Stabilizing slopes in road works on soft soil with progressive settlement, channeling rivers, and protecting against erosion from water flow, where a flexible solution is required that absorbs ground movement and accommodates natural settlement without losing structural integrity, requires a box gabion with double-twist hexagonal mesh. This hexagonal-mesh box gabion—also called gabion box, double-twist gabion, or hexagonal gabion basket—is manufactured by MOLTEXO with hot-dip galvanized double-twist hexagonal mesh with PVC coating, in 2×1×1 m format, designed for hydraulic works, civil engineering, erosion control, channeling, and retaining walls in difficult soil conditions.
Key benefits
- Structural flexibility through double twist: the hexagonal weave with two twists absorbs ground movement and progressive settlement without losing structural integrity, an essential condition for soils with irregular compaction, hydraulic works with dynamic loads, and zones with seismic risk, where a rigid structure would fail by fatigue under cyclic movement.
- Hot-dip galvanizing with PVC coating: double protection against corrosion: deep wire galvanizing by immersion in molten zinc plus an outer PVC layer that protects from marine salt and continuous moisture, a critical condition for Caribbean coastal zones and hydraulic works with continuous water flow.
- Natural permeable drainage: the stone infill maintains free water flow through the wall, preventing buildup of hydrostatic pressure behind the structure, an essential condition in hydraulic retaining walls.
- Natural integration with vegetation and sediment: over time soil accumulates between the stones and local vegetation grows, fusing the structure with the surroundings and adding natural structural reinforcement—a differential advantage over rigid concrete solutions that keep a permanently industrial look.
- Construction efficiency without heavy machinery: the panels are unfolded, assembled, and filled on site with locally available stone, a condition for works in remote or restricted-access areas without needing to transport concrete blocks or formwork.
Typical applications and uses
- Retaining walls in road works with soft soils and predictable progressive settlement.
- Slope stabilization with landslide risk, especially in tropical zones with intense seasonal rainfall.
- River channeling, bank protection, and hydraulic works with continuous water flow.
- Rockfall protection barriers, coastal defenses, and architectural landscaping projects with a natural aesthetic.
Quality and durability
An economical hexagonal gabion fails at two points: the wire galvanizing is superficial without PVC coating (which produces accelerated corrosion in coastal areas with salinity and hydraulic works with continuous water flow, eventually losing structural integrity in a few years) and the double twist is not calibrated (which produces a mesh with lower strength than declared and deformation under load). MOLTEXO works with hot-dip galvanizing plus PVC coating and controlled double twist, which sets a hydraulic-works hexagonal gabion with a service life of decades apart from a generic cage that rusts in the Dominican coastal zone within a few years.
Clean, hard, durable stones slightly larger than the hexagonal mesh opening. Typical options: river-rounded stones, crushed quarry stone, local granite, and resistant Dominican limestone. The size is selected according to the diameter of the hexagonal opening (varies by model): the usual rule is to choose stones with a minimum dimension 1.5 times the opening. For hydraulic works with continuous water flow, dense stone resistant to abrasion from suspended sand is best. For river channelization, larger stone is better to resist transport during seasonal Caribbean floods. Avoid soft or low-density stones.
Yes. The standard technique is to stack in stepped courses with a base wider than the wall crown, forming a truncated pyramidal profile that distributes loads and improves stability. It is mandatory to lace and firmly tie each course to the one below and to the adjacent boxes using galvanized tying wire, creating a monolithic structure. For substantial walls it is best to apply specific engineering with calculation of backfill thrust, surcharge (traffic, dynamic loads), drainage of the back face with a filter geotextile to prevent fines wash-out, and a foundation suited to the local soil. The flexibility of the hexagonal mesh accommodates settlement without failing.
Minimum maintenance under typical conditions. One of the structural advantages of the system: resistance tends to increase over the years as sediments, soil, and roots from local vegetation consolidate between the stones, blending the gabion with the natural surroundings. Recommended inspections: annual checks of the galvanizing plus PVC coating in zones with high salinity exposure or continuous water flow, retensioning of wires in boxes that show looseness due to settlement, and replenishing stone that has shifted inside. In Caribbean coastal areas, a five-year inspection is prudent to detect early corrosion.
Yes, for long-term stability. The base of the first row should be well leveled, compacted, and free of debris or sharp objects that could damage the wire. The flexibility of the hexagonal type allows for some tolerance compared to the welded type, which makes it acceptable on less-than-perfect ground. For soft Caribbean soils (saturated clays, organic soils, areas with a high water table), it may be necessary to install a foundation footing of compacted gravel or a layer of geotextile prior to assembly to distribute loads and prevent differential settlement that compromises the wall. For hydraulic works it is also advisable to protect the front face with riprap or larger stone against scour.
Still have questions?
Ask us and we will gladly help you with whatever you need.
| Dimensions | 2 m x 1 m x 1 m (6.56 ft x 3.28 ft x 3.28 ft) |
|---|---|
| Material | Hot-dip galvanized + PVC coating |
| Mesh size | 80 x 100 mm (3.1 x 4 in), tolerance ±16%, double-twist weave |
| Mesh wire diameter | 2.7 mm (0.11 in) / 3.7 mm (0.15 in) |
| Frame wire diameter | 3.4 mm (0.13 in) / 4.4 mm (0.17 in) |
| Lacing wire diameter | 2.2 mm (0.09 in) |
| Tensile strength | ≥380 MPa (≥55114 psi) |
| Elongation | ≥12% |
| Developed area per gabion set | 11 m² (118.4 sq ft) |
| Weight per gabion set | 22 kg (48.5 lb) |
| Gabion: Width | 100.0 cm (39.37 in) |
|---|---|
| Gabion: Height | 200.0 cm (78.74 in) |
| Gabion: Depth | 2.0 cm (0.79 in) |
| Gabion: Weight | 14.3 kg |
Payment & Security
