Dura-Weld Gabions

Gabion Supply offers US Made Gabion Baskets and Mattresses fabricated from precision welded corrosion resistant steel wire mesh assembled into square or rectangular cells of varying sizes. The most common Gabion Baskets for a retaining wall measures: 3'x3'x3',  6'x3'x3',  9'x3'x3' and 12'x3'x3' with opening of  3" x 3" in a square pattern

Other sizes, shapes, wire gauges and mesh openings are available upon request

Gabions come to the job site pre-fabricated and knocked down for economy in transportation. They are easily erected, set into place and filled with stone to form a monolithic, flexible structure which provides low cost, long-term erosion control and soil stabilization

The high permeability of gabions eliminates buildup of hydrostatic pressure which will displace and crack rigid concrete structures. Gabions conform to irregularities and dynamics of changing soil conditions without compromising performance

Because of their inherent flexibility, gabion structures can yield to earth movement and retain their full efficiency while remaining structurally sound. They are quite unlike rigid or semi-rigid structures which may suffer complete failure when even slight changes occur in their foundations

Gabion structures act as self-draining units which "bleed" off ground waters, relieving hydrostatic heads. Voids between the stones  dissipate the energy from flood, current, and wave action;  the entire structure is, therefore, a ”breathing," self-draining unit needing no additional drainage. Gabion efficiency, rather than decreasing with age, actually increases. During early periods of use, silt and vegetation will collect within the rock filling to form a naturally permanent structure, enhancing the environment

One of the first gabion structures installed in Europe at the turn of the century for river works was examined after 75 years in service and found to be in perfect condition. From an economic perspective, finished gabion work is invariably less expensive than a conventional structure

The cost of gabions and stone fill is nominal; unskilled laborers can be used in construction; the high cost of underwater excavations, driving piling and underground drainage systems is avoided.

Gabions are virtually maintenance free and construction speed is hastened because no forms, reinforcements, setting or curing time are necessary.

Fully assembled Gabions are supplied with all exterior panels and diaphragms attached to the base. When assembled, they are complete standalone gabions ready to be filled or Gabions supplied as un-assembled flat panels which can be assembled on the job site in minutes. This option offers significant reduction in material costs by the eliminating common panels where gabions join together

GABIONS incorporate two important features. First, diaphragms are used to divide the gabions into one cubic yard long cells and are designed to eliminate movement of the rock fill while reinforcing the structure. Second, the wire is hot dip galvanized. Gabion units are also supplied in plain steel, PVC coated steel, aluminum and stainless steel, Galvanized wire coated with durable, fusion-bonded PVC (polyvinyl chloride) for use in sea works, in water polluted by sewage or chemicals or wherever abrasion is prevalent.

RETAINING WALLS. Gabion walls can be built with speed and economy in all circumstances and are particularly suitable for landslide control in mountainous terrain and in areas with persistently unstable conditions. Where ground is liable to subside, the ability of gabions to deform makes them preferable to a concrete wall which would crack and collapse.

WEIRS. Gabion weirs, drop structures, and check dams are constructed across water courses as grade control structures, energy dissipaters, sediment collectors, as well as to form reservoirs, for water irrigation, and water supply in general.

Gabion weirs are normally provided with a gabion mattress scour protection apron both on their downstream side and at the upstream approach zone. The weir's crest or crown is always protected with a thin layer of concrete for abrasion protection of the gabion top.

REVETMENTS. Gabions are well suited as a protective covering on slopes, river banks, channels, etc., to prevent erosion and stabilize. Gabions will withstand alternative tension and compression without losing their structural integrity and permeability.

FLEXIBLE APRONS. Gabions mattresses are commonly used to protect superstructures against the undermining action of river or sea water. Gabion mattresses will closely follow the changing contours of the bed as scouring progresses, until eventually the erosion is completely sealed off. Conventional noncompliant structures necessitate deep foundations extending well below the maximum scour level and offer protection from settlement of the river or sea bed which might otherwise ultimately lead to their partial or total collapse.

COASTAL AND BEACH PROTECTION. Gabions and gabion mattresses offer excellent protection from wave action by dissipating the energy of impact. They are superior to rip rap because the highly corrosion resistant wire mesh prevents rock displacement while allowing conformation to changing grade.

MECHANICALLY STABILIZED EARTH WALLS. Gabions used in conjunction with the Anchor Mesh technology allows rapid construction of large gabion faced MSE walls. The Anchor Mesh Systems extends the gabion’s top and bottom panels into the back fill to form a continuous load bearing plane from the outer gabion surface deep into the wall for super stability, strength and durability.

MATERIAL. a. General: Gabions shall be made of pre-galvanized welded steel wire mesh of a nominal size of 3" x 3(7.5 cm x 7.5 cm). b. Dimensions: Gabions shall be supplied in various lengths and heights. Dimensions for heights, lengths, and widths are subject to a tolerance of “5% of manufacturer's stated sizes.

FABRICATION. Gabions shall be fabricated in such a manner that the base, sides, lids, ends, and diaphragms can be assembled at the construction site into a rectangular unit of the specified size. Where the length of the gabion exceeds its width, the gabion shall be divided by diaphragms into cells of equal length.

The wire mesh shall be made of galvanized steel wire having a diameter of 0.120(3.0 mm) or 0.106(2.7 mm). According to ASTM A-974-97, all wire used in the fabrication of the gabion and in the wiring operations shall conform to US federal specifications QQ-W-461H and possess a soft tensile strength with a class 3 finish 5 zinc coating in accordance with ASTM A-641. Preformed steel wire spiral binders with a 3" pitch are used to assemble and interconnect empty gabions and shall meet the same specifications as the wire used in the mesh.

After assembly, the individual gabion units are interconnected to each other as per manufacturer's instructions and then filled with clean, hard stone from 4-8' in diameter. The lids are then closed and joined to the top edges of the individual gabions and diaphragms. Ring fasteners and twist-ties may be used in lieu of lacing wire for forming individual baskets and joining empty baskets together. A twist tie shall be provided at intervals of about 6". The connection shall be accomplished by turning the twist tie through 1-1/2 turns. Ring fasteners, twist ties and lacing wire can be used in lieu of spiral binders.