Sustainable and striking structures built to last in wire and stone

A leader in its field, Gabion Baskets continues to push the boundaries of product innovation, backed by in-field experience and a unique ability to develop structures that set new industry benchmarks for form and function.

The company was founded 17 years ago in 2006 as a specialist manufacturer in hexagonal double-twisted wire mesh systems, employed worldwide for well over 100 years to form gabion infrastructure predominately used for civil engineering roles like mass gravity retaining walls, and river erosion works.

A more modern, and parallel development is the introduction of welded mesh products that can meet civils specifications but are predominately used for architectural applications that include interior and exterior building cladding, reception desks, freestanding walls, landscaping, and allied designs that naturally enhance the aesthetic appeal of these rock-filled structures.

Gabion Animation

Gabions Baskets’ traditional 2D design services have evolved to encompass 3D animation, enabling clients, architects, engineers and contractors to obtain a virtual perspective and refine their requirements accordingly.

The latter include security and pedestrian barriers, and anything in between. A great example is Gabion Baskets’ launch of its Fire Pit range – essentially a welded mesh circular design that creates a unique entertainment feature for residential and allied commercial applications, such as guest lodges.

National manufacturing centres

Gabion Baskets’ main manufacturing centre is based in Johannesburg, supported by its satellite fabrication facilities in Durban and Cape Town. “In the past, all standard

Further down, an existing pedestrian bridge was rehabilitated by creating a new inlet and outlet culvert on either side. Lowering the height of the bridge and creating a concrete capping walkway allows the water to flow over the bridge if the existing pipes get blocked due to debris or extensive water volumes.

CASE STUDY: RIVER EROSION WORKS

and custom project-related orders were made in Johannesburg for on-site delivery, with Durban and Cape Town only receiving raw woven and welded mesh materials for onward sale to local assemblers,” explains Louis Cheyne, managing director, Gabion Baskets.

“We’re now closing that loop to ensure customers can order ‘ready to assemble’ kits from all three facilities, thanks to recent expansion activities that include a move to a new building for our Durban operation.

“Aside from shorter lead times – so critical for just-in-time construction delivery – the

Gabion Baskets’ Durban office recently provided a design recommendation and installation solution within the Mount Edgecombe Estate 2. The scope entailed the rehabilitation of a small river channel and associated low level road bridge crossing. Generally during normal light rain, stormwater flows are low. However, due to current road construction works on the neighbouring N2, this has increased significantly, overwhelming the capacity of the channel.

The solution entailed the installation of gabion mattresses – resting on a geotextile liner (an essential requirement) – to create a free-flowing channel. This measures 35 m in length and 2 to 3 m in width. A new gabion wing wall was also constructed on the outlet side of the bridge to miminise the risk of downstream embankment erosion, especially during flood events.

The site did have existing 0,5 m high gabion retaining sections. However, without a foundational gabion mattress, they had been progressively undermined by scouring – a problem which was rectified by Gabion Baskets’ design recommendation and installation solution. For all project phases, the wire system used for the baskets and mattresses is Class A galvanised with a polymer coating for added durability against corrosion. In total, 96 tonnes of rock fill were supplied and packed by hand and the project duration was 19 days from start to finish.

Barrier Systems

added benefit is that our locally based project managers and trainers are now much closer to their markets when it comes to design and installation advice for consulting engineers, contractors, and SMME sub-contractors. Plus, there’s an opportunity to stimulate regional growth in the gabion construction segment

Feature And Boundary Walls

and create much needed jobs for private and public sector related works.”

Gabion Baskets’ Johannesburg facility has evolved significantly since 2006, shifting from a predominately manual fabrication process to a high degree of factory automation, in line with world class industrial engineering practices. This has led to recent investments in machinery that enhance worker ergonomics and efficiencies, ensuring consistent throughput quality. A similar ongoing technical upgrade will follow for the company’s satellite centres.

Growth in South Africa and Africa

“In recent years, we’ve experienced an upsurge in demand from South African customers, alongside major export growth into Africa for countries that include Malawi, Mozambique, and Zambia. Further afield, we’re also increasingly supplying South African-based contractors working on projects throughput the African content, as well as governmental clients closer to home within the SADC region for a wide range of requirements. These range from African Union military missions to transportation engineering and mining developments,” Cheyne continues.

Boundary walls and cladding

One of Gabion Baskets’ fastest growing areas is the architectural market. “The number of enquiries continues to grow from architects, engineers, property developers and the general public and we’re responding with creative and ‘out of-the-box’ solutions,” Cheyne continues. “It’s an exciting new frontier with a high degree of interest shown during our recent stand exhibits at the Home and Garden expo, and the Decorex shows in Cape Town and Johannesburg.”

Recent project examples include perimeter walls for housing within the Eagle Canyon Golf and Lifestyle East. These are composed entirely of stacked welded mesh panels founded on a concrete base and internally supported by interspersed rebar. Another recent project in Vanderbijlpark, entailed the design of a perimeter wall composed of brick columns interspersed with welded mesh sections. Clear fence walls supported by gabion columns are also proving popular as an added security feature, as are freestanding feature walls, as well as welded mesh cladding systems for buildings and landscaped wall features.

Retaining walls are mass gravity structures that can be designed in a wide range of configurations to match ground contours. A case in point is an L-shaped structure where Gabion Baskets’ Durban office was requested to provide a design recommendation and build solution for a residential development. The design needed to provide an engineered solution that would also serve as an aesthetic feature wall.

Welded mesh is ideally suited for these designs due to the flat finish and exact tolerances achieved, making it the definitive choice for architectural designs and building cladding. In theory, woven mesh could be used, but as Cheyne points out its core purpose is to perform in an engineering environment, like embankment stabilisation, in conjunction with geotextile systems designed to control permeability and soil retention.

Submerged in a riverine environment, a retaining wall constructed using welded mesh panels would break apart within a short space of time because it doesn’t have the purpose-designed flexible characteristics of woven mesh. However, for land-based structures, welded mesh can be used for retaining walls where the express purpose is to achieve an optimum aesthetic effect.

“Currently, our welded mesh systems

In addition to providing a retaining function, welded mesh gabion panels can serve a dual purpose as cladding to create a striking aesthetic effect

Wall Cladding

come in a standard silver colour due to their Class A Galvanised finish. However, we’re now researching other colour options, either using a polymer or a powder coating, for architectural projects,” Cheyne continues.

“Colour is also an option for woven mesh, thanks to developments in polymer coatings. The latter provide the dual benefits of additional corrosion and scour protection. Plus, colours like tan or green enable engineered gabion structures to blend in with the environment, which may be a design requirement within urban areas,” he adds.

“Either way, the natural beauty of their stone fill makes gabions a default choice for architectural, landscaping and engineering projects, and at times a combination of all three,” Cheyne concludes. www.gabionbaskets.co.za