Hexagonal Gabion Mesh

Hexagonal gabion mesh

Gabion mesh is a type of double twisted, hexagonal woven wire mesh. The wire used to manufacture the gabion baskets is fabricated from high quality tensile, heavily galvanized steel, which is also available with an extruded PVC coating for additional corrosion protection, when required by the application. The double twist of the woven wire mesh provides integrity, strength and continuity to the structure by adding a non-raveling effect that prevents any accidental damage from spreading.

The quality of the iron wire used for the mesh, selvedge wire and lacing wire is one of the key factors in the long term performance of gabions mesh. Nova gabions are manufactured from high quality steel wire woven into a double twist hexagonal mesh to give both mechanical strength and prevent unravelling. 

The steel wire from Nova is strictly controlled and conforms to ASTM 975 or EN/BS 1052:1980 for tensile strength and galvanization.

Specification of hexagonal gabion meshes: 

   Standard gabion Mesh specification:

-  6x8cm,8x10cm,10x12cm,12x15cm,16x18cm

-  Regular size for gabion box:

   Wire diameter:2.7x3.4x2.2mm, mesh size:80x100mm, box size:2x1x1m

-  Regular size for gabion mattress:

   Wire diameter:2.2x2.7x2.2mm,mesh size:60x80mm, mattress size:3x2x0.3m

-  Regular size for gabion mesh roll:

   Wire diameter:2.7x3.4mm,mesh size:60x80mm/80x100mm, roll size:2x50m.

    We can custom make gabion mesh as per your requirements.  

Advantage of gabion mesh: 

1. Flexibility: Flexibility is an important benefit of any gabion structure. The double-twist hexagonal mesh construction permits it to tolerate differential settlement without fracture. This property is especially important when a structure is on unstable soil conditions or in areas where scour from wave action or currents can undermine the toe of the structure and cause structural settlement.

2. Durability
Gabions support plant growth which provides a live coating for the wire mesh and stones, adding to their durability. Generally, the wire mesh is needed for the first few years of the structure’s life; later the void between the stones is filled with soil, silt, and plant roots which act as a bonding agent for the stones.

Strength: Steel wire hexagonal mesh has strength and flexibility to withstand forces generated by water and earth masses, and the previous nature of the gabion allows it to absorb and dissipate much of that energy. This is evident on coast protection installations where gabion structures remain effective long after a massive rigid structure fails. Additionally, the double twisted hexagonal mesh won’t unravel if cut.

3. Permeability
Gabion walls are previous to water and stabilize slopes by the combined action of draining and retaining, precluding the development of hydrostatic pressure behind the gabion wall. Drainage is accomplished by gravity, as well as evaporation as the porous structure permits air circulation through it. As plant growth develops within the structure, the process of transpiration assists in removing moisture from the backfill – a much more efficient system than weep holes in standard masonry walls.

Gabion box is consist of rectangular units, fabricated from a double-twisted hexagonal mesh, filled with stones. In order to reinforce the structure, its edges with a wire having a thicker diameter than the mesh wire. Gabion boxes be divided into cells by diaphragms at every 1 meters.

Application of hexagonalo gabion mesh

The hexagonalo gabion mesh mostly are used as raw material of gabion boxes and gabion baskets, gabions are typically a permanent or semi-permanent slope and/or soil stabilization application.

   Typical installations include:

   -  Retaining walls

   -  Bridge abutments and wing walls

   -  Culvert headwalls and outlet aprons

   -  Shore and beach protection

   -  Water recharge dams / Check dams

   -  Rock slide protection works

   -  River training works

Characteristics of gabion meshes - 

1. Stone filling is characterized by porosity that enables water to flow and doesn’t create hydraulic pressure on the panels of gabion structures, it has drainage function.

2. Gabions are able to deform while still retaining their integrity, they adapt themselves to terrain where the concrete structures may crack and fail, they are suitable for unstable subgrades.

3. The high resistance and durability is secured by outstanding features of steel wire, its surface treatment by heavy galvanization or PVC coating and by the quality of stone filling. During the lifetime the pores are filled up with alluvia and the whole structure is grown through by vegetation what increases its strength and therefore is able to resist against great pressures.

Types of gabion meshes - 

1. Zinc Coated Gabion Box

These are manufactured from mechanically woven double twisted hexagonal wire mesh using Heavily Galvanized steel wire. The edges of the mesh are reinforced with a thicker wire called the selvedge wire to strengthen them and to facilitate construction. Gabions can be divided into cells by fitting diaphragms which reinforce the structure and make installation easier.

2. Zinc + PVC Coated Gabion mesh

In case of marine or highly corrosive environment, an additional protection is provided by extruding a 0.5mm to 0.8mm thick PVC coating over the heavily galvanized wire. PVC coating is done on the galvanized wire prior to manufacturing of the gabion mesh.

3. Galfan Coated Gabion mesh 

Galfan Coated Gabion mesh is a type of gabion mesh that coated with zinc-5% aluminum alloy or zinc-5% aluminum alloy, Compared with traditional galvanized steel gabions with pure zinc coating, Galfan gabion features a heavy zinc – aluminum coating layer which enables an excellent corrosion resistance. The corrosion resistance of Galfan gabion doubles that of traditional pure zinc plating.

Installation - 

1. For easy handling and shipping, gabions are supplied folded into a flat position and bundled together.

2. Gabions are readily assembled by unfolding and binding together all vertical edges with lengths of connecting wire stitched around the vertical edges.

3. The empty gabions are placed in position and wired to adjoining gabions. They are then filled with stones to one-third their depth.

4. Connecting wires, placed in each direction, brace opposing gabion walls together. The wires prevent the gabion baskets from “bulging” as they are filled. This operation is repeated until the gabion is filled.

5. After filling, the top is folded shut and wired to the ends, sides, and diaphragms.