Gabions are classified by weaving method, structure, application, and corrosion-resistant material. Common weaving types include double-twist hexagonal mesh, triple-twist mesh, and welded wire mesh. By structure, gabions include gabion boxes, Reno mattresses, and reinforced gabions used for retaining walls, riverbank protection, and channel lining. Materials include hot-dip galvanized wire, Galfan zinc-aluminum alloy wire, and PVC-coated wire.
Classification by Weaving Technique and Mesh Structure
1. Double-Twist Hexagonal Wire Mesh Gabions
Definition
- Common gabion type used in water control projects. Steel wires are double-twisted at intersections (twist length ≥20 mm), forming hexagonal mesh.
Features
- Flexibility: Double twisting prevents mesh failure if a single wire breaks.
- Permeability: Hexagonal openings allow water flow and reduce pressure.
- Adaptability: Mesh adjusts to foundation settlement without breaking.
Applications
- Riverbank protection, flood control dikes, coastal protection, and ecological restoration.
Common Mesh Sizes
- 60×80 mm, 80×100 mm, 100×120 mm.
2. Triple-Twist Hexagonal Wire Mesh Gabions
Definition
- Wires are twisted three or more times at intersections, providing stronger node locking and higher tensile resistance.
Features
- High Strength: Strong node connection for heavy loads or impact.
- Higher Rigidity: Less flexible than double-twist mesh.
- Higher Cost: Complex production process.
Applications
- Stilling basins, strong scour areas, retaining wall foundations, and military barriers.
- Note: Used mainly in specialized engineering projects.
3. Welded Galvanized Wire Mesh Gabions
Definition
- Steel wires are welded at intersections to form square or rectangular mesh. Surface treatment includes hot-dip galvanizing or zinc-aluminum coating.
Features
- Flat Surface: Uniform mesh and accurate dimensions.
- Rigid Structure: Strong frame but limited flexibility.
- Fast Installation: Prefabricated panels simplify on-site assembly.
Limitations
- Weld points may corrode if coating is damaged. Uneven settlement may cause weld failure.
Applications
- Landscape retaining walls, architectural decoration, park fencing, and slope protection on stable foundations.
- Other Names: Welded gabion boxes, reinforced soil retaining wall panels.
Classification by Structure and Application
1. Standard Gabion Boxes
- Description: Rectangular cages with internal diaphragms for structural stability.
- Applications: Retaining walls, bridge abutment protection, and foundation reinforcement.
- Common Sizes: 2 m × 1 m × 1 m, 3 m × 1 m × 0.5 m.
2. Reno Mattresses
- Description: Low-height gabions, usually 0.17–0.3 m, with large length-to-width ratios.
- Applications: Riverbed paving, channel lining, and erosion control.
- Advantage: Flat structure follows riverbed contours.
3. Reinforced Gabions
- Description: Standard gabions combined with mesh reinforcement strips or geogrids.
- Applications: Reinforced soil retaining walls up to about 10 m high.
4. Rockfall Nets / Ring Nets
- Description: High-strength mesh systems used to intercept falling rocks.
- Applications: Rockfall protection on mountain slopes and tunnel entrances.
Classification by Material and Anti-Corrosion Coating
| Category |
Material Description |
Service Life |
Applicable Environment |
| Cold-Dip Galvanized Gabion |
Electro-galvanized steel wire, coating 3–15 μm |
3–5 years |
Temporary works, dry inland areas |
| Hot-Dip Galvanized Gabion |
Hot-dip galvanized steel wire, coating 30–60 μm |
10–20 years |
Rivers, general atmospheric environments |
| Galfan Gabion |
Zinc–5% aluminum alloy coating |
30–50+ years |
Seawater, acid rain regions, water control projects |
| PVC / PE Coated Gabion |
Galfan wire with plastic coating (green or gray) |
40+ years |
Landscape works, acidic or alkaline water areas |
| Double-Layer Anti-Corrosion Gabion |
Galfan coating with PVC outer layer |
50+ years |
Severe environments, long-term engineering projects |
Selection Recommendations
- River Control and Flood Embankments: Use double-twist hexagonal gabions with hot-dip galvanizing or Galfan coating, including gabion boxes or Reno mattresses.
- Landscape and Residential Walls: Welded galvanized gabion boxes provide a clean structure and easy installation.
- Coastal or Chemical Environments: Use Galfan (Zn–Al) or PVC-coated gabion mesh. Avoid cold-dip galvanized materials.
- High Impact Areas: Use triple-twist mesh or double-twist gabions with thicker wire diameter.
