Welded Gabions - Galvanized and PVC-Coated Wire Mesh Baskets Install and Applications

Welded Mesh Gabions, filled on-site with hard, durable stones, form substantial gravity-retaining structures. Unlike the more flexible twisted mesh type, welded wire mesh gabions are rigid units, typically unsuitable in areas prone to differential settlement or within water courses. Like all gabions, welded units require internal bracing wires during installation and should be overfilled to accommodate granular rock fill settlement. Gabion boxes, crafted from electro-spot welded steel wire mesh grids, feature curved and welded eyelets and locking rods to secure the gabions.

Welded gabion boxes, constructed from galvanized, PVC, or Galfan-coated steel wire mesh, are rigid, rock-filling mesh basket units available in various wire diameters, dimensions, and sizes. Suitable for gravity retaining walls, architectural cladding, and barrier projects, they ensure durability and functionality across applications.

Gabion Assembly

Ensure the surface for gabion placement is trimmed, leveled, and compacted to a minimum dry density of 93%. If needed, excavate a foundation trench along the revetment or wall toe to the dimensions specified or indicated in the drawings.

Assemble and install gabions according to manufacturer's instructions, pending the Engineer's approval. Use a minimum of 600 mm binder wire lengths to stitch joints, securing at least one stitch per 50 mm, and twist each wire end at least two times upon itself. Stitch adjacent gabions together along all adjoining edges with binder wire.

To prevent deformation during stone filling, tension sufficient connecting wires between the vertical sides of all externally visible cells. Securely tie the corners of gabion cages, ensuring a uniform surface and avoiding a block or panel-like appearance.

Lay gabion boxes in a broken bond manner to prevent 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 Backfilling

Upon completing the gabion work, backfill and comprehensively compact the existing soil against the gabion's back face and ends, ensuring it is finished level with the gabion's top surface.

Welded Gabion Transport and Assembly

Welded gabions are supplied flat-packed on pallets, optimizing space and reducing transportation costs.

Quick Assembly of Prefabricated Welded Box Gabions

Factory-fitted vertical joints enhance on-site assembly quality and speed. Depending on the gabion's configuration, base and lid panels connect with 1 horizontal and helical. Accessories, such as bracing ties and joining pins, are pre-adjusted to the gabion type. Additional spirals are required to close the base and lids.

Simple On-Site Assembly and Rock Filling

Setup: Remove a gabion from the pallet and cut the securing brace. Extend the gabion to its full length, close the base helically, and fold the ends 90° inward using standard pliers. This secures the spirals during movement, prevents sharp ends, and reduces injury risk. Flip the gabion.

Connection for Larger Lengths: For extended lengths, connect the gabions to create a monolithic structure using provided prefabricated joining pins. Interlock the spirals, insert the joining pin, and press it downward, ensuring the pin head faces inward for security and vandalism prevention. This should be performed on both sides.

Bracing: To mitigate deformation during filling, each gabion includes bracing wire ties. Depending on the gabion's height, position bracing ties at 1/3 + 2/3 or 1/2 of the height.

Filling: Begin filling the gabion. Place bracing ties 4 meshes from the sides and around the weld to prevent weld breakage or bracing tie movement. Continue this process until the gabion is completely filled.

After filling, close the lid using the included spirals, attaching it at every edge and the diaphragm panel, and twist the ends inward for safety.

When stacking gabions, establish horizontal connections using clips or lacing wire.

Main uses

Welded Mesh Gabions serve various purposes in different sectors due to their robustness, versatility, and ease of assembly. Here are some of the primary applications:

1. Civil Engineering

• Retaining Walls: Gabions are widely used to create retaining walls in various constructions to hold back soil and prevent erosion.

• Erosion Control: They prevent water erosion in areas like riverbanks and seashores by absorbing and deflecting water energy.

• Bridge Protection: Placed around bridge abutments, gabions protect the structures from erosion and provide stabilization.

2. Architectural Applications

• Cladding: Welded gabions are used as an architectural feature for cladding on buildings, providing both aesthetic and functional benefits.

• Fencing: Constructing fences using gabions, filled with stones or other materials, is popular for its visual appeal and durability.

• Sound Barriers: Due to their mass and flexibility, gabions can act as effective sound barriers along highways or in residential areas.

3. Landscape Design

• Garden Features: Welded mesh gabions can be utilized to create visually appealing structures in gardens, like benches, fountains, or planters.

• Decorative Walls: Designing decorative walls using gabions in public parks or private properties enhances aesthetic appeal.

4. Military Use

• Fortification: Gabions, or "Hesco barriers," are used for rapid deployment in military fortifications to provide protection against blasts and bullets.

5. Environmental Conservation

• Habitat Creation: Gabions are sometimes used to create habitats for wildlife, especially in aquatic environments, supporting biodiversity.

• Flood Control: By resisting water flow, gabions help in managing flood situations, safeguarding property and landscapes.

6. Mining Industry

• Slope Stabilization: In mining regions, gabions are implemented for slope stabilization to prevent landslides and protect workers.

• Mining Tunnels: They can be used to stabilize and secure mining tunnels, ensuring safe passage for miners and equipment.

7. Railway Works

• Track Stabilization: Gabions assist in stabilizing railway tracks, especially in areas prone to landslides or erosion.

• Embarkment Protection: They protect railway embankments from erosion, maintaining the stability of the tracks.

8. Agricultural Applications

• Windbreaks: Filled gabions can act as windbreaks, shielding crops and soil from strong winds.

• Livestock Barriers: Using gabions to create barriers for livestock is an effective and durable solution.

The adaptability of welded mesh gabions to different contexts and uses, paired with their durability and ecological compatibility, makes them a favorable choice for various industries. Depending on the specific requirements of a project, gabions can be filled with various materials, like rock, concrete, or even recycled materials, enhancing their utility and versatility.