PRODUCT INSTALLATION GUIDE

Rev: 01, Issue Date 04.01.2005

GABION
Material Delivery
Gabions are manufactured with all components mechanically connected
at the production facility, as per ASTM A975-97. All gabions are diaphragm
supplied in the collapsed form, either folded and bundled or rolled. The projecting selvedge wire
bundles are compressed and strapped together at the factory for easy
shipping and handling. Lacing wire is shipped in coils. Fasteners are
shipped in boxes. Preformed corner stiffeners are shipped in boxes.
folding lines

Assembly
Open and unfold each gabion on a flat, hard surface and remove any
shipping fold if necessary. This can be done by placing the fold over a 2"
x 4" board and walking along the sides. Lift up the sides, ends and
diaphragms into a vertical position to form an open box shape (Fig. 1).
Connect the back and the front panels of the gabion to the end panels
and center diaphragms. The top corner of the end panels and center
diaphragms have the selvedge wire extending out approximately 4 in. Figure 1
(102 mm) from these panel edges. Raise the end panels and the
diaphragms to a vertical position and wrap the selvedge wire around the
edge wire of the top and back panels.
Connect the edges of the gabion and diaphragms by using either lacing
wire or ring fasteners (Fig. 2). Ring fasteners shall not be spaced more
than 6 in. (150 mm) apart. The procedure for using lacing wire consists
of cutting a sufficient length of wire, and first looping and/or twisting the
lacing wire to the wire mesh. Proceed to lace with alternating double and
single loops through every mesh opening approximately every 6 in. (150
mm) pulling each loop tight and finally securing the end of the lacing
wire to the wire mesh by looping and/or twisting. The use of pliers to aid
assembly and tying of the units using the lacing wire supplied with the
gabions is normally recommended.
Erect the diaphragms into the vertical position, and tie them to the side
panels in the same manner. secure diaphragms
to front and back
Fastening Procedure secure ends to side
When using lacing wire, cut off a piece of wire approximately 1.5 times
the length of the edge to be tied. Longer edges shall be joined by Figure 2
several lengths of wire. Tie wires shall be secured around the selvedge
wire or heavier edge wire, where present, by looping and twisting the
lacing wire around itself. Proceed tying with alternate double and single fro
nt
loops. Double loops shall be made at intervals not greater than 6 in. p an
(150 mm). The baskets should be pulled tightly together during the tying e l
l ne fro
d pa nt
pa
operation. The other end of the tie wire shall be secured by again l en
ane ne
looping and twisting the wire around itself. When using lacing wire to en dp l
assemble the units, pliers may be used to create tight joints. Care
should be taken to avoid damaging the wire coating.
When steel ring fasteners are used, the use of either a mechanical or a
pneumatic fastening tool is required. Spacing of the rings shall be in
accordance with ASTM A975-97 Table 2, Panel to Panel connection,
Pull-Apart Resistance. In any case, ring fasteners spacing shall not
exceed 6 in. (150 mm). Rings shall be installed at the end and center
diaphragms and along all edges. Care should be taken to ensure the Figure 3
steel ring fastener is completely closed after installation. When this is
not possible, connection must be complemented with lacing wire. Lacing wire Rings

Foundation Preparation
The foundation on which the gabions are to be placed shall be level, and
graded to the elevations as shown on the project construction drawings.
Max 6 in.
150 mm

The foundation for gabions shall be level, smooth, and free of surface
irregularities, loose material, and vegetation in accordance with the
project specifications. Appropriate measures shall be taken for filtering
and drainage of the foundation, as per the project specifications (filter
cloth, drain works, etc.). Geotextiles required to be installed behind
gabion structures shall comply with the requirements for subsurface
drainage applications.

Figure 4
 Maccaferri reserves the right to amend product specifications without notice and specifiers
are requested to check as to the validity of the specifications they are using.

Installation and Filling Cross ties with lacing wire Cross ties with pre-formed stiffeners
After the foundation has been prepared, the pre-assembled gabions are
placed in the desired location to form the structure. Gabions shall be
connected together and aligned before filling the baskets with rock. All
connections (panel-to-panel and basket-to-basket) shall be already
carried out as described in the assembly operations.
Rocks for gabions may be produced by any suitable quarrying method,
and by the use of any device that yields the required sizes within the
gradation limits chosen. Rocks shall be hard, angular to round, durable
and of such quality that they shall not disintegrate on exposure to water
or weathering during the life of the structure.
Gabion rocks shall range between 4-8 in. (100-200 mm). The range in
sizes may allow for a variation of 5% oversize and/or 5% undersize rock,
provided it is not placed on the gabion’s exposed surface. In all cases,
the oversize rock shall not be larger than 10 in. (250 mm), and the
undersize rock shall not be smaller than 2 in. (50 mm). Figure 5
During the filling operation some manual stone placement is required to
minimize voids. The exposed faces of vertical structures may be
carefully hand placed to give a neat, flat, and compact appearance. The
cells shall be filled in stages so that local deformation may be avoided.
That is, at no time, shall any cell be filled to a depth exceeding 1 ft (300
mm) higher than the adjoining cell (Fig. 7). When using PVC gabions,
care should be taken when placing the stone to assure that the PVC
coating on gabions will not be damaged.
Stiffeners or crossties shall be installed as indicated (Fig. 6), fixed at 1/3
and 2/3 of the height for 3 ft or 1 m gabions as the cell is being filled. In
1.5 ft (500 mm) high units stiffeners may be fixed at the half height level,
if required. Preformed corner stiffeners are installed at 45° to the face/
side of the unit, extending an equal distance along each side being Figure 6
braced (approximately 1 ft [300 mm]). Minimize the number of voids by
using a well-graded stone and avoid large stones in order to achieve a
dense, compact stone fill. All corners should be securely connected to Phase 1
the neighboring gabions of the same layer before filling the units.
When more than one layer of gabions is required, in order for the
individual units to become incorporated into one continuous structure,
the next layer of gabions must be connected to the layer underneath
after this layer has been securely closed (Fig. 8). Phase 2
Gabion placement should be front to front and back to back, so that
pairs of facing lids can be wired down in one process.
Secure the end from which the work is to start, by partially filling the end
unit with rock.
Phase 3
Closing
To allow for settlement, level off the fill 1-1.5 in. (25-40 mm) above the
top of the mesh. In slow protection aprons downstream of weirs and
places where water will fall directly on the gabions, install bracing wires
vertically between the top and bottom mesh. Be sure to keep the top Figure 7
edge of the diaphragm exposed. Fold the lid down and pull the edges of
the panels to be connected using an appropriate tool such as a lid closer
(Fig. 9). The lids shall be tightly laced along all edges, ends and
diaphragms in the same manner as described for assembling units (Fig.
4). Adjacent lids may be securely attached simultaneously. All end wires
should then be turned in to avoid protrusions.

A B C

Pneumatic
Lid closer Manual tool
Spenax tool
Figure 9 Figure 8

10303 Governor Lane Boulevard MACCAFERRI INC. 3650 Seaport Boulevard

© 2005 Maccaferri Inc. Printed in USA