Gabion, also called gabion basket or gabion box, is a wire mesh structure made from galvanized steel wire or zinc-aluminum alloy wire. Proper installation ensures structural stability and long-term protection.
Pre-construction Preparation
Technical Preparation
- Drawing Review: Check design drawings. Confirm gabion size (length × width × height), wire diameter, mesh size, and layout.
- Technical Briefing: Train workers on assembly, stone filling, and binding. Provide safety instructions.
Material Preparation
- Gabion Boxes: Inspect boxes for damage or deformation. Ensure galvanized or PVC coating is intact.Common wire diameter: 2.0–4.0 mm.
- Internal Partitions: Install diaphragms according to design spacing to maintain box stability.
- Filling Stones: Use hard, weather-resistant stones. Stone size usually 1.5–2 times mesh size (60–150 mm). Avoid weathered stones and thin slabs.
- Grading Requirement: Large stones over 70%. Mix small stones to fill gaps.
- Binding Materials: Use galvanized wire or spiral binders matching the gabion material.Wire diameter not less than 2.2 mm.
- Auxiliary Materials: Geotextile for erosion control. Crushed stone base layer 10–20 cm thick.
Tools and Equipment
- Hand Tools: Wire cutters, wrenches, wooden hammer, crowbar, measuring tape.
- Machinery: Excavator for foundation and lifting, loader, transport vehicles.
Detailed Construction Steps
Step 1: Foundation Preparation
- Site Clearing: Remove weeds, roots, debris, and sharp stones to protect the gabion mesh.
- Leveling and Compaction: Level and compact the base. Required compaction degree ≥ 90%.
- Subbase Layer (Optional): In soft soil areas, install geotextile or a 10–20 cm crushed stone layer.
Step 2: Gabion Assembly and Placement
- Unfold Gabion: Open the folded gabion mesh and place it at the designed position.
- Erect Panels: Raise side panels and internal partitions to form the box structure.
- Binding and Fixing: Use binding wire to connect edges. Tie every 50 mm using twisting or double-strand wrapping.
Secure corners tightly and avoid damaging the galvanized coating.
Step 3: Layered Stone Filling
- Layer Filling Rule: Do not fill the cage at once. Gabions over 50 cm require 2–3 layers.
- Bottom Layer: Place large stones manually with flat surfaces facing down.
- Middle and Upper Layers: Continue filling stones and add smaller stones to reduce gaps.
- Surface Leveling: Arrange stones manually to keep the surface compact.
- Filling Height: Stone level should be 2–3 cm above the cage before compaction.
Step 4: Closing and Connecting
- Compaction: Compact the top stones manually or mechanically.
- Install Cover Panel: Pull the lid over the cage and secure it tightly.
- Edge Binding: Tie all edges between the lid, side panels, and partitions.
Step 5: Unit Connection:
- Same Layer: Connect adjacent cages using binding wire.
- Upper and Lower Layers: Tie the bottom frame of the upper cage to the lower cage.
- Staggered Layout: Arrange cages like brickwork to avoid continuous vertical joints.
Step 6: Special Area Treatment
- Steep Slope Installation: For slopes steeper than 1:1, build from bottom to top and install anchors or steel bars.
- Edge Finishing: At ends or corners, cut and fold the mesh and seal the opening with binding wire.
Key Quality Control Points
| Inspection Item |
Standard Requirement |
| Gabion Dimensions |
Length, width, height tolerance within ±3%. |
| Binding Quality |
No missing or loose bindings; wires secure; coating intact. |
| Stone Filling |
Hard stones, correct size, compact filling; porosity <30%. |
| Surface Flatness |
Stones arranged evenly; cover panel tight and level. |
| Structural Stability |
Units firmly connected; staggered joints applied. |
Safety and Precautions
Weather Conditions
- Rainy Season: Ensure foundation drainage. Avoid long exposure of gabions to muddy water.
- Low Temperature: Below 5 °C, steel wire becomes brittle. Handle carefully or suspend construction.
Worker Safety
- Workers should wear gloves, safety helmets, and non-slip shoes. Use caution when handling stones.
- Repair damaged galvanized coating with zinc-rich paint.
Ecological Measures
- In ecological areas, fill soil between gabions and plant grass seeds to support vegetation growth.
Common Problems and Solutions
| Problem |
Cause |
Solution |
| Gabion Deformation |
Stones filled too quickly or too small |
Fill stones in layers; use proper stone size; add internal bracing if needed. |
| Connection Cracks |
Loose or missing binding |
Bind all edges securely, especially corners and layer joints. |
| Foundation Settlement |
Poor foundation preparation |
Compact the base; reinforce soft soil with geogrid or replacement layer. |
Following these guidelines helps gabion projects achieve strength, durability, and ecological performance. Proper installation and management ensure gabion structures perform well in river control and slope protection.
