What is gabion mesh?
A gabion is a wire-mesh basket filled with stone to build retaining structures, erosion barriers and architectural walls. The mesh must be heavy, corrosion-protected and strong enough to hold the fill without bulging. Two constructions dominate: rigid welded panels and flexible double-twist hexagonal netting. See gabion walls for design context.
Welded vs woven (double-twist) gabions
| Feature | Welded gabion | Double-twist hexagonal gabion |
|---|---|---|
| Construction | Spot-welded square mesh panels | Twisted hexagonal netting |
| Appearance | Sharp, straight, architectural | Softer, traditional |
| Flexibility | Rigid | Flexible, tolerates ground movement |
| Failure mode | Weld can fail if overloaded | Twists do not unravel if a wire breaks |
| Typical use | Facing & decorative walls | Engineering, erosion control, slopes |
Wire gauge and aperture
Gabion wire is thick to resist the load and abrasion of stone fill. Hexagonal gabions are described by their mesh type (for example 80 x 100 mm) and double-twist construction; welded gabions by aperture and wire diameter.
| Type | Typical aperture | Typical wire dia. (mm) |
|---|---|---|
| Welded gabion | 76 x 76 mm | 3.0 - 5.0 |
| Welded gabion (heavy) | 50 x 50 mm | 4.0 - 6.0 |
| Double-twist hex | 60 x 80 mm | 2.2 - 2.7 |
| Double-twist hex (heavy) | 80 x 100 mm | 2.7 - 3.0 |
Coatings
- Heavily galvanised: a thick zinc coating for general durability in most ground conditions.
- Galfan (zinc-aluminium alloy): offers markedly better corrosion resistance than standard galvanising for longer design life.
- PVC-coated: a polymer layer over galvanised or Galfan wire for aggressive, marine or polluted environments and a coloured finish - see galvanised vs PVC.
Standard basket sizes
- Common box gabions: 2 x 1 x 1 m, 2 x 1 x 0.5 m and 1 x 1 x 1 m.
- Mattress gabions for erosion control: typically 0.17 to 0.30 m deep over larger plan areas.
- Sack and cylindrical gabions for underwater or rapid placement.
- Internal diaphragms divide long baskets into cells to control bulging.
How to choose and buy gabion mesh
Pick welded baskets for sharp architectural facing and double-twist for engineered, flexible structures on settling ground. Match wire gauge and coating to the design life and exposure, and confirm basket dimensions, diaphragm spacing and the lacing or fastening method. Estimate stone fill and wire weight with the weight calculator, and check the buying guide.
For coastal or polluted sites, specify PVC-coated or Galfan wire - standard galvanising alone may not reach the required design life in aggressive conditions.