Gabion Wall- Gabions Retaining Wall- Modular Prefabricated Gabions Network-Gabion Units, Geo Grid, Geotextile and Filling Stone

Gabion Wall, or Gabions Retaining Wall, is a wire mesh network made with prefabricated gabions filling with stones or rocks for a wide range of application such as Slope stabilization, noise barrier, landscaping, facing-element and soil retaining works in construction and engineering projects. We supply retaining wall gabions for building of gabion wall of different designs and effects.

Welded gabion retaining walls are used in industrial, architectural and landscaping projects, highway and railway bridge construction projects, flood control and water management.

Woven twisted mesh gabion retaining walls are mainly used in erosion control and environmental projects, slope stabilization, natural and rural landscaping, also hydraulic and water management projects.

Gabions Wall Types

 

Gabion Retaining Wall - complete with all required material, including gabion units of double twisted woven steel wire mesh, geogrid and geotextile for Canal Construction Project

Gabions Units

Supply of Gabion units of 0.3m high made of mechanically woven, double twisted, hexgonal shaped steel wire Mesh type 10x12 with minimum punch strength 19kN, Mesh wire dia 2.7/3.7mm(ID/OD), Galmac(Zn90%+Al10%)+PVC coated, Mechanically edged/selvedged and shall have minimum 10 numbers of mesh openings per meter of mesh perpendicular to twist, with partition at 1 m interval as per the detailed technical specification.

Site Primary Reinforcement by GeoGrid

Supply of high strength flexible geo‐grid as primary reinforcement with a high quality coating like LDPE or equivalent. Latex or PVC coating or geo‐textile or any other coating not permitted. Selection of geo‐grid be strictly based on long term design strength values for a design life of 120 years at 30oC. GEOGRID shall have High Strength Flexible Uniaxial with low creep characteristics consisting of polyester (PET) & having an outer protective coating of low density polyethylene sheath. It shall have Ultimate tensile strength as mentioned below against each sub item for reinforcement in Flexible Retaining Wall etc. High Strength Geogrid of 200 kN/m

Providing and Executing of Gabion fascia

Providing and Executing of Gabion fascia with integrated tail units of Thermally bonded non woven geotextile as filter media behind Gabion fascia units and Mattress, as per geotextile. The width of the geotextile roll shall not be less than 4.5m, at easily accessible location including top and bottom, with all leads and lifts, manpower and machinery, materials, labour etc. complete as per the detailed techncial specifications.

Draining

Supply of drainage composite for use behind walls, between two different fills, alongside drains of road, below concrete lining of canals etc. Three dimensional composite with thermobonding a draining core having “W” configuration in extruded monofilaments of minimum thickness 6mm, with two filtering UV stabilized polypropylene nonwoven geotextile of minimum thickness of 0.75mm and tensile strength of 8.0 kN/m that will be working as separation or protecting layer, geocomposite having in plane flow capacity of 2 L / (m.s) at hydraulic gradient of 1.0 & 20 kPa pressure and tensile strength of 15 kN/m, with mass per unit area of 660 gsm, at easily accessible location including top and bottom, with all leads and lifts, manpower and machinery, materials, labour etc. complete and as directed.

Laying Gabions

Providing and laying Gabion of mechanically woven, double twisted, hexgonal shaped steel wire Mesh type 10x12 with minimum punch strength 19kN, Mesh wire dia 2.7/3.7mm(ID/OD), Galmac(Zn90%+Al10%)+PVC coated.

UNDERLAYER (GABION STONES)

Rock shall be hard, sound homogenous rock of good durability. It shall be free from laminations and weak cle.avage planes and shall be of such character that it will not disintegrate or erode from the actions of air, water, wetting and drying and impact due to wave action. It shall not contain harmful materials such as iron pyrites, coal, mica, laminated material or any materials in sufficient quantity to adversely affect the strength and durability of the material. It shall be capable of being handled and placed without undue fracture or damage. It shall be free from coating of clays or other deleterious material.

ROCK PRODUCTION AND HANDLING

Rock shall only be obtained from sources approved by the Engineer.
Rock quality shall be carefully monitored throughout the quarrying process and the Contractor shall ensure that quarried materials are produced to the size, quality, weight and shape specified herein. The Contractor shall ensure that damage to the armour rock during stockpiling, transportation and handling is kept to a minimum.

QUALITY OF ROCK

Rock for sea defence construction shall comply with the limiting values for tests listed. The tests shall be carried out on representative samples of rock to be used in the Works. A new series of tests will be required for each new source of rock and if there is a change in the nature of rock in any one quarry.

GRADING OF GABION STONES

Rock for under layer usage shall comply with the grading limits listed . These limits shall apply to any load of such material delivered to the Site.The median weight of individual rocks in any load to be used in the under layer shall be between 7kg and 1 Ikg.
Each set will contain a 0.35 kg, 0.65kg, 2 kg, 9 kg, 13kg and 20 kg. One such set of labelled rocks will be displayed at a prominent position at each site and one set at the quarry. Compliance with the above stated mass distribution will be ascertained by the Engineer by visual inspection on work site.

Sandwiched Gabion Wall Element

The gabions can be a sandwich element consisting of wire mesh, with hexagonal mesh in front of the face side accompanied by coconut fabric, plastic mesh, backed by mesh fabric of large wire diameter, used as a filling material used in soil compaction or recycling. Modular prefabricated gabions network made with hexagonal wire netting has the whole system consisting of integrated parts to form a firm and flat surface gabion work.

 

Gabion Retaining Wall - Welded Cage Gabions

Welded cages 6'-9' long by 1.5' wide and 3' tall, opening 3" x 3" ,wire diameter 4-6mm, galvanized or galfan treated, for installation of gabion retaining wall
Welded mesh gabion baskets non-rust corrosion protected finish for gabion retaining wall (80' L x 1.5' D x 3' H) ,
2m high wall x 5m long.
3m high wall x 4m long.
front facing of the baskets 10cm departments for stones.

Gabion retaining wall max retained height=3.0m

500highx 1000 gabion baskets filled with clean stone, as below:

Gabion retaining wall max retained height 2.0m
Gabions position with backwards lean of 3 degrees.

 

Gabion Wall Basket

Galvanized Zinc Coated Gabion Wire Mesh, 100mm x 100mm Openning, Gabion basket wire wall

Drawing reference:

Specification
Gabions are made from welded steel mesh grid with welding strength 70% of the ultimate tensile strength of the wire.
Mesh Size:
The mesh openings shall be square and of a nominal dimension of 100mm on the mesh grid
Mesh Wire:
The nominal wire diameter shall be either 3.0mm or 4.5mm diameter wire. The tensile strength shall be in the range of 500-770 N/mm2
Corrosion Protection:
Galvanized wire mesh heavy zinc coated.
Gabion size
1m x 1m x 1m

 

Rock Filling Material for Gabion Retaining Wall

Gabion Basket Wall can be designed and constructed with crushed concrete and faced with high quality stone fill. High-quality rock filling materials are crucial for gabion retaining walls to ensure the effectiveness, durability, and stability of the structure. Rock filling and other filling materials maintain gabions work Structural Integrity and Stability.

Gabion walls often support significant. High-density, high-quality rocks provide the necessary weight and strength to resist lateral earth pressure, enhancing the structural stability and reducing the risk of displacement under load and preventing wall failure.

Rock Fill Requirement

Rock for filling of gabions and gabion mattresses shall consist of quarried or selected stone of suitable materials. The specified stone sizes correspond to a nominal mass of stone as follows below. Stones should be semi-round.

The rock and gabion fill shall be designated by size in such a way that the smallest individual stone should have a spherical diameter 1.5 times of the largest opening size D of the gabion mesh. 

The stone size distribution must satisfy the following requirements:

Cumulative weight passing sieve	Sieve size (mm)
90 < y < 100%	350
10 < y <  50%	180
0 < y <  10%	90
0 < y <   2%	1.5 D

The weight of each sample must be at least 700 kg and be sieved by a sieve with square openings of 350 mm, 250 mm, 180 mm, 125 mm, 90 mm and 63 mm. The sieve shall comprise steel rods of 12 mm diameter welded together at right angles, thus forming square openings with the above given square opening sizes with tolerance ± 0.5 mm. Sieves from perforated metal plate shall be in accordance with ISO 565.

The average density of rock must be > 2.600 kg/m3 with 90% of the stones having a density of at least 2,500 kg/m3. 

Retaining walls for highways and railways construction

Project example: Gabion walling is being used to construct an access track along the length of an existing train station. The access track will be used by a pilling rig that will be required to place new foundation when the existing station is demolished and the new railway station constructed. The gabion wall is constructed both sides of railway line and has to be constructed and backfilled in 4m lengths. This limits the chance of slipage to the embankment.