hard and durable stones to form mass of gravity retaining structures.

Welded wire mesh gabions are inflexible mesh units compared with twisted mesh type, generally not considered suitable in areas susceptible to differential settlement, or in water courses.
In common with all gabions during installation, all welded units need internal bracing wires to be overfilled to allow for settlement of the granular rock fill.
Gabion box made of electro-spot welded steel wire mesh grids with curved and welded eyelet and locking rod locking gabions.

Gabions Assembly

The surface upon which gabions are to be laid shall be trimmed to line and level and compacted to a minimum dry density of 93% . Where required, a foundation trench shall be excavated along the toe of the revetment or wall, to the dimensions indicated on the Drawings or specified.

The assembly and installation of gabions shall be in accordance with the manufacturer's instructions, subject to the Engineer's approval. Joints shall be stitched together with 600 mm minimum lengths of binder wire, with at least one stitch per 50 mm, and each end of the wire shall be fixed with at least two turns upon itself. Adjacent gabions shall be stitched together with binder wire along all touching edges.

Sufficient connecting wires shall be tensioned between the vertical sides of all the outer visible cells, to prevent the deformation of cages as they are filled with stone. The corners of gabion cages shall be securely tied together to provide a uniform surface, and ensure that the structure does not resemble a series of blocks or panels.

Gabion boxes shall be laid with broken bond throughout to avoid continuous joints both horizontally and vertically.

Alignment of Gabions

The alignment of the gabion structure shall be correct to within a tolerance of 100 mm of the specified alignment and the level of any course of gabion shall be correct to within a tolerance of 50 mm of the specified level. In addition adjacent gabions shall not vary by more than 25 mm in line and/or level from each other.

Gabion structures, as constructed shall be within a tolerance of ± 5% on the specified height or width and ± 3% on the specified length.

Gabions shall be handpacked with clean, hard, durable, unweathered boulders or broken rock of 150 mm minimum dimensions and 300 mm maximum dimension. The sides shall be packed first in the form of a wall, using the largest pieces, with the majority placed as headers with broken joints to present a neat outside face. The interior of the gabion shall be hand packed with smaller pieces and the top layers shall be finished off with larger pieces. The whole interior and top layers shall be packed tight and hammered into place.

Using of Geotextile Behind Gabion Faces

A geotextile of approved quality and grade shall placed behind gabion faces in contact with existing or backfilled ground. The Contractor shall ensure that the geotextile is not damaged during the construction or backfilling around the gabion works and any damaged or torn material shall be replaced.

Soil Back Filling

At the back face and ends of completed gabion work, the existing soil shall be backfilled, thoroughly compacted against the sides of the gabions and finished flush with the top surface of the gabion.

PVC or Galv welded Wire Gabions
2m x 1m x 1m
3m x 1m x 0.5m
4m x 1m x 0.5m
4m x 1m x1m

Carbon steel welded wire mesh baskets 2x1x1 m,
Each basket consists of:
-3 pieces size 1x1 m
-4 pieces size 2x1 m
Diameter: 8mm bars
Opening of 10x10 cm.
Sheets dimensions:
1x1 m
2x1 m
-High Tensile plain wire supplied on a 50kg coil.

Welded Gabions are supplied in flat pack for easy transpotation and saving of spaces

Gabions are delivered in folded condition (flat-packed) on a pallet. This saves space and cost in transportation.

Prefabricated Welded Box Gabions for Quick Assembly

All verical joints are factory fitted which increases the quality and speed of assembly on site. Depending upon the configuration of the Gabion, the base and lid panels are connected with 1 horizontal and helical. The accesories (bracing ties and joining pins) are prefabricated and adjusted to the Gabion type. To close the base and lids additional spirals are neccessary.

What Needs to be done is simple for on site assembly and rock filling:

1, Take a Gabion from a pallet and cut the securing brace. Lift the accesories and pull the Gabion untill full length is reached. Close the base helically and fold the ends 90° inwardly. Now the spirals won't detach when moving and turning the Gabion. This will also prevent sharp end and injuries. This can be done with standard pliers. Now turn over the Gabion.

2, For large lengths, the Gabions should be connected as to form a monolithic structure. Prefabricated joining pins are provided for each Gabion. Simply grasp the 2 spirals then push them into each other. Place the joining pin into the section and push it downwardly. Care must be taken that the head of the pin faces should be inward. This must be done for security reasons and will prevent vandalism. The joining must be done at both sides.

3, Bracing wire ties are supplied in each Gabion to prevent heavy deformation caused by filling the Gabions. Depending upon the height of the gabion, the bracing ties are placed at 1/3 + 2/3 or 1/2 of the height.

4, Now start filling the first part of the Gabion.
Bracing ties are placed 4 meshes from the sides and around the weld. If not, the weld can break or the bracing tie can move. Repeat this principle untill the Gabions are fully filled.

After filling the Gabion, the lid can be closed. Use the included spirals and attach the lid at every edge including the diaphragm panel. Also twist the ends inwardly for safety reasons.

When superpositioning Gabions, the horizontal connections must be done. This is usually carried out with the help of clips or lacing wire.