Enviromesh Guide To Fs Walls and Cladding

Designing with Gabions
Volume 2
A Reference Guide for

Architectural Gabion Cladding
and Free Standing Walls
Registered Office: Unit 5, The Cobden Centre, Folly Brook Road, Emerald Park, Emersons Green, Bristol BS16 7FQ
Enviromesh is a trading name of Cerana Limited. Registered in England No. 5065615
Contents
CONDITIONS & LIMITATIONS PAGE 1
INTRODUCTION PAGE 2
APPLICATIONS PAGE 3
GABION FILLING MATERIALS PAGES 4 - 5
GABION SPECIFICATIONS PAGE 6
DESIGN PAGE 7
- Stability requirements
- Structural dimensional requirements
GABION UNIT SIZES PAGES 8 - 10
INSTALLATION OF CLADDING PAGES 11 - 21
FREE STANDING WALLS PAGES 22 - 23
SPECIFICATIONS PAGES 24 - 30
- gabion 27 system - 50.8mm / 4.00mm
- gabion 27 system - trapezoidal
Conditions & Limitations
The copyright, design right or other intellectual property in this guide
and the products set out herein shall as between Cerana Limited,
trading under the Trade Mark of Enviromesh and any customer or
potential customer of Enviromesh be the property of Enviromesh.
This publication is intended as a general overview of the subjects dealt

with and is not intended and should not be used as a substitute for
taking detailed and specific advice in any specific situation. The
recommendation and advice given in this booklet is given without
liability on the part of Enviromesh or its employees and should not be
relied upon for any particular action or inaction.
Enviromesh shall not be liable to compensate any other party for any
loss, including any consequential loss, arising out of any inaccuracies
in or omissions from this guide.
It is the responsibility of all parties to satisfy themselves that the

designs, calculations and specifications set out in proposals submitted
by Enviromesh are correct and no responsibility is accepted by
Enviromesh for the accuracy of the designs and specifications
included in such proposals.
Enviromesh
Garner Street Business Park
Etruria
Stoke-on-Trent
Staffordshire
ST4 7BH
Tel: 0044 (0) 845 136 0101

Fax: 0044 (0) 845 136 0202
Email: roger.farmer@enviromeshgabions.com
Web: www.enviromeshgabions.com
1
Introduction
In recent years, architects have shown great interest in gabions as a cladding system for
buildings as well as perimeter and sound walling.
Various reasons have given rise to this:
The quality of welded mesh gabion schemes have improved due to

the system of manufacture.
Requirements for using recycled fills i.e. crushed concrete, saving on

materials for disposal and the reduced costs to that of rock fill.
Architects embracing new construction materials and textures.
To achieve the required quality of construction, gabions are manufactured from heavier
mesh wire diameters and the module/unit sizes are non standard as industry standard size
gabions would not necessarily achieve what is required.
The design of the systems are generally bespoke as no two buildings are the same.
The cladding of buildings can be of a thin veneer, generally 300mm thick secured back to
the building. These are supported by wind posts or designed as free standing walls in front
of the building.
The techniques of design and manufacture are extended to free standing perimeter or
sound walling and also as a gabion fencing.
2
Applications
Structure Types
Cladding:
As a facade: - Thin gabion walls secured back to structural walls or steel
frame work.
As a column
supported facade: - Thin gabion walls part secured to steel framed buildings
and supported intermittently with additional columns,
where no structural supporting wall is available.
Free standing
Facade: - Mass gravity walls designed for stability as for free
standing walls
Rain screen: - Minimum width faced walls, generally 0.152m wide or
constructed in panel form and secured as panels
to a structural wall or suitable framework.
Buildings:
Gabions have previously been used as external and internal structural
support walls to buildings. This is a specialist application requiring
consideration for design as well as insulation and weatherproofing. Although
these type of structure have successfully been built on the project list below,
advice should be sought from Enviromesh when considering such schemes.
Earth Centre, Doncaster

Classroom of the Future, London
The Boat House, Tunbridge Wells
Free Standing Walls:

Stability is achieved by virtue of the mass of the structure.
The design is based on wind loadings and any other horizontally
applied loads. Their format can be as follows:
`
Vertical faced gabion walls
Vertical on one face, inclined on other face
Inclined on both faces
Gabion Fencing:
Stability is achieved by post or columns embedded into the gabion.
The design is based on wind loadings and any other horizontally
applied loads. Their format is normally as follows:
Normally vertical on both faces and of a narrow width.
3
Gabion Filling Materials
Aggregate Types
Quarried Stone:
This type of fill is the most commonest type of gabion fill used and where available is
considered the most practical, both for performance (having good interlock
properties) as well as its aesthetics. The gabion fill must be a hard durable non frost
susceptible rock. The typical rock fill types are as follows :-
Sandstone (not soft sandstone that is degradable)

Limestone (beware of sources of Rag Stone that contain Hassock)
Granite
Basalt
Slate (Flat in nature. The dimension can be larger than 200mm
in the longest dimension)
These rock fill types are either blocky or very angular. Blocky stone is very good for
giving a dry stone wall appearance and is normally used when a coursed face
is required. Angular fill generally requires more careful placement to give a
good dry stone wall appearance.
Crushed Concrete:
Generally crushed concrete is the cheapest type of gabion fill available. It should be
from a structural application and therefore non degradable as well as being free of
debris and foreign materials. The grading of the crushed concrete is normally poor
and selection of the mesh opening size is critical. The grading of the fill must be
greater than the mesh opening size and no greater than 2/3rds the unit width or
200mm whichever is the less.
Crushed concrete, generally has rounded edges and requires careful
packing, as the interlock in the fill is not as good as an angular rock fill. It
is therefore recommendable to specify a 5mm mesh wire diameter for external
facings.
Flint Reject or Cobblestone:
This type of fill is not angular and so has no interlocking properties. It is therefore
necessary for the wire diameter of the mesh to be 5mm to limit the
amount of deflection of the face mesh. The mesh aperture selected is
important in that the grading of fill available must be greater than the mesh
openings. The restriction on the maximum size is dependant upon the
width of the gabion unit. Normally this type of fill is machined placed with no hand
facing (generally considered as a self compacting fill).
4
Gabion Filling Materials
Aggregates:
Aggregate fill is self compacting and is of a small stone size that requires a mesh
with a small aperture. The minimum apertures available are 76.2mm x 12.7mm,
50.8mm x 25.4mm or 25.4 x 25.4mm. Therefore aggregates only retained by
these meshes can be used.
Due to the fluid nature of the fill and wire diameters available, the units may
require additional internal mesh diaphragms to limit deflection. These issues should
be discussed with Enviromesh prior to design and procuring of materials.
Brick Fill:
Whole brick should be coursed and must be of an engineering type brick. Whole
brick can be used as an un cemented coursed facing with broken brick infill. Whole
brick should never be used as the mass fill, as there is potential for arching to occur
within the fill resulting in possible settlements and distortion of the facing.
Broken or crushed brick again must be of an engineering type brick. The brick
is generally machined filled and therefore care must be taken on the mesh opening
size as a half brick will not be retained by a standard 76.2mm x 76.2mm mesh.
5
Gabion Specifications
The specification of gabions is an important factor in ensuring the quality and aesthetic appeal of
the installation.
Although Galfan (95%Zinc-5%Aluminium) coated mesh is used extensively for normal civil
engineering gabion works, it is preferable to use Hot Dip Galvanised after coated mesh in
accordance with BS EN ISO 1461.
The reason for this is that Galfan coated mesh is formed from welding the coated wires, the mesh
is then cut after welding. Although this is not detrimental to the corrosion resistance of the mesh,
the ends of the cut wire have a surface which rusts giving brown coloured cut ends. In
contrast, a panel of mesh cut prior to coating and then Hot Dip Galvanised after manufacture,
provides all surfaces and cut ends with a zinc coating to give an aesthetic finish akin to the
requirements of the architectural finish.
Therefore, where the project (gabion cladding or otherwise) is in close proximity to the building
and close visual inspection is possible, then the Hot Dip Galvanised after process for the mesh is
the preferred specification.
Note: The coating weight of Hot Dip Galvanised wire is greater than that of the Galfan coated
wire, resulting in similar durability.
Specifications Mesh opening Wire Diameters
Hot Dip Galvanised ISO 1461 76.2mm x 76.2mm 4.0mm
Where the structures are remote from the building, either a Hot Dip Galvanised specification or
Galfan specification can be used.
Specifications Mesh opening Wire Diameters
Galfan 76.2mm x 76.2mm 4.0mm
Galfan 76.2mm x 76.2mm 5.0mm
Galfan is not generally readily available in a 50.8mm x 50.8mm mesh aperture.
Non standard meshes are available in Hot Dip Galvanised coating as well as Stainless Steel. The
Architect or Designer should contact Enviromesh to discuss these particular requirements. The
cost implications of using Stainless Steel meshes is 3 to 4 times greater than that of Galfan or Hot
Dip Galvanised products.
6
Design
Stability Requirements
These types of architectural structures must be designed to withstand all external forces
that are present such as:-
- Wind loading.
- Horizontal forces such as pedestrian barrier loadings (please note that gabions
must not generally be considered for vehicular impact loadings).
- Vertical loadings.
- Earth pressure forces where the structure up to a certain height is acting as

as a retaining structure.
- Design of any support columns where required.
- Design of foundations for support columns where required.
- Lintel design for door or window openings.
- Foundation requirements. Normally a concrete foundation is recommended as

gabions are flexible in nature, therefore any localised settlement will be
transformed throughout the structure and is difficult to rectify.
Structural Dimensional Requirements
Consideration must be given to the overall lengths, widths and heights of structures.
Gabions are not like timber, concrete or steel constructions where the tolerances can
be accurately specified. Although the mesh is of a fixed dimension. the method of
jointing adjacent gabions generally gives rise to an increase in the unit dimensions.
This increase is difficult to quantify and may be up to 18mm dependant upon the type of
jointing used. This makes it very difficult to design a wall to a specific dimension,
especially when there are fixed dimensions between openings.
This variation can be accommodated in the method of construction and manufacture

of the gabion units.
It may be a necessity, that the setting out of the gabions is to be carried out to a
certain method to ensure that the system will fit. This is normally determined by
Enviromesh when the installation layouts are prepared.
7
Gabion Unit Sizes
Standard Gabion Units
Standard sizes available in Galfan coated wire are as follows:-
1m x 1m x 0.5m 1.5m x 1m x 0.5m 2m x 1m x 0.5m

1m x 1m x 1.0m 1.5m x 1m x 1.0m 2m x 1m x 1.0m
Cell Sizes:
Gabion units are sub-divided by diaphragms (partitioning panels) in to cells for the
integrity of the unit as well as restraint against deformation of the product.
Cell sizes are a function the unit length and the mesh aperture size.
For unit heights of nominal 1.0m and 0.5m, the unit length is divided into
cells as follows for differing mesh sizes:
Mesh size Unit length Unit Height Cell Sizes
76.2mm x 76.2mm 2.057 0.457m or 2 unequal cells

0.991m 0.991m and 1.066m
Use of standard units may not be compatible for these types of application. It is
recommended that the units be of a bespoke manufacture to address the
requirements of the scheme. The product can be sized to any multiple of the mesh
opening. For economy of manufacture, there are specific unit lengths, dependant on
the mesh size that are more appropriate.
Bespoke Cladding Units:
Sizes can be manufactured to suit required dimensions, but where possible, adoption of
standard formats should be used.
Optimum Unit Lengths:
` Mesh size Unit lengths
76.2mm x 76.2mm 0.762m or 1.524m

50.8mm x 50.8mm 0.762m or 1.524m
Optimum Unit Widths:
The unit widths are not so critical. Most widths, as a multiple of the mesh opening
are possible with the restriction that the unit width must be at least 2 mesh openings
for 76.2mm x 76.2mm mesh and 4 mesh openings for 50.8mm x 50.8mm mesh.
Reference should be made to the grading of the fill, such that the cladding width be
at a minimum of twice the width of the minimum stone size.
8
Gabion Unit Sizes
Optimum Cell Heights
Unit heights of multiples of the mesh openings are possible, although certain
unit heights are preferable.
Unit Height Mesh Size Unit Height Mesh Size
0.457m 76.2mm x 76.2mm 0.457m 50.8mm x 50.8mm

0.686m 76.2mm x 76.2mm 0.711m 50.8mm x 50.8mm
0.991m 76.2mm x 76.2mm 1.016m 50.8mm x 50.8mm
For constructional reasons in cladding units, 1.0 m high gabions are not recommended for
the placing of fill and hand facing the stone. 0.5m high gabions result in higher supply costs
and greater installation costs.
Gabion 27 system, where the unit heights are 0.686m or 0.711m dependant upon the mesh
size, were developed by the writer after extensive investigation in to the design, supply and
installation of gabions, both as retaining structures and architectural applications and
normally form the basis of our design proposals.
The resulting optimum unit sizes for cladding are as follows:
Mesh Unit Unit Unit Cell Number of

Size Length Height Width Cells
(Horizontal x Vertical)
76.2mm x 0.762m 0.686m 0.762m 1x1

76.2mm 0.762m 0.991m 0.762m 1 x 1 base cell only
0.762m 1.372m 0.762m 1x2
0.762m 2.057m 0.762m 1x3
1.524m 0.686m 0.762m 2x1
1.524m 0.991m 0.762m 2x1
1.524m 1.372m 0.762m 2x2
1.524m 2.057m 0.762m 2x3
50.8mm x 0.762m 0.711m 0.762m 1x1

50.8mm 0.762m 0.991m 0.762m 1 x 1 base cell only
0.762m 1.422m 0.762m 1x2
0.762m 2.133m 0.762m 1x3
1.524m 0.711m 0.762m 2x1
1.524m 0.991m 0.762m 2x1
1.524m 1.422m 0.762m 2x2
1.524m 2.133m 0.762m 2x3
Where the wall height does not suit a combination of the above unit heights, then the top cell can
be either reduced in height to fit on site or it may be possible to manufacture a bespoke height unit
during production of the products.
It is important for aesthetics to maintain coursing throughout the structure.
9
Gabion Unit Sizes
Trapezoidal Gabions
Trapezoidal gabions are manufactured with a mesh face, a base and rear panel with frame
supports at intervals along the unit length to provide restraint. The base of the unit above,
forms the lid of the unit below. The only unit that has a lid is the very top one.
These gabions can be manufactured with both faces inclined or with one face vertical and
one face inclined. To determine the inclination angle, the mesh base of the unit above must
be a function of the mesh size and the slope length of the face panel should be a multiple of
the mesh size with a tolerance of 10mm.
The base width, unit height and unit length must also be a function of the mesh size.
Typically the inclination of the face is equivalent to the following:
76.2mm mesh 1 or 2 meshes over the unit height

50.8mm mesh 1, 2 or 3 meshes over the unit height
For other inclinations greater than the above, please contact Enviromesh direct for advice.
Where the structure is adjacent to buildings, then use a Hot Dip Galvanised mesh
specification. If the structure is remote from the building, use either Galfan or Hot Dip
Galvanised specification.
Unit lengths are as follows:
76.2mm mesh 2.057m with frames at 0.686m centres
50.8mm mesh 1.524m with frames at 0.711m centres
The ends of the structure are closed with a preformed mesh panel to suit the required
trapezoidal configuration. Similarly, preformed panels are used at corners or changes in
direction of the structure to give clean joints.
Gabion Fence
This application is similar to cladding as described, except that the unit is supported by a
wind post. Dimensions of units are as for cladding.
10
Installation of Cladding
Installation Design Methods
Cladding systems require some method of securing them in to position to maintain stability.
The type of fixing is normally dependant upon the construction of the main structure.
Structural Reinforced Concrete Walls:-
Units are secured by means of clamp bars or clamp discs located within the gabion.
These are anchor bolted through the mesh into the structural wall effectively
clamping the mesh to the structural wall.
It is recommended that cladding over 3.0m in height has a secondary horizontal

support such as a beam or angle section of width equal to 2/3rds of the
cladding width.
Block Work Walls:-
The suitability of fixing back to block work is dependant upon the height of the `
cladding. Up to one storey, clamping as for structural walls is normally
satisfactory, however it is recommended to use resin anchored bolts.
Where the cladding height is greater than one storey, horizontal support should be
provided to take the vertical load of the gabions. This horizontal support must be
linked to a concrete or steelwork framework. An alternative is to provide
additional support columns or vertical steelwork embedded within the cladding (see
details within the next section).
A typical method of providing vertical steelwork support is to provide columns at 1.0

to 2.0m intervals to suit the gabion unit lengths. Further columns may be required for
openings. The columns are either founded in concrete or bolted into a concrete
foundation
Where it is not practical to provide column support bolted to or embedded in the

foundation, a vertical angle section restrained at floor beam levels may be installed
instead with the gabion being secured by a clamp bar bolted to the angle section.
Additional steelwork can be used to offset the vertical angle section to create
the void for membranes and /or insulation in the cavity wall construction.
11
This drawing is the copyright of Cerana Limited (ENVIROMESH), no unauthorised copying is permitted without the permission of Cerana Limite(ENVIROMESH)
The design and specifications of gabions and associated materials are limited to materials sourced from Cerana Ltd(ENVIROMESH)
CLAMP BARS WITH 3 NUMBER BOLT FIXINGS ARE

TO BE LOCATED EVERY OTHER CELL VERTICALLY
AND IN EVERY UNIT LONGITUDINALLY.
U NI T
LE NG
TH
SUPPORT FRAMES
OR MESH
DIAPHRAGMS
STRUCTURAL WALL
GABION CLADDING
UNITS
CLAMP BAR ARRANGEMENT

FOR GABION CLADDING
GABION 27 CLADDING SYSTEM - WELDED MESH GABIONS FORMED FROM HOT DIP GALVANISED MESH TO BS EN ISO 1461-
76.2mm x76.2mm OR 50.8mm x 50.8mm IN 4mm OR 5mm DIAMETER WIRE TO THE FACE, BASE, LID AND HORIZONTAL DIAPHRAGMS.
VERTICAL DIAPHRAGMS CAN BE FORMED FROM MESH OR FRAMES:
VERTICAL DIAPHRAGM MESH SPECIFICATION IS AS FOR THE PRINCIPLE PANELS.
INTERMEDIATE FRAMES FORMED FROM HOT DIP GALVANISED WIRE TO BS EN ISO 1461 - 10mm DIAMETER. VERTICAL
SPACING OF THE CROSS BARS IS TO SUIT THE MESH APERTURE AND UNIT HEIGHT, BUT NOT EXCEEDING 0.25m.
END PANELS ARE SUPPLIED TO CLOSE OFF THE END RUN OF GABIONS.
DRAWN RDF SCALE NOT TO SCALE

PROJECT TITLE
REVISIONS DATE
CLAMP BAR FIXING

Garner Street Business Park, Etruria, Stoke-on-Trent, Staffordshire, ST4 7BH
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202
www.enviromeshgabions.com
PROJECT NUMBER DATE
CLADDING-1 08-01-2007
CLAMP DISCS EVERY OTHER CELL WITHIN UNIT AS

BELOW. EACH OF THE END CELLS SHOUL BE
CLAMPED
U NI T
LE NG
TH
SUPPORT FRAMES
OR MESH
DIAPHRAGMS
STRUCTURAL WALL
GABION
CLADDING
UNITS
CLAMP DISC ARRANGEMENT

FOR GABION CLADDING

PROJECT TITLE
REVISIONS DATE
CLAMP DISC ARRANGEMENT

Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202
PROJECT NUMBER DATE
CLAMPS 26-01-2007
SECTION THROUGH A WALL WITH A GABION

OUTER LEAF AND BLOCKWORK INNER LEAF
0.762m TYP. 0.3m

B
ONE MESH VOID WITHIN
CLADDING
MEMBRANE PROTECTED
WITH GEOTEXTILE
BLOCKWORK
unit cell height

0.686m for 76.2mm mesh
0.383m
B
SECTION THROUGH BB
FOR STABILITY OF THE CLADDING, IT MUST BE SECURED BACK TO THE

BUILDING.
FOR BLOCK WORK WALLS THE MAXIMUM HEIGHT OF CLADDING SHOULD BE
2M.
IF THE HEIGHT EXCEEDS THIS, THEN SUPPORT MEMBERS WILL BE REQUIRED
WITHIN THE GABION.

PROJECT TITLE
REVISIONS DATE
CLADDING TO BLOCKWORK
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202
PROJECT NUMBER DATE
CLADDING - 3 04-01-2007
0.3m 0.3m
STEEL SUPPORT
STEEL SUPPORT COLUMN WITH
COLUMN WITH BASE PLATE
BASE PLATE BOLTED TO
BOLTED TO CONCRETE
CONCRETE FOUNDATION.
FOUNDATION. COLUMNS
COLUMNS DESIGNED TO
DESIGNED TO RESIST WIND
RESIST WIND LOADINGS.
LOADINGS.
POST CAN BE
CENTRAL TO THE
DEPTH OF THE
GABION BUT THE UNIT
DEPTH SHOULD BE
200mm GREATER
unit cell height THAN THE POST
0.711m for 50.8mm mesh WIDTH
CONCRETE FOUNDATION CONCRETE FOUNDATION
SUPPORT COLUMN FOR CLADDING SUPPORT COLUMN FOR CLADDING

TO NON STRUCTURAL WALL. TO NON STRUCTURAL WALL.
COLUMN SITED TO REAR OF COLUMN SITED CENTRAL TO THE
THE UNIT. DEPTH OF THE GABION.
COLUMN (STEEL COLUMN /

MEMBER AS REQUIRED BY
DESIGN)
CLAMP BAR BOLTED TO COLUMN TO SECURE GABION
DETAIL OF CLAMP BAR FIXING

GABION TO COLUMN

PROJECT TITLE
REVISIONS DATE
COLUMN SUPPORTED CLADDING

Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202
PROJECT NUMBER DATE
CLADDING - 4 08-01-2007
Gabion Cladding as an Outer Leaf in Cavity Wall Construction.
Gabion units are free draining. When used as an outer leaf to cavity wall
constructions, an impermeable membrane is required within the cavity.
Where no insulation material is to be provided within the cavity, a

suitable membrane can be installed to the inner leaf within the cavity. If
insulation material is required within the cavity then a membrane is installed
against the rear gabion face. Gabions are manufactured from wire that could
potentially penetrate the membrane, therefore a non woven geotextile should be
placed between the gabion and the membrane to prevent a puncture occurring.
It is also a recommendation that the gabion be manufactured with a narrow cell to

the rear of the unit that remains as a void to prevent any sharp edges of the
gabion fill or pressure from the fill damaging the membrane or insulation.
Where it is decided to use wall ties to link the inner and outer gabion cavity,
the tie must be securely fixed to the gabion. Where the ties pass through
the membrane, it must be sealed.
Independant Gabion Cladding
In this form of construction, the gabion cladding is designed to be stable under

its own mass i.e. designed as a free standing wall. For economy, the wall is
normally tapered with the thinner top of the wall being secured back to the
structure. The details for forming cavity construction are as above.
16
TOP WIDTH
NOTE: IF THE TOP OF THE WALL IS LESS THAN 0.457m WIDE, THEN
CLAMP BARS OR CLAMP DISCS ARE REQUIRED TO TIE THE GABION
BACK TO THE STRUCTURE.
unit cell height

CONCRETE FOOTING
BASE WIDTH
FREE STANDING WALLS ARE TO BE DESIGNED AS

MASS GRAVITY WALLS TO RESIST WIND LOADINGS
TOP WIDTH
NOTE: IF THE TOP OF THE WALL IS LESS THAN 0.457m WIDE, THEN
CLAMP BARS OR CLAMP DISCS ARE REQUIRED TO TIE THE GABION
BACK TO THE STRUCTURE.
NON WOVEN
GEOTEXTILE / IMPERMEABLE
MEMBRANE
SECONDARY CELL ONE

MESH WIDE UNFILLED AS
VOID
unit cell height

BASE WIDTH
FREE STANDING WALLS WHERE REQUIRED ARE TO HAVE AN IMPERMEABLE

BARRIER BETWEEN THE GABION AND THE STRUCTURE.
THE GABION CLADDING IS TO BE DESIGNED AS A MASS GRAVITY WALL TO
RESIST WIND LOADINGS.

PROJECT TITLE
REVISIONS DATE
INDEPENDANT CLADDING WALLS

Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202
PROJECT NUMBER DATE
CLADDING 5 08-01-2007
Doors, Window Openings and Services
Where openings within the cladding system are required, a suitable lintel must be placed
above the opening to support any vertical loads above (the gabion density is approximately
1.7 tonnes/cum).
The lintel on thin vertical claddings will normally require some form of steelwork
support, whereas on a tapered wall the lintel is supported on a concrete pad within a
cell at least 0.3m from the opening.
The lintel must be set 10mm above the soffit of the opening, so that no vertical load is
transferred to the vertical side panels of the openings.
The lintel is normally of a width of 75mm less than the cladding depth to allow for a face
stone within the baskets to hide the lintel.
Door jams can be secured to vertical steelwork set within the gabion.
Box outs can also be created where required. This is achieved by inserting suitable panels
within the gabion to form a box cell of width and height greater than the box out
required. The face and / or rear mesh within the box out is then cut away.
Where services are required to pass through the wall, this can be achieved by
forming box outs as above or within a conduit sleeve set within the gabion.
18
SECTION THROUGH WALL WITH GABION OUTER LEAF AND BLOCKWORK INNER LEAF
0.3m
0.762m typical
B
ONE MESH VOID WITHIN CLADDING.
INNER FACE TO BE LINED WITH AN IMPERMEABLE
MEMBRANE, PROTECTED BY A NON WOVEN GEOTEXTILE.
LINTEL TO BE SET 10mm ABOVE THE UNDERSIDE OF THE

LINTEL GABION FOR ONE CELL EITHER SIDE OF THE OPENING.
LINTEL STEEL COLUMN SUPPORT
unit cell height

B CELLS EITHER SIDE OF OPENING,

SECTION THROUGH BB
300MM WIDE ROCKFILLED TO FULL DEPTH.
UNIT CAN BE INCREASED IN DEPTH

TO INFILL BACK TO THE BLOCK WORK.
0.762m typical
A ONE MESH VOID WITHIN CLADDING.
0.3m
INNER FACE TO BE LINED WITH AN IMPERMEABLE
MEMBRANE, PROTECTED BY A NON WOVEN GEOTEXTILE.
LINTEL
PAD PAD
STONE LINTEL STONE PAD STONE TO BE SET 10mm ABOVE THE UNDERSIDE OF THE
GABION FOR ONE CELL EITHER SIDE OF THE OPENING.
unit cell height

A SECTION THROUGH AA
CELLS EITHER SIDE OF OPENING

300MM WIDE ROCKFILLED TO FULL DEPTH
UNIT CAN BE INCREASED IN DEPTH
TO CLOSE BACK TO BLOCK WORK
REVISIONS DATE DOOR AND WINDOW

OPENINGS
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202
PROJECT NUMBER DATE
CLADDING-2 04-01-2007
VERTICAL
LID
DIAPHRAGM
FRAMES OR MESH
PANELS
2 X INTERMEDIATE LIDS
AND FACE PANELS
SUPPLIED LOOSE FOR SITE
FITTING. REAR PANEL
VERTICAL END
PANELS
INTERMEDIATE
PANEL SET
INTO POSITION
BASE ON SITE
FIRST LIFT
FACE PANEL
SCHEMATIC DRAWING OF UNIT MANUFACTURE
CLADDING UNITS ARE MANUFACTURED IN MODULE LENGTHS OF 0.762m OR 1.524m.

ALL VERTICAL JOINTS ARE TO BE HELICALLED.
RECOMMENDED MESH SPECIFICATION IS HOT DIP GALVANISED COATED IN 4mm WIRE DIAMETER.
INTERMEDIATE LIFTS ARE NORMALLY EQUAL TO THE MODULE LENGTH TO GIVE A SQUARE PATTERN
ON THE FACE. WHERE THE CLADDING HEIGHT IS NOT A MULTIPLE OF THE STANDARD CELL HEIGHT,
THE BASE CELL HEIGHT CAN BE INCREASED UP TO 0.991m OR THE TOP CELL REDUCED TO MINIMUM
OF 0.152m
UNIT DEPTHS ARE TO BE A MULTIPLE OF THE MESH SIZE.

PROJECT TITLE
REVISIONS DATE
CLADDING UNIT
MANUFACTURE Garner Street Business Park, Etruria, Stoke-on-Trent, Staffordshire, ST4 7BH
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202
PROJECT NUMBER DATE
CLADDING 8 04-01-2007
INTERMEDIATE LIDS
AND FACE PANELS
SUPPLIED LOOSE
SECURE GABIONS BACK

TO THE STRUCTURE WITH
CLAMP BARS OR CLAMP
DISCS
STAGE 4
STAGE 1
FORM BASKET INTO ITS OPEN FRONTED
BOX SHAPE AND JOIN TO ADJACENT UNITS
ACCORDINGLY USING HELICALS TO
ENCOMPASS THE MESH AND FRAMES.
INTERMEDIATE
LIDS AND FACE
PANELS
SUPPLIED LOOSE
STAGE 5
STAGE 2
ROTATE THE FIRST FACE PANEL INTO

WIRE DOWN LID TO
POSITION AND HELICAL AND PLACE
CLOSE OFF UNITS
ROCK FILL INTO THE CELL.
NOTES:
A RUN OF UNITS SHOULD BE

INTERMEDIATE LIDS ASSEMBLED AND FIXED WITH
AND FACE PANELS CLAMP BARS OR DISCS TO THE
SUPPLIED LOOSE WALL AS PER STAGE 1
A SINGLE HELICAL IS USED TO

CONNECT THE ADJACENT FACE
PANELS AND THE FRAME FOR
EACH LIFT.
STAGE 3
INSERT LOOSE INTERMEDIATE LIDS AND

FACE PANELS, THEN CONNECT TO THE
REAR PANEL AND THE FACE PANEL OF
THE CELL BELOW. ROTATE THE FACE
PANEL INTO POSITION AND PLACE ROCK
FILL INTO THE CELL.

PROJECT TITLE
REVISIONS DATE
CLADDING CONSTRUCTION
SEQUENCE Garner Street Business Park, Etruria, Stoke-on-Trent, Staffordshire, ST4 7BH
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202
PROJECT NUMBER DATE
CLADDING 7 08-01-2007
Free Standing Walls
Typically free standing gabion walls take one of the following forms:
Vertical Walls
Gabion modules of uniform width either in the standard Gabion 39 unit sizes or
the Gabion 27 system (note:- higher quality and ease of construction is achieved with
the Gabion 27 system).
Wall heights (nominal)
0.686m, 0.991m and 1.362m in Gabion 27 system x 0.686m wide.
1.676m to 2.360m in Gabion 27 system x 1.0m wide.
Maximum of 2.5m in standard Gabion 39 system - 1.0m wide.
Trapezoidal walls
Walls can either be sloped on one face or both faces. The slope angle is either 1 mesh or
2 meshes in the unit height, on one or both faces.
i.e. Gabion 27 system: 9 in 1 (6.35 degrees from vertical)

9 in 2 (12.6 degrees from vertical)
Gabion 39 system: 13 in 1 (4.4 degrees from vertical)
13 in 2 (8.75 degrees from vertical)
The walls are designed as mass gravity walls against wind loading and earth
pressures if the wall is part retaining.
The minimum width at the top is normally 0.457m, though this may increase
dependant upon the stability.
It is possible to have walls part trapezoidal in the upper courses and vertically faced in the
lower courses.
Gabion Fence
This is basically the same as a cladding unit but has a post central to the width of the unit
secured to the internal frames normally at a maximum of 3 cell lengths. The support posts
can be concreted into the ground at the required intervals and provided with a nominal
200mm depth of concrete foundation. Alternatively, the posts can be bolted down to a
ground beam.
The concrete foundation is provided to ensure that the gabion fence alignment is linear. If
no suitable foundation is provided, differential settlements may occur affecting the
wall alignment.
22
granular or concrete
foundation
VERTICAL FACE
STEPPED WALLS
foundation
COMBINED VERTICAL
AND INCLINED FACED
WALLS
foundation
INCLINED FACED WALLS
FREE STANDING MASS GRAVITY GABION WALLS

PROJECT TITLE
REVISIONS DATE
FREESTANDING WALLS
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202
PROJECT NUMBER DATE
CLADDING 6 08-01-2007
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202
WELDED MESH GABION SPECIFICATION

Gabion 27 Cladding - 4.0mm Wire Diameter Hot Dip Galvanised
Gabions shall comply with the following specifications
MANUFACTURE: Gabions shall be manufactured from a hard drawn steel wire formed into a bi-axial mesh
grid by electrically welding the cross wires at every intersection. The weld strength is to be
70% of the ultimate tensile strength of the wire. Gabions are to be factory assembled with
stainless steel clips (minimum one every third mesh opening) connecting side panels and
diaphragms to the base panel. Units shall be supplied in lengths of 1.52m, with horizontal
diaphragms at typical 0.711m lifts and vertical diaphragms at 0.762m intervals. Units shall
be designed such that the coursing remains continuous along the length of the structure
with modification of the top and lower cells heights as required to accommodate the
stepping arrangement of the top of the wall and foundation levels. The unit is to be
manufactured such that the maximum height is 2.133m and assembled to allow filling of
the unit in lifts of typically 0.711m.
MESH SIZE: The mesh openings shall be square and of a nominal dimension of 50.8mm on the grid.
MESH WIRE: The nominal wire diameter shall be 4.0mm all in accordance with BS EN 10218-2 1997.
The tensile strength falls within a range of 540-770 N/mm2.
DEFORMATION The maximum deformation coefficient is to be 0.25 for the unsupported mesh facing.
CO-EFFICIENT:
CORROSION: Wire shall be Hot Dip Galvanised in accordance with BS EN ISO 1461.
JOINTING: Gabions shall be provided with Galfan coated (95% Zinc / 5% Aluminium) helicals in
3.0mm wire diameter for vertical joints and lacing wire / helicals for horizontal joints except
for the lid which shall be helical jointed. Lacing wire shall be Galfan coated and of a
minimum wire diameter of 2.2mm for final jointing.
ROCKFILL: Gabion fill shall be a hard durable and non frost susceptible (rock or stone type) having a
minimum dimension not less than the mesh opening and a maximum dimension of
200mm.
CONSTRUCTION: Units to be secured to the concrete wall with 1500mm x 50mm x 10mm clamp bars
galvanised to BS EN ISO1461 bolted to the wall with 4 no. anchor bolts (clamp bars are
predrilled with 13mm holes). Clamp bars are to be located at a maximum of 1.4m vertical
centres. All rock fill shall be packed tightly to minimize voids and the rockfill on the
exposed face of the gabion is to be hand packed. Corner bracing ties 2 per cell installed
at mid height across each corner on 0.711m high cells and at 1/3rd and 2/3rd height on
cells greater than 0.711m in height. Units shall be filled such that the mesh lid bears down
onto the rock fill. The lid shall be wired down on all joints and across the diaphragms.
SPEC 8: 01-02-2007
24
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202

Gabion 27 Cladding 4.0mm Wire Diameter Hot Dip Galvanised
MANUFACTURE: Gabions shall be manufactured from a hard drawn steel wire formed into a bi-axial
mesh grid by electrically welding the cross wires at every intersection. The weld
strength is to be 70% of the ultimate tensile strength of the wire. Gabions are to be
factory assembled with stainless steel clips (minimum one every third mesh opening)
connecting side panels and diaphragms to the base panel.
Units shall be supplied in lengths of 1.52m, with horizontal diaphragms at typical
0.686m lifts and vertical diaphragms at 0.762m intervals. Units shall be designed such
that the coursing remains continuous along the length of the structure with modification
of the top and lower cells heights as required to accommodate the stepping
arrangement of the top of the wall and foundation levels.
The unit is to be manufactured such that the maximum height is 2.057m and assembled
to allow filling of the unit in lifts of typically 0.686m.
CO-EFFICIENT:
3.0mm wire diameter for vertical joints and lacing wire / helicals for horizontal joints
except for the lid which shall be helical jointed. Lacing wire shall be Galfan coated and
of a minimum wire diameter of 2.2mm for final jointing.
ROCKFILL: Gabion fill shall be a hard durable and non frost susceptible (rock or stone type) having
a minimum dimension not less than the mesh opening and a maximum dimension of
200mm.
predrilled with 13mm holes). Clamp bars are to be located at a maximum of 1.4m
vertical centres. All rock fill shall be packed tightly to minimize voids and the rockfill on
the exposed face of the gabion is to be hand packed. Corner bracing ties 2 per cell
rd rd
installed at mid height across each corner on 0.686m high cells and at 1/3 and 2/3
height on cells greater than 0.686m in height. Units shall be filled such that the mesh lid
bears down onto the rock fill. The lid shall be wired down on all joints and across the
diaphragms.
SPEC 9: 01-02-2007
25
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202

diaphragms to the base panel. Units shall be supplied in lengths of 1.52m, with horizontal
diaphragms at typical 0.711m lifts and vertical diaphragms at 0.762m intervals. Units shall
be designed such that the coursing remains continuous along the length of the structure
with modification of the top and lower cells heights as required to accommodate the
stepping arrangement of the top of the wall and foundation levels. The unit is to be
manufactured such that the maximum height is 2.133m and assembled to allow filling of
the unit in lifts of typically 0.711m.
CO-EFFICIENT:
200mm.
centres. All rock fill shall be packed tightly to minimize voids and the roc kfill on the
exposed face of the gabion is to be hand packed. Corner bracing ties 2 per cell installed at
mid height across each corner on 0.711m high cells and at 1/3rd and 2/3rd height on cells
greater than 0.711m in height. Units shall be filled such that the mesh lid bears down onto
the rock fill. The lid shall be wired down on all joints and across the diaphragms.
SPEC 10: 01-02-2007
26
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202

diaphragms to the base panel.
Units shall be supplied in lengths of 1.52m, with horizontal diaphragms at typical 0.686m
lifts and vertical diaphragms at 0.762m intervals. Units shall be designed such that the
coursing remains continuous along the length of the structure with modification of the top
and lower cells heights as required to accommodate the stepping arrangement of the top
of the wall and foundation levels.
The unit is to be manufactured such that the maximum height is 2.057m and assembled to
allow filling of the unit in lifts of typically 0.686m.
MESH WIRE: The nominal wire diameter shall be 5.0mm for exposed all in accordance with BS EN
10218-2 1997. The tensile strength falls within a range of 540-770 N/mm2.
CO-EFFICIENT:
200mm.
centres. All rock fill shall be packed tightly to minimize voids and the rock fill on the
exposed face of the gabion is to be hand packed. Corner bracing ties 2 per cell installed at
mid height across each corner on 0.686m high cells and at 1/3rd and 2/3rd height on cells
greater than 0.686m in height. Units shall be filled such that the mesh lid bears down onto
the rock fill. The lid shall be wired down on all joints and across the diaphragms.
SPEC 11: 01-02-2007
27
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202

Trapezoidal Gabion 27 System 3.00mm / 4.0mm Wire Diameter Hot Dip
Galvanised
stainless steel clips (minimum one every third mesh opening) connecting face and rear
panels to the base panel and the lid to the face panel where required.
Welded A-Frames to a maximum width of 1.0m are to be manufactured to the required
shape (one frame per 0.686m cell to be provided for installation on site).
MESH WIRE: The nominal wire diameter shall be 3.0mm for the base, ends, lids and diaphragms where
required and 4.0mm for the front and rear panels all in accordance with BS EN 10218-2
1997. The tensile strength falls within a range of 540-770 N/mm2.
FRAME WIRE: The A-Frames are to be manufactured from 10mm mild steel bar.
CORROSION: All Wires for the mesh and A-Frames shall be Hot Dip Galvanised in accordance with BS
EN ISO 1461.
JOINTING: Gabions shall be provided with Galfan coated (95% Zinc / 5% Aluminium) helicals
manufactured from 3.0mm wire diameter and Galfan coated lacing wire manufactured
from a minimum wire diameter of 2.0mm for final jointing.
200mm.
CONSTRUCTION: All rock fill shall be packed tightly to minimize voids and the rock fill on the exposed face of
the gabions is to be hand packed.
Internal windlass bracing ties are to be positioned at 1 per face cell at midpoint on 0.686m
high units and at mid point and third heights on 1.0m high units.
Adjacent units are to be jointed with full-length helicals on all vertical joints and laced
horizontally with lacing wire through every mesh space at the front and rear of each
course.
Units shall be filled such that the mesh base of the unit above bears down onto the rock
fill. The lid shall be wired down on all joints and across the diaphragms.
SPEC12: 01-02-2007
28
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202

Gabion 39 System - 4.00mm Wire Diameter - Galfan Coated
diaphragms to the base panel and the lid to the face panel.
Diaphragms to be at nominal 1m centres on the unit length, except for 1.5m long
gabions which have no internal diaphragm.
MESH WIRE: The nominal wire diameter shall be 4.0mm in accordance with BS EN 10218-2 1997. The
tensile strength falls within a range of 540-770 N/mm2.
CORROSION Wire shall be galfan coated (95% Zn / 5% Al) in accordance with BS EN 10244-2:
PROTECTION: 2001.
JOINTING: Gabions shall be provided with lacing wire for site assembly. The lacing wire shall be of a
nominal wire diameter of 2.2mm (all in accordance with the corrosion protection specified)
for final jointing.
ROCKFILL: Gabion fill shall be a hard durable and non frost susceptible (rock or stone type)
having a minimum dimension not less than the mesh opening and a maximum dimension
of 200mm.
the gabion is to be hand packed. Internal windlass bracing ties are to be incorporated at 2
per 1sqm of face at 1/3rd & 2/3 intervals for 1m high units and 1 placed centrally for 0.5m
high units. The adjacent gabion units are to be tied together with continuous lacing on the
vertical joints as well as horizontally at the front and rear of coursed joints. The units shall
be filled such that the mesh lid bears down onto the rock fill. The lid shall be wired down on
all joints and across the diaphragms.
Above jointing and internal bracing is supplied as standard. The following alternatives are also acceptable:
Full height helicals in 3.0mm galfan coated wire for vertical jointing
Pneumatically closed galfan coated C rings for vertical and horizontal jointing at 1 ring
every other mesh opening.
Galfan coated preformed corner bracing ties 4 per m2 of face.
SPEC 3: 29-01-2007
29
Tel: +44 (0)845 136 0101 Fax: +44 (0)845 136 0202

Gabion 39 System - 5.00mm Wire Diameter - Galfan Coated
diaphragms to the base panel and the lid to the face panel.
Diaphragms to be at nominal 1m centres on the unit length, except for 1.5m long
gabions which have no internal diaphragm.
MESH WIRE: The nominal wire diameter shall be 5.0mm in accordance with BS EN 10218-2 1997. The
tensile strength falls within a range of 540-770 N/mm2.
CORROSION Wire shall be galfan coated (95% Zn / 5% Al) in accordance with BS EN 10244-2:
PROTECTION: 2001.
JOINTING: Gabions shall be provided with lacing wire for site assembly. The lacing wire shall be of a
nominal wire diameter of 2.2mm (all in accordance with the corrosion protection specified)
for final jointing.
ROCKFILL: Gabion fill shall be a hard durable and non frost susceptible (rock or stone type)
having a minimum dimension not less than the mesh opening and a maximum dimension of
200mm.
the gabion is to be hand packed. Internal windlass bracing ties are to be incorporated at 2
per 1sqm of face at 1/3rd & 2/3 intervals for 1m high units and 1 placed centrally for 0.5m
high units. The adjacent gabion units are to be tied together with continuous lacing on the
vertical joints as well as horizontally at the front and rear of coursed joints. The units shall
be filled such that the mesh lid bears down onto the rock fill. The lid shall be wired down on
all joints and across the diaphragms.
Above jointing and internal bracing is supplied as standard. The following alternatives are also acceptable:
Full height helicals in 3.0mm galfan coated wire for vertical jointing
Pneumatically closed galfan coated C rings for vertical and horizontal jointing at 1 ring
every other mesh opening.
Galfan coated preformed corner bracing ties 4 per m2 of face.
SPEC 5: 29-01-2007
30
Garner Street Business Park, Etruria, Stoke-on-Trent,
Staffordshire, ST4 7BH
Tel: +44 (0) 845 136 0101 Fax: +44 (0) 845 136 0202
CONTACTS:
Roger Farmer Mob: +44 (0) 7725 244 636

Technical Director Email: roger.farmer@enviromeshgabions.com
Neil Holmes Mob: +44 (0) 7725 244 637

Commercial Director Email: neil.holmes@enviromeshgabions.com
01/02/07 Edition 1

Enviromesh Guide To Fs Walls and Cladding

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Enviromesh Guide To Fs Walls and Cladding

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Designing with Gabions

A Reference Guide for

GABION FILLING MATERIALS PAGES 4 - 5

GABION SPECIFICATIONS PAGE 6

GABION UNIT SIZES PAGES 8 - 10

INSTALLATION OF CLADDING PAGES 11 - 21

FREE STANDING WALLS PAGES 22 - 23

This publication is intended as a general overview of the subjects dealt

It is the responsibility of all parties to satisfy themselves that the

Tel: 0044 (0) 845 136 0101

Various reasons have given rise to this:

The quality of welded mesh gabion schemes have improved due to

Requirements for using recycled fills i.e. crushed concrete, saving on

Architects embracing new construction materials and textures.

Earth Centre, Doncaster

Free Standing Walls:

Normally vertical on both faces and of a narrow width.

Sandstone (not soft sandstone that is degradable)

Specifications Mesh opening Wire Diameters

Hot Dip Galvanised ISO 1461 76.2mm x 76.2mm 4.0mm

Hot Dip Galvanised ISO 1461 50.8mm x 50.8mm 4.0mm

Hot Dip Galvanised ISO 1461 76.2mm x 76.2mm 5.0mm

Hot Dip Galvanised ISO 1461 50.8mm x 50.8mm 5.0mm

Specifications Mesh opening Wire Diameters

Galfan 76.2mm x 76.2mm 4.0mm

Galfan 76.2mm x 76.2mm 5.0mm

Galfan is not generally readily available in a 50.8mm x 50.8mm mesh aperture.

- Earth pressure forces where the structure up to a certain height is acting as

- Design of any support columns where required.

- Design of foundations for support columns where required.

- Lintel design for door or window openings.

- Foundation requirements. Normally a concrete foundation is recommended as

Structural Dimensional Requirements

This variation can be accommodated in the method of construction and manufacture

Standard sizes available in Galfan coated wire are as follows:-

1m x 1m x 0.5m 1.5m x 1m x 0.5m 2m x 1m x 0.5m

Mesh size Unit length Unit Height Cell Sizes

76.2mm x 76.2mm 2.057 0.457m or 2 unequal cells

Bespoke Cladding Units:

Optimum Unit Lengths:

` Mesh size Unit lengths

76.2mm x 76.2mm 0.762m or 1.524m

Optimum Unit Widths:

Unit Height Mesh Size Unit Height Mesh Size

0.457m 76.2mm x 76.2mm 0.457m 50.8mm x 50.8mm

The resulting optimum unit sizes for cladding are as follows:

Mesh Unit Unit Unit Cell Number of

76.2mm x 0.762m 0.686m 0.762m 1x1

50.8mm x 0.762m 0.711m 0.762m 1x1

Typically the inclination of the face is equivalent to the following:

76.2mm mesh 1 or 2 meshes over the unit height

Unit lengths are as follows:

76.2mm mesh 2.057m with frames at 0.686m centres

50.8mm mesh 1.524m with frames at 0.711m centres

Structural Reinforced Concrete Walls:-

It is recommended that cladding over 3.0m in height has a secondary horizontal

Block Work Walls:-

A typical method of providing vertical steelwork support is to provide columns at 1.0

Where it is not practical to provide column support bolted to or embedded in the

CLAMP BARS WITH 3 NUMBER BOLT FIXINGS ARE

CLAMP BAR ARRANGEMENT

VERTICAL DIAPHRAGM MESH SPECIFICATION IS AS FOR THE PRINCIPLE PANELS.

DRAWN RDF SCALE NOT TO SCALE