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.

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.

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.

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.