Gabions Retaining Wall System

Gabions Retaining System Wall

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We supply gabion cage baskets and mattresses retaining wall system.

Gabions Retaining Wall System
The work including assembling, and filling wire mesh gabions with rock.
MESH GABION AND FITTING PRODUCTS
PVC 8x 10 cm Custom Gabion 12' x 3' x 3'
PVC 8x 10 cm Custom Gabion 9x3x3'
PVC 8x 10 cm Custom Gabion 6x3x3'
PVC 8x 10 cm Custom Gabion 12x4.5x3'
PVC 8x 10 cm Custom Gabion 6x4.5x3'
PVC 8x10 cm Jumbo Gabion Mattress 12x6x1.5'
Stainless steel hog rings packed in boxes, 1600/box
Pneumatic hog ring gun
Geotextile fabric 15' x 300'
Metal staples: 6 "

WOVEN MESH GABIONS - SHALL MEET ASTM A975-97(2003)
A. Wire (Zinc Coated)

Tensile strength: both the wire used for the manufacture of the gabions and the lacing wire, shall have a maximum tensile strength of 75,000 psi, in accordance with ASTM A641
Elongation: the test must be carried out on a sample at least 12in. long. Elongation shall not be less then 12%, in accordance with ASTM A370-97a
Zinc coating: minimum quantities of zinc according to ASTM A641, Class III soft temper coating
Adhesion of zinc coating: the adhesion the zinc coating to the wire shal be such that, when the wire is wrapped six times around a mandrel having four times the diameter of the wire, it does not flake or crack when rubbing it with the bare fingers, in accordance with ASTM A641.
B. PVC (Polyvinyl Chloride) Coating

Specific gravity: 81-84 pcf in accordance with ASTM D792-00, Table 1
Hardness: between 60 and 60 Shore D, according to ASTM D 2240-04
Tensile strength: not less than 2, 985 psi, according to ASTM D412-98a
Abrasion resistance: the percentage of weight loss shall be less than 12%, according to ASTM D1242-95A.
Heat Aging Test: prior to UV and abrasion degradation, the PVC polymer coating shall have a projected durability life of 60 years when tested in accordance with UL 746B
The accelerated aging tests to be per formed:
a, Salt spray test: test period 3, 000 hours, test method ASTM B117-97
b, Exposure to UV rays: test period 3, 000 hours at 145 degrees F, test method ASTM D1499-99 and ASTM G152-00
c, Brittleness temperature: no higher than 15 degrees F, when tested in accordance with ASTM D746-04.
Results of the aging test shall be as follows:
a, Appearance of coated mesh: no cracking, stripping or air bubbles and no appreciable variation in color.
b, Specific gravity: variations shall not exceed 6%
c, Hardness: variationg shall not exceed 10%
d, Tensile strength: variationg shall not exceed 25%
e, Modulus of elasticity: variations shall not exceed 25%
f, Abrasion resistance: variations shall not exceed 10%
g, Brittleness temperature: shall no exceed +64 degrees
C. Galvanized and PVC coated wire mesh basket gabions (8x10 mesh type)

PVC coating thickness: Nominal -0.02 in., Minimum-0.015 in.
Lacing Wire: Diameter -0.106 in internal, 0.146 in. external
Selvedge Wire: Diameter - 0.134 in. internal, 0.174 in. external
Mesh Opening: Nominal Dimension D=3.25 in.
D. Galvanized and pvc coated lacing wire and internal stiffeners.

PVC coating thickness: Nominal - 0.02 in., Minimum -0.015 in.
Lacing wire: Diameter - 0.087 in internal, 0.127 in. external
Cross Tie/Stiffener Wire: Diameter- 0.087 in internal, 0.127 in. external
Preformed Stiffener: Diameter - 0.134 in, internal, 0.174 in. external

E. Steel Mesh properties

Mesh Tensile strength: Minimum strength of 2900 lb/ft when tested in accordance with ASTM A975 section 13.1.1
Punch Test Resistance: Minimum resi stance of 5300 lb when tested in accordance with ASTM A975 13.1.4
Connection toselvedges: Mini9mun resistance of1200 lb/ft when tested in accordance with ASTM A975
F. Overlapping Fasteners: Over lapping stainless steel fasteners may be used in lieu of, or to complement, lacing wire for basket assembly and installation, The spacing of the fasteners during all phases of assembly and installation shall be in accordance with spacing based on 1200 lbs/ft pull apart resistance for PVC coated mesh when tested in accordance with ASTM A975 secction 13.1.2 and with nominal spacing of 4 in., and not to exceed 6 in.

Stainless steel fasteners:
a, Diameter -0.120 in according to ASTM A313, Type 302, class I.
b, Tensile strength- 222, 000 to 253, 000 psi in accordance with A313.
TOLERANCES

A. wire: Zinc coating, in accordance with ASTM A641, Class III soft temper coating.
B. Gabions: plus or minus 5% on the length, width, and height.
C. Mesh opening: Tolerances on the hexagonal, double twisted wire mesh opening shall not exceed plus or minus 10% on the nominal dimension D.

FABRICATION
A. Gabions shall be manufactured and shipped with all components mechanically connected at the production facility. The front, base, and lid of the gabions shall be woven into a single unit. The ends and diaphragm(s) shall be factory connected to the base. All perimeter edges of the mesh forming the basket and top, or lid shall be selvedged with wire having a larger diameter.
B. The gabion is divided into cells by means of diaphragms positioned at approximately 3 ft centers. The diaphragms shall be secured in position to the base so that no additional lacing is necessary at the jobsite.

ROCK
The rock for gabions 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 beween 4 in. and 8 in. The range in sized shall allow for a variation of 5% oversize and/or 5% undersize rock, provided it is not placed on the gabion exposed surface.

The size shall be such that a minimum of three layers of rock must be achieved when filling the gabions.


RETAINING WALL EXECUTION

ASSEMBLY

Assemble the units individually by erecting the sides, ends, and diaphragms ensuring that all panels are in correct position, and the tops of all sides are aligned. The four corners shall be connected first, followed by the internal diaphragmas to the outside walls, All connection should use lacing wire or fastener

The first lopping of the lacing should secure the lacing to the wire mesh. Proceed to lace with alternating double and single loops through every mesh opening approximately every 6 in., pulling each loop tight and finally securing the end of the lacing wire to the wire mesh by looping and/or twisting.

The fasteners shall be used in proper way.

INSTALLATION

Gabions are to be carried to their final position and then securely joined together along the vertical and top edges of their contact surfaces using the same connecting procedure as described above.

Whenever a structure requires more than one layer, the upper empty baskets shall also be connected to the top layer of the lower layer along the front and back edges of the contact surface using the same connecting procedure as described above.

ROCK FILLING

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. Care shall be taken when placing fill material to ensure that the sheathing on the PVC coated baskets is not damaged.

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-foot higher than the adjoining cell, Slightly overfill the baskets by 1 to 2 in. to allow for settlement of the rock. Behind gabion walls, compact the backfill material simultaneously to the same level as the filled gabions.


INTERNAL CONNECTING WIRES

A. Preformed stiffeners or lacing wire can be used as internal connecting wires when a structure requires more than one layer of gabions to be stacked on top of each other. Internal connecting wires with lacing wire shall connect the exposed face of a cell to the opposite side of the cell. Internal preformed stiffeners shall connect the exposed face of a cell to the adjacent side of the cell. Preformed stiffeners are installed at 45 degrees to the face/side of the unit, extending an equal distance along each side to be braced. An exposed face is any side of a gabion cell that will be exposed or unsupported after the structure is completed.

3 Feet High Gabions: Connecting wire/bracings shall be installed after the placement of each layer, that is, at 1 foot high and 2 feet high.
1. 5 Feet High Gabions: These unita shall be filled in two layers, 9 in. high at a time. Connecting wires shall be installed after the placement of the first layer.


LID CLOSING
Once the gabion baskets are completely full, the lids will be pulled tight until the lid meets the perimeter edges of the basket. A tool such as a lid closer can be used. The lid must be tight laced an /or fastened along all edges, ends, and tops of diaphragm(s).

Mesh Cutting And Folding

The gabions shall be cut, folded and fastened together to suit site conditions. The mesh must be cleanly cut and surplus mesh either folded back or overlapped so that it can be securely fastened together with lacing wire or fasteners. Any reshaped gabions shall be assembled, installed, filled, and closed properly as instructed.