Case Study 1: Koshi Riverbank Protection Project, Sunsari District (Eastern Nepal)

• Client: Government of Nepal (Department of Water Resources and Irrigation - DoWRI)

• Contractor: Nepalese Civil Engineering Consortium

• Challenge: Severe erosion threatening farmland and settlements during monsoon floods. Needed rapid deployment of high-strength, flexible revetment.

• Solution: Locally manufactured gabion boxes (80x100mm mesh, 2.7mm PVC-coated wire) produced using a Chinese double-twist gabion weaving machine.

• Machine Role:

  • Supplied consistent, high-quality mesh at ~30 m²/hour.

  • Double take-up system enabled near-continuous production to meet tight pre-monsoon deadlines.

  • Handled voltage fluctuations (common in rural Sunsari) reliably with an external stabilizer.

  • Local operators trained by the Chinese supplier managed production efficiently.

• Outcome: Successful installation of over 5km of gabion revetment before the monsoon. Significant reduction in erosion observed during subsequent floods. Project cost reduced by ~15% compared to importing finished gabions.

Case Study 2: Kathmandu Outer Ring Road Slope Stabilization

• Client: Nepal Roads Authority (Department of Roads - DoR)

• Contractor: International JV (with Nepali Sub-contractor)

• Challenge: Stabilizing steep, unstable cut slopes along a new highway section near Kathmandu (approx. 1,400m ASL). Required durable, permeable facing.

• Solution: Gabion retaining walls and mattresses (100x120mm mesh, 2.2mm Galfan wire) manufactured on-site.

• Machine Role:

  • Chinese machine set up in a dedicated facility near the project site.

  • Produced mesh tailored to specific wall/mattress dimensions, minimizing waste.

  • PLC control ensured consistent mesh geometry crucial for structural integrity.

  • Withstood the dusty environment prevalent during road construction.

• Outcome: Effective slope stabilization achieved. On-site manufacturing ensured just-in-time delivery, optimized logistics costs, and created local skilled jobs. The project demonstrated the viability of local gabion production for large infrastructure.

Case Study 3: Community-Based Micro-Hydropower Channel Protection, Rukum District (Western Nepal)

• Client: Local Community Cooperative (NGO Supported)

• Contractor: Local Construction Group

• Challenge: Protecting intake channels and forebay structures of a small hydropower plant from debris flow and erosion in a remote, mountainous area. Limited budget and technical skills.

• Solution: Small gabion structures (60x80mm mesh, 2.0mm PVC-coated wire) produced using a smaller, semi-automatic Chinese gabion machine.

• Machine Role:

  • Lower power requirement suited to limited local generation capacity.

  • Simpler operation and maintenance manageable by locally trained technicians.

  • Portability allowed setup close to the project site, reducing transport costs for heavy wire spools.

  • Enabled community self-reliance for future maintenance gabions.

• Outcome: Critical hydropower infrastructure protected affordably. Project empowered the local community with manufacturing capability for future resilience projects.