Gabion Mesh Manufacturing Process‌

‌1. Raw Material Preparation‌

• ‌Wire Processing‌: Low-carbon steel wire rods undergo cold drawing to achieve target diameters (typically 2.0–4.0 mm). Surface treatment includes hot-dip galvanizing (zinc coating ≥245 g/m²) or PVC coating for corrosion resistance.
• ‌Material Selection‌: Wires are classified by tensile strength (≥395 MPa) and alloy composition (e.g., 6% aluminum zinc alloy for marine environments).

‌2. Automated Weaving‌

• ‌Hexagonal Mesh Formation‌:
  • Warp wires (longitudinal) and weft wires (pre-formed helical coils) are interwoven using heavy-duty double-twist machines.
  • Standard mesh patterns (e.g., 60×80 mm, 80×100 mm) are created via 3- or 5-rotation twists (360° wraps).
• ‌Drive System‌: Servo motors (15–22 kW) enable precision control, achieving speeds of 165–200 meters/hour. PLCs dynamically adjust tension to minimize wire breakage.

‌3. Cutting & Edge Reinforcement‌

• ‌Panel Trimming‌: Continuous mesh rolls are slit to required dimensions (e.g., 4 m × 2 m).
• ‌Selvedge Finishing‌:
  • Edges are mechanically bent and secured with border wires (thicker-gauge steel) via hydraulic/mechanical locking.
  • Manual inspection ensures joint integrity and eliminates deformation risks.

‌4. Assembly & Quality Assurance‌

• ‌Component Fabrication‌: Panels are folded into box cages, mattresses, or sack gabions; corners fastened with spiral binders or clips.
• ‌Testing Protocols‌:
  • Mesh uniformity, coating adhesion, and absence of defects (e.g., skipped welds) are verified per EN10223-3.
  • Wire samples undergo tensile tests (elongation ≥12%) and salt spray resistance checks.

‌5. Packaging & Storage‌

• ‌Compression & Bundling‌: Finished products are hydraulically compacted and strapped to reduce shipping volume.
• ‌Storage‌: Units are palletized and wrapped in moisture-resistant film to prevent corrosion during transit.

‌Key Technological Innovations‌

• ‌Automation‌: PLC-controlled lubrication systems reduce mechanical wear; real-time monitoring optimizes production efficiency.
• ‌Sustainability‌: Porous structure supports bioengineering applications (e.g., vegetation growth, sediment filtration).

‌Workflow Summary‌:
Wire Processing → Weaving → Trimming/Edge Locking → Assembly/QC → Packaging

Complies with ISO 9001, EN 10223-3, and ASTM A975 standards.