Looking for Gabions and not sure where to start?

While we offer a ton of options to insure we have the right product for the right project we know it can be overwhelming. We’ll try to walk you through how our products are organized and answer a lot of the most common questions we get.

A few notes that will help with the below information:
We generally refer to gabion dimensions with Length x Width x Height as shown in the below photo.

A gabion is composed of front, back, bottom, lid, and end panels. When the length exceeds 3’ in length there are dividing panels added in the gabion so that there is a dividing panel at least every 3’.

Our gabions are divided into 3 main categories based on their construction method:

DuraFlex Gabion
DuraFlex Gabion
DuraWeld Gabion
DuraWeld Gabion
DuraGuard Gabion
DuraGuard Gabion

DuraFlex Gabions:

DuraFlex gabions are our double twisted hexagonal mesh gabions manufactured in accordance with ASTM A975-97. This style is most common in civil and erosion control applications in both basket shape and as a reno mattress. DuraFlex gabions are available in standard sizes and most orders ship within a few days. DuraFlex gabions are shipped partially assembled with tie wire to finish the assembly. On larger orders it is well worth the investment to purchase a hog ring gun and hog rings for assembly as it can save up to 30% on your labor.

DuraFlex Twisted Mesh Gabion Baskets are available in 11 gauge galvanized wire for most applications and 12 gauge galvanized wire with PVC coating for fresh water and high and low soil acidity applications. The mesh size is 3.25”x4.5” and generally uses a 4”-8” angular fill. The basket dimensions are available in the below options.

DuraFlex Twisted Mesh Gabion Reno Mattresses are available in 13 gauge galvanized wire for most applications and 13 gauge galvanized wire with PVC coating for fresh water applications. The mesh size is 2.5”x3.25” and generally uses a 3”-6” angular fill. The mattress dimensions are available in the below options.

A few accessories that come in handy when installing DuraFlex gabions are:

Lid Closure Tool: Is a lever tool that allows you to press the lid closed to insure a tightly filled and fitted gabion when closing the lid after filling.
Corner Closure Tool: These pliers allow you to grip two corners of gabions and squeeze together while securing seams to insure a tight fit.
Gabion Guard: These folded steel guards are placed on the end panels and diaphragms while filling the gabions. By dissipating the force from stone hitting the top edges of the gabions it allows you to fill the gabions with equipment more efficiently because you are not having to constantly straighten and readjust the panels as the gabions are being filled. Generally 3-5 guards are sufficient for most projects.
Hog Rings and Hog Ring Guns: As mentioned above, while a hog ring gun can be an expensive investment they can quickly pay for themselves thanks to significant labor savings. We also offer a buy back program allowing you to use a gun for your project and if still in good working order we will buy the gun back at a reduced rate.

DuraFlex Gabion Standard Sizes
DuraFlex Gabion Standard Sizes
DuraFlex Mattress Standard Sizes
DuraFlex Mattress Standard Sizes

DuraWeld Gabions

DuraWeld standard gabions are our welded wire mesh gabions manufactured in accordance with ASTM A974-97. While welded wire gabions can be utilized in civil and erosion control options similar to twisted mesh gabions, due to their aesthetics and flexibility in basket dimensions they are the most common style for landscape and architectural applications. When we discuss DuraWeld STANDARD versus CUSTOM gabions we are referring to the mesh itself. All of our DuraWeld gabions both standard and custom are made to order so the basket dimensions just have to be in increments of the mesh size. Our standard DuraWeld mesh is a 3”x3” mesh so the basket dimensions need to be in increments of 3”.

Our standard DuraWeld mesh options are all 3”x3” but we have several choices in both finish and wire diameter.

The standard options are as follows: 11 gauge galvanized, 12 gauge galvanized with PVC, 9 gauge raw steel (is allowed to rust), and 9 gauge galvanized steel.

While our DuraWeld standard gabions are most commonly found in the typical dimensions found in DuraFlex baskets we have much more freedom in basket sizing as shown below with ability to offer dimensions in 3 inch increments within the ranges given. Our standard DuraWeld gabions are shipped partially assembled and lead time ranges from 1.5 weeks to 2.5 weeks depending on what orders are in the queue. Our standard DuraWeld gabions ship with a variety of standard accessories that allow the gabions to be assembled quickly. The gabions are partially assembled with helical spirals and will ship with enough helical spirals, stiffening rods, and tie wire to finish assembling the gabions on site.

Our CUSTOM DuraWeld mesh options cover various mesh opening sizes, basket sizes, wire diameter, and material type and finish.

While custom mesh may end up being more expensive when comparing basket to basket, when taking into account the overall project, such as fill amount and installation time, it can end up saving you money in the long run.

Smaller mesh openings can allow you to utilize smaller fill material which in turn allows you to utilize a thinner basket in landscaping or veneer applications reducing the amount of stone needing to be purchased and loaded. In addition to custom mesh manufacturing capabilities we can also provide framed gabions. In many cases it is cheaper and more efficient for the end user to apply framed angle iron on site as the gabions can not be folded flat for shipping once the frames are added to the panels. Applying the frames onsite also gives you more flexibility in fitting your gabion units to the site requirements which can change during install depending on the project.

Regarding our custom mesh options:
-We can offer mesh spacing from 3/4” up to 8” and can do both square and rectangular patterns.
-We can offer 13 gauge up to 4 gauge wire diameter.
-Material options for custom mesh are as follows: Raw Steel, Galvanized before Welding, Galvanized after Welding, Galfan, Grade 304 Stainless Steel, and Grade 316L Stainless Steel. -We can do up to 12’x6’ panels and our custom gabion mesh is shipped unassembled as individual panels on pallets for assembly on site.
-The assembly accessories included with our custom gabion mesh orders vary depending on the material type, mesh spacing, and quantity. These accessories are often shipped separately from the panels themselves by either UPS parcel or LTL on a pallet for larger quantities but MAY include spirals, tie wire, hog rings, and corner stiffeners.

A few accessories that come in handy when installing DuraWeld standard and custom gabions are:

Lid Closure Tool: Is a lever tool that allows you to press the lid closed to insure a tightly filled and fitted gabion when closing the lid after filling.
Corner Closure Tool: These pliers allow you to grip two corners of gabions and squeeze together while securing seams to insure a tight fit.
Gabion Guard: These folded steel guards are placed on the end panels and diaphragms while filling the gabions. By dissipating the force from stone hitting the top edges of the gabions it allows you to fill the gabions with equipment more efficiently because you are not having to constantly straighten and readjust the panels as the gabions are being filled. Generally 3-5 guards are sufficient for most projects.
Hog Rings and Hog Ring Guns: While Hog Ring Guns are not common with standard DuraWeld baskets because spirals are already a quick installation option, they are still used occasionally for aesthetic reasons. With Custom DuraWeld gabions, depending on the mesh size, basket dimensions, and quantity, hog ring guns may be the optimal method for assembling the baskets. We also offer a buy back program allowing you to use a gun for your project and if still in good working order we will buy the gun back at a reduced rate.

DuraWeld Standard Sizes
DuraWeld Standard Sizes

DuraGuard Gabions

DuraGuard gabions are constructed of 100% virgin, UV stabilized polypropylene plastic biaxial geogrid and sewn together with marine grade nylon cordage so they are an excellent option for salt water applications. An optional assembly version is with Grade 316L Stainless Steel but it should be noted that ALL steel will eventually rust in salt water. Our DuraGuard baskets have small apertures, approximately 1.5”x1.5”. While below sizes are the standard options we have the ability to make custom sizes as they are all made to order.

DuraGuard Standard Sizes
DuraGuard Standard Sizes

Summary

We hope this provided a good breakdown of your options when deciding on the right gabion for your project. We have more detail and information throughout our website including details on various gabion applications. We also have a YouTube Channel that has several webinars as well as short explainer videos. You can also reach out to us via phone (866.391.6295) or email (info@gabionsupply.com) and speak with one of our sales associates and we will be happy to help you!