Gabions are manufactured with all components Red star wire mesh factory connected at the production facility. All gabions are suppliedin the collapsed form, either folded and bundled or rolled. The bundles are compressed and strapped together at the factory for easy shipping and handling. Lacing wire is suppliedin coils. Ring fasteners (Figure 9) are shipped in boxes which must be stored in a dry environment. Preformed braces are shipped in bundles.
The folded units shall be taken out from the bundle and placed on a hard flat surface. Gabions shall be opened, unfolded and pressed out to their original shape. Front, back, and end panels shall be lifted to a vertical position to form an open box and lid (Figure 1). Panels shall be fa stened together with the projecting heavier gauge selvedge wire by firmly wrapping the selvedge wire around the selvedge or edge wire of the intersecting panel or back panel (Figure 2). Inner diaphragm panels shall be lifted into a vertical position and secured in the same manner to the front and back of the gabion (Figure 3).
When using lacing wire, cut off a length of wire approximately 1,5 times the length of the edge to be tied. The maximum length of the edge to be tied at one time shall not exceed 1 m. Longer edges shall be joined by several lengths of wire. Lacing wires shall be secured around the selvedge wire or heavier edge wire, where present, by looping and twisting the lacing wire around itself. Proceed tying with alternate double and single loops (Figure 4). Double loops shall be made at intervals not greater than 300 mm. All panels shall be pulled tightly together during the tying The other end of the lacing wire shall be secured by again looping and twisting the wire around itself. When using lacing wire to assemble the units, care should be taken to avoid damaging the wire coating. When steel ring fasteners are used, the custom made Maccaferri Manual Spenax Tool (Figure 10) is required and is available for hire. Rings shall be installed at the top and the bottom connections of the end and centre diaphragms and then a maximum spacing of 100 mm along all edges shall be used (Figure 4).
The foundation on which the gabions are to be placed shall be level and graded to the elevations as shown on the project drawings, and free of surface irr egularities, loose material, and vegetation in accordance with the project specifications. Appropriate measures must be taken for drainage around the foundation, as per the project s pecifications (geotextile, drain bion structures shall works, etc.). Geotex tiles installed behind gabion structures shall comply with the requirements for subs
Installation and Filling
After the foundation has been prepared, the pre-assembled
gabions shall be placed in position empty, and tied or fastened to adjacent gabion units along all edges in order to form a continuously connected, monolithic structural unit (Figure 8).
Rocks for the gabions may be produced by any suitable quarrying method, and by the use of any device that yields the required sizes within the gradation limits chosen. Rocks shall be hard, angular to round, durable and of such quality that they shall not disintegrate on exposure to water or weathering during the life of the structure.
Welded gabion mattress is manufactured from cold drawn steel, electronically welded at each section to form welded mesh panels and covered with PVC coating for additional anti-corrosive property.
The PVC coated heavy hexagonal mesh is manufactured from low carbon steel wire and coated with a PVC coating to strengthen the anti-corrosive property.
Gabion mattress is also called reno mattress, it is mainly composed of double twisted hexagonal wire mesh, thus the mesh shape is often hexagonal shape.