Manufacturing of Double Twist Wire Mesh for Rockfall Protection, Gabions and Gabion Mattresses

Mesh Manufacturing and Edge Reinforcement | Panel Cutting and Assembly of Internal Diaphragms | Pressing, Packaging and Logistics

Double twist hexagonal steel wire mesh forms the basis of gabion systems. The mesh is manufactured on fully automated production lines using low-carbon steel wire with diameters ranging from 2.2 to 3.0 mm in accordance with EN 10223-3.

To achieve high corrosion resistance in aggressive environments, the wire is available with several protective coatings:
● Hot-dip galvanized coating (Class A according to EN 10244-2);
● Zinc-aluminium alloy coating (Galfan / Zn-Al5);
● Zinc-aluminium coating with an additional polymer layer (PVC or PE) for hydraulic and marine applications.
These protective systems provide excellent resistance to moisture, aggressive environments and long-term service loads, allowing gabion structures to achieve a design service life of up to 120 years, depending on the selected system and operating conditions.

MESH WEAVING AND EDGE REINFORCEMENT

The key manufacturing stage is the automated weaving process, where steel wire is formed into the characteristic hexagonal mesh (typically 60 × 80 mm or 80 × 100 mm openings). The double-twist construction prevents the mesh from unravelling in the event of localized mechanical damage.

The entire weaving process is numerically controlled, ensuring consistent mesh geometry and high manufacturing accuracy.

Edge reinforcement: each mesh panel incorporates a heavier selvedge wire along its edges (for example, 3.4 mm edge wire with 2.7 mm mesh wire). This reinforcement limits deformation during stone filling, handling and long-term service.

PANEL FORMING AND DIAPHRAGM ASSEMBLY

After leaving the production line, the mesh is accurately cut into panels according to the required dimensions. The cut edges are mechanically wrapped around the selvedge wire to maintain the structural integrity of the panel.

At this stage the gabion baskets are fitted with:
● Internal diaphragms, typically installed at 1 m intervals or according to project requirements;
● Side panels and end panels.

After assembly, the gabions are folded flat to optimise storage space and reduce transportation costs.

COMPRESSION, PACKAGING AND LOGISTICS

Finished gabions are stacked into bundles and hydraulically compressed to minimise transport volume.

The bundles are then:
● Secured with steel straps;
● Labelled with product identification, dimensions, coating type and batch number;
● Prepared for transport on pallets.

This packaging system reduces logistics costs while ensuring safe handling and efficient unloading directly at the construction site.