Gabion Wire Guide &#; Everything About Gabions

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Introduction

Gabion wire is a versatile product that has applications in a wide range of industries. It&#;s often used as a fencing material or as a support for retaining walls, although it&#;s also used as a streambank erosion control or to stabilize slopes. In agriculture, it can be used to cover seeds while they germinate and to protect the roots of young plants. (I hope you didn&#;t see that coming!) But what is gabion wire, exactly, and how is it made? Read on to learn more.

What is Gabion?

Origin of Word Gabion

The word gabion has been derived from the Italian word &#;gabbione.&#; It refers to a cage or a cylinder or a closed compartment made out of welded wire. This box is then filled with materials like concrete, sand, or rocks.

Applications of Gabion Wire

The gabion is then put to use in the civil engineering, military, and landscaping projects, to name a few. The engineers create gabions of different types as per need and use them in engineering works as per the requirement. At times, it is necessary to boost the durability of the gabion. The maker of the gabion places branches with deep roots between the rocks that are in the gabion.

What are the types of gabions?

Based on structure of gabion, it can be classified into several type viz.Gabion Baskets / Gabion BoxGabion Mattress /

Gabion Baskets / Gabion Box / Wire Box Gabion

gabion basket

These are wire mesh boxes made for use by project engineers for the highway and railway projects. The engineers make them out of double-screw steel wires twisted hexagonally. They then fortify with fillings of stones, mud, and soil. The dimensions can be of various types.

Gabion mattresses

gabion mattress

They are also called reno mattresses and used for channel coating. It prevents erosion caused by waves due to their velocity.

Gabion sacks

gabion sack

These are in the form of a porous structure, which is also flexible. It is beneficial in hydraulic projects.

Gabion wire mesh

gabion wire mesh

Gabion wire mesh is convenient to keep away loose rocks from falling off the cliffs and mountains onto highways and rail tracks. The wire mesh is also helpful to maintain slopes&#; stability close to rail tracks and highway roads.

Decorative Gabion Elements

gabion decorative

If you want to decorate your garden and landscape, you can use the decorative gabion elements. They are perfect for the quick growth of plants.

Welded Gabions

welded gabion

It is possible to make welded gabions by using galvanized wire mesh. They coat these wire mesh with zinc and PVC.

What are the various applications of gabions?

Gabions are multipurpose utility structures. The engineers use them for many of the heavy engineering as well as military projects.Some of the more common uses in engineering are as under:

Strengthen Walls:

Gabions are used to strengthen walls along embankments as well as cuttings

Prevent Corrosion

Gabion structure can help to prevent corrosion of river walls, canal banks and to protect lakesides

Noise Pollution

Gabion are effective to prevent and reduce noise pollution

Foundation For Dams

To serve as a strong foundation for dams and other such construction structures. The cylindrical gabion of metal is of great use here.

Prevent Flood

Gabions are often utilized to create temporary walls and prevent floods from entering. They are often used to divert the flow of water so that weak structures are not affected by water force.

Decoration

As listed earlier, gabions often serve as decorative structures for landscaping

Prevent Erosion

It can be also used to cover channels such that there is no erosion

Boost Energy Dissipation

To boost energy dissipation in channels by using them as fish screens and as stepped weirs

Promote Air Movement in Building

Modular Wire Mesh Gabions with quarried stone are used to promote air movement in buildings to cool the temperature.

Military Applications

When it came to military use, the gabions proved to be versatile in their utility. In earlier times, they made round gabions that had open tops and open bottoms. They make them using wickerwork and by filling them with mud earth to fortify structures. These wickerwork gabions were lightweight. The military sappers and artillery gunners carried them for their protection. In the field, they use the gabion to construct a bulletproof wall. They do this by filling it with soil and by staking it into the ground and in position.In modern times, the gabions are very protective to FOBs or forward operating bases. They shield from any mortar and artillery fire and also from fragmentary explosions. Usually, the gabions are very useful at mess halls, quarters, and other unprotected places.

Main advantages of the gabion wire.

High durability

Due to the zinc coating, the gabion is highly resistant to any atmospheric corrosion. PVC coating can further extend the life of the wire.

Flexibility

The gabion can stand on even unstable surfaces as well as on water. The gabion maker twists the wire mesh in a double hexagonal manner to lend it a lot of flexibility.

Permeability

There is no need to provide separate drainage provisions. The seamless permeability of the gabion was enough.

Strength

Gabions are very robust as they can resist floods, torrential winds, and even ice.

Affordable

The gabion is affordable to set up. That is because the materials used are not expensive, and labor is not very costly to engage.

Environment friendly

Materials used for the gabion filling are usually soil, earth. There is tremendous scope for the growth and regrowth of plantations on them. They remain unaffected by any natural forces.

What are the main characteristics of gabions?

Characteristics of Gabion Wire are dependent on the

• Galvanized wire diameter
• Coating used and
• Aperture size for the twisting of the metal coating.

More information

• The Standard ASTM A 975 PVC coating or zinc coating makes the gabion&#;s durability and strength much better.
• The tensile strength is generally not less than 38kg/m2, with the wire diameter in the range of 2.0 to 4.0mm.
• The aperture can be 60*80mm, 80*100mm, 80*120mm, 100*120mm, and 120*150mm.

The makers of the gabion do the surface treatment of gabion baskets by the hot-dip method. In this, the zinc quantity used can be or more than 245g/m2. This treatment develops strong anti-corrosion properties in the gabion. Then there is the galfan coated treatment, a coating of an alloy of zinc and aluminum. The PVC coating is generally 1.0mm in its thickness. All these coatings keep the gabions free from corrosion.The structure of the gabions also depends on the types of welded mesh used. Widely spaced mesh is required for Lighter applications. For a gabion wall, the steel wire mesh with a much heavier diameter of wire is used. It makes the structure robust. For filling the gabion, stones of various types is used, and sizes may vary. The bigger the rocks, the more difficult it is to place them in order.When you decide on the height of the gabion structure, you have to keep in mind restrictions that are in force within the neighborhood or town. You may also want to include other features such as lighting or water for the gabion. For this, you need to plan for adequate wiring and plumbing facilities.

Gabion Wire Mesh Manufacturer in India

We are Systematic Group are leading Gabion Wire / Gabion Wire Mesh Manufacturer in India

Our Technical Specifications of Gabion Wire are 

Diameter2.20 mm &#; 4.00 mmGradeMild SteelTensile Strength350 &#; 500 N/mm2Zinc Coating220 to 300 GSM BS ()StandardsASTM A 4 11 , BS EN -1 (), IS 280(), BS Part 3, EN -2, ASTM 641, EN

Benefits of Using Systematic Gabion Wire

Kuojiu supply professional and honest service.

• The steel wire used in the manufacturing of gabions has a heavy zinc coating. Our in-house wire drawing and galvanizing facility ensures maximum control on the end products.
• We ensure that gabions made from our wires provide added protection for use in polluted environments or wherever the risk of corrosion is present.

More Articles

References:

Wikipedia

TheConstructor

Quick Woven Gabion Installation Guide

• Prepare the Woven Gabion:

  Take out the neatly folded woven gabion and lay it flat on the ground. Have binding wire and tools ready by your side.

• Unfold the Gabion Box:

  Unfold the four sides and cover plates of the gabion mesh separately to distinguish the various panels and edges of the gabion that need to be tied together.

• Installation with Cooperation:

  Work together with 2-3 people to use the provided binding wire to tie the partitions and the perimeter of the woven gabion.

• Stone Filling:

  Fill the well-assembled gabionbasket with stones.

• Install Cover Plates:

  After filling with stones, install the cover plates on top of the gabion.

What is Woven Gabion?

Woven gabion basket is made of corrosion-resistant, high-strength galvanized wire or PVC-coated galvanized wire. The woven mesh opening is hexagonal, so it&#;s also called hexagonal gabion mesh. 

Compared to welded gabion box, the woven gabion basket has a certain flexibility in structure, adapting to changes in terrain and enhancing protective effectiveness. Moreover, the installation and construction of woven gabion mesh are straightforward, leading to significant time and cost savings.

Various Applications of Woven Gabion

As a cost-effective and relatively simple solution, woven gabion is suitable for different sizes, designs, and purposes, making it the preferred choice for many professional engineers and gardening enthusiasts. 

In hydraulic engineering, woven gabion basket can be used for riverbank protection, dam protection, riverbed regulation, etc. In geological conservation, it can be applied to slope protection, rock stabilization, landslide control, and more. 

Infrastructure construction benefits from its usage in slope protection for roads, railway safeguarding, and bridge preservation. In ecological environmental construction, it can be utilized for river ecological restoration, slope vegetation restoration, and more.

Step-by-Step Woven Gabion Installation Guide

Like other construction materials and projects, ensuring the secure and stable installation of gabion is always a top priority. 

Whether you are a professional engineer, a distributor providing gabion solutions, or a gardening expert, this article will provide you with detailed installation steps and key considerations for woven gabion basket.

Prepare the Woven Gabion Basket

Before starting the installation, gather all the materials and tools needed for gabion installation. This includes the compressed gabion mesh received from your supplier, along with the provided binding wire. 

Other items include tools like binding hook, ruler and micrometer, and protective gloves. Here, we are demonstrating a set of woven gabion basket with dimensions of 2 meters x 1 meter x 1 meter, and wire diameter of 2.7mm.

Unfold the Woven Gabion

Now, let&#;s unfold the four sides and cover of the woven gabion basket to prepare for the installation work ahead. We can notice that the gabion basket consists of a bottom panel, four side panels, a cover lid, and a middle partition.

Therefore, installing the woven gabion basket is quite simple. We just need to connect the four sides, the partition, and the cover.

Installation with Cooperation

Now, it&#;s time to secure everything with binding wire. For a smooth installation, we recommend collaborating with 2 people. Have 1 person hold the gabion mesh panel sides and partition steady, while another person secures the woven gabion basket with binding wire.

Install Cover Plates

Once all gabion mesh panels are securely in place, you can add the stones. Pop on the gabion basket cover lid and secure it using the same double stranded binding wire method. Congratulations, you&#;ve successfully installed a 2m X 1m X 1m woven gabion basket. Isn&#;t that simple.

7 Must-Know Pro Tips for Installing Woven Gabion

What Should I Check The Woven Gabion?

First thing first, let&#;s measure the hexagonal gabion basket wire diameter, wire mesh hole opening, ensuring that the gabion mesh size and wire diameter match the design specifications. This is crucial for guaranteeing stability and tensile strength.

In the meanwhile, it&#;s important to inspect the surface treatment of the gabion mesh. The zinc quantity and quality of the galvanized wire mesh play a crucial role in determining its corrosion resistance and overall longevity.

How to Tie Gabion Baskets?

Some customers have mentioned concerns about the amount of provided binding wire. The key lies in the binding method. We highly recommend using double-stranded binding wire for a secure connection.

Cut the gabion wire roll to 25cm long binding wire, fold it in half at both ends, thread it through the two-intersection gabion mesh panel, use the binding hook to revolve the double-stranded binding wire to secure. You can also check how to make this in our previous video or on YouTube.

This not only ensures stability of gabion basket but also speeds up the installation process. For each intersection, secure the two gabion mesh panel in every 25 cm. 

Does Gabion Mesh Require a Foundation?

Compared to traditional walls, one of the main advantages of a gabion mesh wall is that it does not require a conventional foundation. Most gabion retaining walls do not need a concrete foundation. Generally, a compacted layer of filler (such as crushed stone) is sufficient to provide a solid foundation for the gabion basket.

While there is no requirement for a foundation, placing the gabion mesh on a flat and stable surface is imperative.  Once filled, the gabion basket becomes very heavy. For example, a cubic meter of gabion box requires about 1.7 tons of rocks to fill, meaning there must be a solid surface underneath the gabion. 

In slope protection structures, the sides of the gabion wall can also be fitted with geotextile fabric that meets requirements.

Depending on the height of the gabion wall, for walls not exceeding 1 meter in height, we recommend using compacted hard core foundation of around 10mm. For taller walls up to approximately 3 meters, we suggest laying a layer of 50-100mm gravel cushion. The gravel cushion should be evenly laid with staggered joints layer by layer.

How to Secure Gabion Wall?

For gabion installed next to or above finished gabion, tie the binding wire along the frame or lower frame of the newly installed gabion to the adjacent gabion, connecting the gabion baskets into a cohesive whole. 

During construction, the gabion layers can be slightly tilted backward between 6 to 10 degrees according to the slope. Unlike stacking one gabion mesh basket of the same size on top of another to form a flat wall, this stepped design provides a more stable structure for the gabion mesh wall. Such a gabion wall will be more stable than a completely vertical gabion wall.

What is the Fastest Way to Fill Gabion?

While we&#;re demonstrating manual stone placement here, if you are installing for larger projects, it&#;s better using machinery for efficient stone filling. Fill a portion with machinery, then manually place stones to minimize gaps.

Simultaneously uniformly feed filling material into each box of the same layer, keeping the thickness of each layer below 30cm. After partially filling, manually place stones to minimize gaps between them. 

Any gaps will increase the risk of gabion wall movement, affecting the safety of your  gabion project. Typically, for 1 meter high gabion boxes, material is filled in four times.

Fill the top with stones slightly above the gabion box, and manually or mechanically stack and level the exposed filling stones. In the end, the entire gabion basket is compact, with filling stones interlocking and any remaining gaps filled with small stones.

How to Prevent Woven Gabion Basket from Bulging?

In addition to using double-strand wire binding for fixation, we also recommend using supports as an additional safety measure. Supporting is crucial for the long-term integrity of the gabion wall. Bulging not only affects aesthetics but also causes unevenness in the gabion wall, increasing the risk of rapid wear and even collapse.

Cross-binding wire in opposing directions on the front and back, as well as left and right sides of the woven gabion basket. This can effectively strengthen your gabion basket project.

Installing supports during basket assembly helps prevent the sides of the basket from bulging outward, allowing the gabion wall to maintain its shape and strength for a longer time. 

What is the Best Stone Material for Filling Gabion?

Not all stones are equal when it comes to filling gabion basket. Firstly, the stones must be hard, not prone to weathering, free from cracks, and of a type not affected by frost. 

Permeable rocks will rapidly weather due to freeze-thaw action. Weathered rocks can compromise the stability of the structure, and smaller stones may fall out of the gabion mesh opening. After the number of filling stones decreases, the stability of the gabion wall decreases.

Ideally, interlocking angular stones are best for filling gabion box. The surface of the stones should be free from impurities such as dirt and rust. The stone density should be greater than 25kN/m3, and compressive strength should be greater than 60MPa. The diameter of the stones should be above 20cm to prevent them from slipping through the mesh holes of the gabion basket.

Conclusion

Now you have been learning all the woven gabion installation guide step-by-step, and some more pro tips.

If you have other concerns about gabion basket assembly and installation, you can always reach out for our gabion specialists.

Contact us to discuss your requirements of Pvc Coated Gabion Box. Our experienced sales team can help you identify the options that best suit your needs.