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Gabion Baskets - Galfan Gabion Baskets, Double Wire Woven Mesh Gabion Baskets, Matresses

Gabion Baskets are rectangular mesh containers made of mild tensile steel wire, diameter ranging from 2mm to 8mm, welded or woven, galvanised, galfan or plastic coated, for retaining wall construction filled with appropriately sized rock or quarry stone, featuring flexibility, durability, strength, permeability, economy, and landscaping. The hexagonal double-twist wire mesh basket gabions are generally class A galvanized to SABS 675 of 1993, the gabions baskets are sub-divided into cells by inserting diaphragms which are mesh panels with the same characteristics as the external sides, spaced 1m from each other to give the structure strength and facilitate it's speedy construction.

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Gabion baskets can be manufactured in welded mesh or woven wire, are used in many situations including the stabilization of earth movement and erosion, river control, reservoirs, canal refurbishment, landscaping and retaining walls.

 

Gabion Baskets of Galvanized Steel Hexagonal Wire Mesh

Basket shape compartmentalized containers are made of galvanized steel hexagonal wire mesh twisted have sufficient strength to contain the stone used as a fill, suitable for channel and foundation shifts.

The galvanized wire, before being woven, can be coated with a special PVC (polyvinyl chloride) coating 0.5mm thick. This additional coating gives full protection from corrosion in marine or heavily polluted environments.

This type of gabion baskets must have the following features to meet the various needs:

· Hexagonal mesh pattern critical points
· Double twist to avoid unraveling
· Reinforcing wires woven into corners to reinforce critical points
· A diaphragm securely attached at the base that will prevent the shifting of some and reinforce the gabio.

THE ADVANTAGES
1. FLEXIBLE
Superior to rigid type structures. The hexagonal mesh construction permits natural adjustment to varying conditions of earth settlement without causing fracture or collapse of the structure.
2. DURABLE
Gaps between the stones silt up naturally as time passes. Silting supports the growth of grass and plants which serve as a bonding agent for the stone.
3. PERMEABLE
A Gabion structure allows water to pass through, water pressure cannot build up behind it and the structure is continuously drained.
4. STRONG
The flexibility of the Gabion structure provides the inherent strength to withstand and dissipate pressures exerted by water and earth masses.
5. ECONOMICAL
Filling materials are usually found on or near the site. No structural maintenance is needed and foundation work is usually unnecessary.
6. NATURAL APPEARANCE
Natural stone makes the structure aesthetically pleasing especially when subsequent vegetation growth takes place.
7. SIMPLE
Unskilled labour can be used for quick assembly.
8. MAINTENANCE
Gabion structures are easily maintained using additional mesh or grouting.
9. FUNCTIONABLE
Once the structure is built there is no waiting period – it functions immediately.
10. EXTENDABLE
Extensions are simple. Additional units are simply attached to the existing ones.

Baskets come in flat pack form and are assembled on site. They can be used in a range of applications from small domestic projects to large industrial schemes.
The infill to the baskets is usually locally sourced stone ranging from 200mm - 100mm. Hand facing ensures that the wall has good cosmetic appearance.

 

PROJECTS

HEAVY GALVANIZED MATTRESS BASKET OF GABIONS WORK

Resistance: Heavily galvanized with Galfan, a Zn-5% Al-MM (mischmetal) alloy, then a 0.5 mm thick PVC/Epoxy coating is applied.

Gabion Size: 2x1x0.3 and 2x1x0.5

Materials
The quality of stone for gabion shall be as specified in Clause 5.1. The smallest dimension of any stone shall be at least twice that of the longer dimension of the mesh of the box.

Cage wire: The cages shall be constructed from steel wire with mechanical characteristics higher than ones suggested from EN 10223-3. 

The steel wire used in the manufacture of the gabion must be heavily galvanized with Galfan, a Zn-5% Al-MM (mischmetal) alloy, then a 0.5 mm thick PVC/Epoxy coating is applied. 

Zinc coating: The Minimum weight of zinc coating per unit area of uncoated wire surface shall be at least 200 gms per square meter.

Tensile strength of the wire: between 40-50 kg / mm2

Gabion mesh: The wire netting double twisted to form a square mesh of 100 mm x 100 mm size or triple twisted to form a hexagonal mesh of 80 mm x 100 mm. 

The 10 gauge wire shall be used for the formation of the mesh panels. 

The tolerance on diameter of wire shall be ±2.5%.

All edges of the boxes shall be finished with a selvedge wire of 8 gauges. 

Diaphragms shall be manufactured of the same materials as the parent gabion and shall have selvedge wire throughout their perimeter. 

Diaphragms shall be positioned in such a way that no internal dimension in a gabion box and mattress exceeds 1.0 m along length of the gabion boxes.

All boxes shall be supplied with binding and connecting wires of sufficient quantity to bind all diaphragms and closing edges.

GABION BASKETS AND MATTRESSES, GALFAN COATED

Wire thickness: 5mm
For JAMAICA project

Baskets
1800mm length x 900mm width x 1000mm high gabion basket
Held together with 8x10 double twisted hexagonal steel woven wire mesh as per ASTM A975-97
Tensile strength between 372-470 according to ASTM A856), 5mmØ galfan coated

Basket Mattress
3600mm length x 2400mm wdith x 150mm high (9' x 6' x 6")
Galvanized Mattressess, held together with 8 x 10 double twisted hexagonal steel woven wire mesh as per ASTM A975-95
5mmØ galfan coated

MATTRESS AND GABION BASKETS FOR BELGIUM PROJECT

Gabion works are constructed with mattress and baskets as follows:

Double wire woven mesh Gabion-baskets:
Dimensions: 1,0 x 0,5 x 0,5 m (length x width x height)
Mesh size: 80 x 100 mm
Wire diameter: 2,7 / 3,7 mm.
Border wire: 3,4 / 4,4 mm.
Galfan coated wires, hot dipped,
GALFAN alloy: 5% Aluminium + 95% Zinc
Designed with seperate covers

Double wire woven mesh Gabion-matresses

Dimensions: 1,0 x 1,0 x 0,2 m (length x width x height)
Mesh size 60 x 80 mm.
Wire diameter: 2,2 / 3,2 mm.
Border wire 2,7 / 3,7 mm.
Galfan coated wires, hot dipped
GALFAN alloy: 5% Aluminium + 95% Zinc
Designed with seperate covers

GALVANIZED IRON WIRE GABION BASKETS FOR INDIA

Mesh: 100 mm x 100 mm mesh
Wire: 10SWG galvanized iron wire
Zinc coating: Wire (annealed) having a zinc coating of 80-150 grams per sq. meter
Gabion size: 3m x 1m x 1m fitted with two equally spaced dividers of 1m x 1m

GABIONS FOR PANAMA SLOPE STABILITY PROJECT

Solution with gabions for the slope stability in Panama: to set up a gabion wall 

Gabion Basket Dimensions
The standard dimensions of the gabion basket are 1.50m (width) x 1.00 (height) x 2.00m (length). 
The gabion length can vary to 4.00m.
The gabion box is divided into internal cells of 1.00m, by diaphragms.

Gabion Mesh 
Material: Double twisted wire mesh
Mesh type: 80 x 100 mm, double twisted hexagonal woven steel wire mesh.
The double –twisted wire mesh and the lacing wire or split rings used are conform the standard for gabion manufacture: ASTM A975-97 (2003).

The relevant European standards for mechanical and corrosion protection properties of the wire and the mesh are given as below.

European Standards for Double Twisted Wire Mesh

Wire properties European tetsing standards Steel wire composition EN 10218-2:1997 Steel mesh composition EN 10223-3:1998 Corrosion protection (galvanising) EN 10244-1:2001
EN 10244-2:2001 Corrosion protection (ploymer coating) EN 10245-1:2001
EN 10245-2:2001
EN 10245-3:2001

Corrosion protection
The most highly corrosion resisting galvanisation process is used, together with plastic coating to protect the gabions from marine salty environment.
To increase durability, steel wires are protected from corrosion risks. Steel wires are highly galvanised with galfan and covered with plastic coating.
Mesh wire diameter: 3.9mm, coating min. mc = 290 g/m²

Corrosion protection for the mesh is provided in two ways: first by the process of galvanising the wire and second by an additional polymer coating, PVC, manufactured in accordance with EN 10245:2001.

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Want more information on woven gabions? Feel free to contact us.

The Galfan coating, comprises of 95% zinc and 5% aluminium. A 95 Galfan coating is three to four times more durable than the same amount of conventional zinc protection.

Galfan coated wire mesh gabion baskets modules filled with boulders, layer on layer for construction of gabion wall

Stainless Steel Wire Mesh Cages ( Baskets) for Gabion Wall Project in Singapore

Basket dimension : 450mm x 450mm x 1500mm(H)
Mesh: Woven gabion (twisted gabion) Type, mesh 75 x 75 mm
Material: SS316
Wire diameter: 4mm

Twisted Stainless Steel Wire Minimum Sizes:
Diameter of wire for mesh: 2.95 mm min.
Selvedges wire: 3.80 mm min.
Binding wire: 2.20 mm min.
Interlocking wire fasteners: 3.17 mm min.

Gabion cages can be knock-down or folded into panels for easy export packing.
Accessories also supplied: Spiral, U-Clip connectors, C-Ring and etc.

Gabion Baskets for Gabion and Pond Works Projects

Lined gabion basket in two sizes:
1500 x 1000 x 1000mm
1000 x 1000 x 1000mm

STANDARD GABION SIZES
(80 x 100 x 2.7mm)

1 x 1 x 1 1,5 x 1 x 1 2 x 1 x 1 3 x 1 x 1 4 x 1 x 1 2 x 0,5 x 0,5 2 x 1 x 0,5 3 x 1 x 0,5 4 x 1 x 0,5 6 x 2 x 0,5 To suit site conditions the manufacture of other custom made sizes is possible.
Class A galvanized or with an additional PVC coating.

To suit site conditions the manufacture of other custom made sizes is possible.Class A galvanized or with an additional PVC coating.

NOTES TO DESIGN ENGINEERS
Today, Gabions are recognized as a standard civil engineering material and as such, are specified on most civil contracts. A neat, well-defined structure is not only aesthetically pleasing, but is the first step towards a sound and durable structure.
We have found in the past, that of the few structures that have failed, most failures were due to poor construction. Great care should be exercised to ensure that the baskets are properly wired together, pretensioned, cross-braced and filled with stone that will not pass through the mesh.
We, therefore, draw particular attention to the construction procedure.

SECURITY
It is well known that gabions offer a formidable defense against enemy attack, such as rocket fire, bomb blasts, grenades etc. A 1m high wall around a farmstead offers some protection. Bunkers and bomb shelters can also be additionally protected with gabions.

APPLICATIONS

Basket Gabions have a wide range of uses, we have listed the most common ones below for your information:
Mass-gravity walls,Reinforced soil walls, River canal lining,River training structures, Groynes,Gabion weir or dam structures, Roadway culvert in or outlet structures, Low-level crossings,Longitudinal river structures, Biofilters,Rockfall mesh netting, River diversion structures, Architectural cladding, Barrier work, decorative applications, Bridge abutments and protection.

Contact us for any information if you may need any gabion baskets or information in regard to building gabion works project.

You’ve probably seen them in all kinds of places: wire baskets of stones piled up against slopes and rivers, or neatly dividing green spaces. Gabion walls have seen a resurgence in use and popularity lately, but they are far from new. Used by military and structural engineers for thousands of years, including on the banks of the River Nile, they form a time-tested and dependable structure that has countless benefits and uses.

What are gabion walls?

The word gabion comes from the Italian gabbione which literally translates as “big cage”, and this is essentially what they are – cage-like enclosures filled with inorganic material like stone, brick or broken concrete. Also known as gabion cages, their main use in structural engineering has been for protecting shorelines, river banks and slopes from erosion, and they're either laid at angles in “mattress” form or, more commonly, stacked incrementally like bricks.

Nowadays though, they are used for all kinds of other practical reasons, as well as purely aesthetic reasons. More and more gardens, urban spaces, towns and land re-development projects are transforming the way gabion baskets can be used and are employing them to build walls, pillars, benches and base structures, as well as to separate and divide areas, reinforce earth walls, and as a buffer for water features. The baskets themselves can come in a range of different sizes to suit all kinds of needs and designs, and are constructed using tough, galvanised wire mesh, usually of a 3mm thickness.

One of the reasons gabion walls are so popular with gardeners and landscapers is because anyone can build and place their own baskets and use them how they want to – they’re the DIY way to build walls and other similar structures in your own space. All it takes is a plan and some elbow grease.

Images by Catherine Stewart.

Take a look at Catherine Stewart’s post which explains every step she took to build a gabion wall in her front garden, including step-by-step pictures to show you how everything went together. As Catherine explains, she was able to fill hers with on-site sandstone which they broke up themselves, but that doesn’t mean you need an abundance of available stone on your doorstep in order to fill up your basket. Gabion stone can be sourced easily and in a range of sizes and colours, meaning you can tailor your design to fit your environment, making them an attractive and customisable addition to your space.

Benefits of Gabion Walls.

1. Flexibility.

One of the core reasons that gabion walls have stood the test of time – ever since they were used on the banks of the River Nile – was that they are extremely flexible and durable. Under great stress, a gabion basket will deform, buckle or compress very slightly, rather than break. This is a functional feature that prevents loss of structural integrity and ultimately makes it stronger over the course of time. Additionally, not being fixed to the ground (like a normal wall would be) means there will be an allowance for all the small ground movements which happen naturally.

2. Strength.

Though it might not look it, the wire mesh that makes up the basket or cage is very strong under tension and acts as a reinforcement of the overall structure, rather than just a container. And due to silt and vegetation collecting in between the filling over time, they actually become even stronger with age, and form a naturally permanent structure. Many people have taken advantage of this fact to use gabion baskets as a base for tables and benches.

3. Permeable.

The nature of the way gabion baskets are made means there is space in between the stone filling. This allows both air and water to pass through, which allows the whole structure to breathe. On the other hand, concrete structures can build up hydrostatic pressure due to their impermeability, and this can compromise their structural integrity.

4. Cost-effective.

Made from wire mesh, gabion baskets are less expensive than most construction materials like concrete, and can be put together easily by anyone, avoiding the need to buy heavy concrete or to mix it yourself. Filling like stone or broken concrete can usually be sourced locally and at a much lower cost. At Mainland Aggregates, we supply a wide selection of gabion stones to fill gabion baskets. Our range includes white gabion cobbles, blue pennant gabion stone, dove grey gabion stone and Cambrian green gabion stone.

Labour costs can also be all but eliminated, as almost anyone can construct a gabion basket structure without the need to hire people to do it. The only exception here is if you’re building over a metre in height – then we recommend consulting a professional in order to keep it safe.

5. Firm Base.

One of the key benefits of gabion walls over traditional walls is that you don’t need a conventional foundation – a compacted layer of filling like crushed rock is often all that is required to give the baskets a firm footing. You may think that translates to the base not being firmly planted in the ground, but this isn’t the case. As long as you’ve flattened and prepared the ground to put the wall on, the fill at the bottom of the basket will settle into the ground directly, providing frictional strength which keeps the baskets in place and prevents the structure from being dragged away by a river or stream.

6. Reduce Erosion.

The principal benefit and practical use for gabion walls, as mentioned above, is to reduce or prevent erosion. This works by absorbing the force of flowing water, as the energy is dissipated by the stone fill, thus protecting areas under risk of erosion. For this reason, they’re used to bolster river banks and shorelines that are under threat of erosion. If you have a pond or a stream, or your garden backs onto a river, a gabion wall be a great practical way to protect the land.

7. Aesthetics.

A major reason that gabion baskets and walls are popular is that, despite being man-made structures, they still look natural and can match a space to its local terrain through the use of local filler materials. Baskets of many different sizes and shapes can be used, including curved baskets which form a bend or circle when put together, and filling of all kinds of colours, textures and sizes can be used inside them.

8. Eco-friendly.

When local material is used for filling, transportation costs and the associated fuel consumption are almost eliminated, meaning putting together a gabion wall takes much less toll on the environment than a traditional concrete wall. Also, since the filling is making use of materials that already exist, there is no extra demand on the creation of concrete or other such materials. Thanks to their strength and permeability, gabion walls are also extremely long-lasting, durable and sustainable, so won’t need replacing or repairing as often as other walls.

9. Easy to Install.

As long as you’ve done some research and have what you need, you can put together your own gabion wall within one day. All it takes is to fasten the baskets together, prepare the ground where they will lie, and fill with your chosen filling. One key trick is to pick your flattest and best-looking pieces of stone or rock for the sides that will be seen most frequently – many people line the edges with the best pieces and fill the centre with cheaper filling like broken concrete, as well as saving any rare right-angled pieces for the corners. If you’re building over a metre in height or planning to build on top of the wall or baskets, then you should consult a structural engineer, but for other uses, they really can be done all by yourself.

10. Not Permanent.

Unlike a concrete wall or structure, gabion baskets aren’t fixed to the ground, and can therefore be moved or taken down with relative simplicity, to accommodate a changing environment or just aesthetic preference. This can give you the flexibility to try out a garden or landscape design, and if you don’t like the look of it or how it works practically, you can take apart the baskets and move them around however you like, as many times as you like. Just be prepared for a bit of heavy lifting! 

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