WELDED GABIONS ASSEMBLEY GUIDE

Dunstall Hill Trading Estate,Gorsebrook Road,Wolverhampton, WV6 0PJTel: 01902 712200 Fax: 01902 714096e-mail: sales@hy-tengabions.comWeb: www.hy-tengabions.comASSEMBLY AND ERECTION INSTRUCTIONS FOR STANDARD GABIONSGabion unit assemblyGabions are supplied flat packed to site.To assemble units, raise face, side and diaphragm panels into the vertical positionand fix one cable tie securely at the top ofthe unit at each juncture to temporarily secure the unit in its box form.For units supplied with lacingwire only (see fig 2) :-For single unit construction, lace all the vertical joints together in a continuous operation looping through each mesh andpulling tight. Ensure that lacing is startedand terminated with at least 3 tight loops.For construction of a line of units, the corners of adjacent units and the joint between units can be laced in one operation. Other vertical joints should belaced as for a single unit.For units supplied with lacingwire and helicals (see fig 3) :-For single unit construction, helical all thevertical joints together. The last turn at eitherend of the helical should be turned through90 degrees with pliers to lock it in position.For construction of a line of units, the corners of adjacent units and the joint between units can be helicalled in one operation. Other vertical joints should behelicalled as for a single unit.GABION SOLUTIONSCable TieContinuous LacingFig 1Fig 2Fig 3HelicalPAGE 1/5Dunstall Hill Trading Estate,Gorsebrook Road,Wolverhampton, WV6 0PJTel: 01902 712200 Fax: 01902 714096e-mail: sales@hy-tengabions.comWeb: www.hy-tengabions.comSITE MADE HELICALSGABION SOLUTIONSFig 4Fig 6 Fig 7Fig 8Fig 5In order to make lacing easier it is possible to make a light helical fromthe lacing wire as per figures 4 – 8.To form the helical use a piece of round material such as a smoothpiece of broom stale or pipe. Cut a length of the wire e.g.; for a 1m jointuse approx 1.3m of wire, hold the wire firmly against the pipe as fig 4,then wrap the wire around to form a spiral/helical. This should be astight as possible so that it resembles a closed spring. Leave approximately 100mm of wire at each end as in fig 7, slide thecoils off in the palm of your hand and then proceed as in fig 8.Once you have twisted the wire through the joint, wrap each end arounda piece of steel and pull firmly until the wire closes tightly around theedge wires of the gabion, then secure the ends so that they do not unravel and trim off the excess.Caution: The wire ends may be sharp so gloves should be worn, asthey should be for the whole installation process.PAGE 2/5Dunstall Hill Trading Estate,Gorsebrook Road,Wolverhampton, WV6 0PJTel: 01902 712200 Fax: 01902 714096e-mail: sales@hy-tengabions.comWeb: www.hy-tengabions.comASSEMBLY AND ERECTION INSTRUCTIONS FOR STANDARD GABIONSFILLING OF GABIONSGabions should be filled with a hard durable stoneof grading 100 to 200mm.Fill should be placed into units to the third height for 1m deep units (fig 9) and to half height for 0.5m deepunits. Filling can be carried out carefully with machine. Internal windlass ties should be placed at the thirdheight centrally within each cell compartment (fig 9),the windlass should encompass a minimum of 2 meshesand no more than 3 meshes, ensure that the windlass isnot too loose otherwise bulging of the face will occur andlikewise not too tight to cause the mesh to bow inwards.WINDLASS BRACING TIESTies to be formed by wiring across two meshes at theface, back through the gabion and across 2 meshes onthe rearface, with the two ends meeting within the unitand tied together such that it forms a continuous loop.GABION SOLUTIONSFig 9Repeat the filling to two thirds the height for 1m deepunits and install windlass bracing.Fill unit to full height so that when the lid is closed it bearsdown on the fill.Fully lace lid down around the perimeter and across thediaphragms.If required by specification, the face should be handpacked to give a dry stone wall appearance, to preventany large voids being present in the fill the stone may require re-orientating.Using a flat rock inserted between the loop twist until thewindlass is taught. Do not overtighten or leave slack otherwise deformation of the face will occur.PAGE 3/5Dunstall Hill Trading Estate,Gorsebrook Road,Wolverhampton, WV6 0PJTel: 01902 712200 Fax: 01902 714096e-mail: sales@hy-tengabions.comWeb: www.hy-tengabions.comASSEMBLY AND ERECTION INSTRUCTIONS FOR GABION 700 SYSTEMGabion unit assemblyGabions are supplied flat packed to site.To assemble units, raise face side and diaphragm panels into the vertical positionand fix one cable tie securely at the top ofthe unit at each juncture to temporarily secure the unit in its box shape. The SYSTEM 700 units have an extendedbase panel.For Triple Life 700 units (see fig 10) :-For single unit, helical all the vertical jointstogether. The last turn at either end of thehelical should be turned through 90 degrees with pliers to lock it in position.For construction of a line of units, the corners of adjacent units and the joint between units can be helicalled in oneoperation. Other vertical joints should behelicalled as for a single unit.PVC coated 700 units are supplied with lacing wire only. Triple life units are supplied with lacing wire and helicals :-PVC coated units (see fig 11) :-For single unit construction, lace all the vertical joints together in a continuous operation looping through each mesh andpulling tight. Ensure that lacing is startedand terminated with at least 3 tight loops.For construction of a line of units, the corners of adjacent units and the joint between units can be laced in oneoperation. Other vertical joints should belaced as for a single unit.GABION SOLUTIONSContinuous LacingFig 11Fig 10HelicalPAGE 4/5Dunstall Hill Trading Estate,Gorsebrook Road,Wolverhampton, WV6 0PJTel: 01902 712200 Fax: 01902 714096e-mail: sales@hy-tengabions.comWeb: www.hy-tengabions.comASSEMBLY AND ERECTION INSTRUCTIONS FOR GABION 700 SYSTEMFILLING OF GABIONSGabions should be filled with a hard durable stoneof grading 100 to 200mm.Fill should be placed into units to the half height.Filling can be carried out carefully with machine. Ifrequired by specification the face should be handpacked to give a dry stone wall appearance, toprevent any large voids being present in the fill thestone may require re-orientating.Fill unit to full height so that when the the base ofthe next course which forms the lid will bear downon the fill. (fig 13). The step can either be on the face or rear of the wall dependant on the design.Fully lace the next unit around the perimeter.The top unit of the wall is supplied with a lid whichagain is to be fully laced down.If you would like Hy-Ten to design and supply gabionsand land reinforcement products for you, please contactSales Office on: 01902 712200.GABION SOLUTIONSFig 12Internal windlass ties should be placed at the halfheight centrally within each cell compartment (fig 12), the windlass should encompass a minimum of2 meshes and no more than 3 meshes. Ensure that thewindlass is not too loose otherwise bulging of the facewill occur and likewise not too tight to cause the mesh tobow inwards.2m x 0.7m / 1m x 0.7m2m x 1m / 1.4m x 0.7m2m x 1.4m x 0.7mFig 13PAGE 5/5