Gabions and Mattresses are factory cut from plain and PVC coated galvanized welded wire mesh.
The components are fastened together at our factory with binders, then folded and shipped flat to the job site. No flattening, bending or folding is required in the field. The sides and diaphragms are raised and connected with temporary fasteners. The baskets are then ready to be placed on a prepared foundation.
Once the first course is in place, all gabions are permanently secured with “corkscrew” spiral binders the full height of all corners to hold them in place. Next, preformed stiffeners are installed (3’ baskets only) and filling can begin. Typically, a 3’x3’x6’ gabion takes less than five minutes to assemble and is ready for fill.
The strength of welded wire mesh offers many advantages. It allows machine filling. It is easy to hold the alignment of the face. Also, if a gabion must be cut to fit site conditions, the wire can be cut with bolt cutters without losing structural strength.
TOOLS NEEDED: Wire cutting pliers and bolt cutters (light duty).
1. Prepare the foundation by excavation or stripping, if required, or on fill compacted to 95%. The foundation must be reasonably level and capable of supporting imposed loads.
2. Open the gabion out. See Figure 5.
3. Stand the sides up and join the edges with temporary fasteners. See Figure 6.
4. Raise and attach the diaphragms at 3’ intervals with temporary fasteners. See Figure 6. The mattress-shaped gabion is similar to the welded gabion shown in Figure 6 except that the lid is not factory-attached.
5. Gabions may be field cut to fit curves, culverts or changes in the plans. Reconnect the ends of the boxes the same way you would assemble a standard gabion. See Figure 7.
6. Place the first course of gabions on the foundation. Permanently bind the gabions together as shown for the full height of all corners and diaphragms. Crimp ends of all spiral binders. See Figure 8.
NOTE: This guide shows assembly with temporary fasteners and spiral binders because it is faster. You may use the wire and half-hitch lacing for all connections if desired. Temporary fasteners are not permanent connections and must be followed by spiral binders or tie wire.
