How Horizontal Gabion Machine Works – Full Production Process Explained

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A horizontal gabion machine is the backbone of modern gabion mesh production, blending advanced automation with careful manual operation. This unique combination guarantees that galvanized or PVC-coated wire is woven into sturdy, precise mesh structures for engineering needs such as slope protection, riverbank reinforcement, and road construction.
Below is a detailed, step-by-step guide to how our horizontal gabion machine works — designed to help you understand our manufacturing process, ensure quality control, and give you confidence in the equipment you’re choosing.

Raw Material Preparation & Warping

Wire Loading:
The process starts by placing large coils of galvanized wire (or Galfan, PVC-coated, or customized material) on the support rack behind the machine. Operators then untie the coils, preparing them for smooth unwinding.
Warping Process:
Each wire is threaded through the warping device and pulled vertically to the rolling axis to become the warp wire (longitudinal wire). Uniform tension is key — this prevents knots, tangles, or twists that could compromise mesh accuracy.
Key Requirements:
  • Wire diameter must match the design specs (typically 2.0–4.0 mm).
  • Wire strength must be suitable for the final mesh’s purpose.
  • Warped wires must stay parallel, tight, and perfectly aligned.

Weft Wire Preparation (Spring Coiling)

Coiling:
Next, wires are coiled on the spring shaft to form the weft wires (cross wires). Once the preset length is reached, the spring coil is removed and stored for weaving.
Loading into Storage Tubes:
The coiled springs are carefully placed into storage tubes, ready for the weaving step.
Technical Tip:
The resilience of the coiled wire determines the mesh’s flexibility — so winding parameters may vary depending on whether the mesh will be used for flood control or slope protection.

Machine Setup & Adjustment

Fixing Warp & Weft Wires:
Operators guide the prepared warp and weft wires into the designated slots in the machine, ensuring they’re aligned for consistent weaving.
Parameter Settings:
Machine parameters are set based on the project order:
  • Mesh Size: Common sizes like 60×80 mm or 100×120 mm are controlled by gears or PLC programming.
  • Twist Type: Choose double twist for efficiency or triple twist for extra strength.
  • Dry Run: A short test run checks that the break detection system, auto-stop safety features, and lubrication are working properly.
Safety Note:
Always disconnect power during adjustments. Never touch moving parts while wearing gloves.

Automatic Weaving Process

Start Weaving:
Once the settings are confirmed, the weaving begins. Warp and weft wires interlace automatically — the weft wires are pushed through the warp gaps and twisted precisely according to the preselected twist type.
Real-Time Monitoring:
Operators watch for wire breaks, loose knots, or skipped twists. Monitoring motor current and bearing temperature is essential — if temperatures exceed 70 °C, the machine must be stopped for inspection.
Output Control:
Finished mesh panels are rolled onto the output reel. When the preset length is reached, the machine signals the operator to stop and prepare for cutting.

Mesh Finishing & Quality Control

Cutting the Mesh:
After weaving, the mesh is cut to required sizes, such as 2 m × 1 m. Edges are checked for straightness.
Edge Folding & Welding:
Hydraulic tools flatten and fold the mesh edges, and joints are welded or securely tied to boost strength.
Compression & Packing:
Hydraulic presses compress the finished gabion mesh into compact bundles for easy transport and storage.
Quality Checks:
  • Mesh dimensions must be within a ±5 mm tolerance.
  • Knot tensile strength must meet EN 10223-3 standards.
  • No rust spots or coating damage should be visible.

Safety & Maintenance Guidelines

Operator Safety:
Wear fitted work clothes and safety goggles. Long hair must be tucked into a cap. Never wear gloves near moving parts.
Daily Maintenance:
Lubricate bearings and gears every two hours. Remove wire scraps daily to prevent oil buildup, slipping, or fire hazards.
Emergency Measures:
In a power outage, switch off the machine immediately and reset controls only after checking. If unusual vibrations occur, stop the machine and inspect fasteners and transmission systems.

Why Choose a Horizontal Gabion Machine?

Thanks to its flexible setup, our horizontal gabion machine handles a wide range of mesh widths (1–4 m). It’s ideal for producing gabions for hydraulic engineering, erosion control, and infrastructure reinforcement. The porous mesh structure combines water permeability with strong resistance to scouring — a must for long-lasting protection.
Note: Details may vary based on machine model (manual or PLC-controlled) or customized features like branded logo imprinting. Always refer to your manufacturer’s manual for precise instructions.

Get Your Gabion Mesh Solution

Ready to upgrade your production line? Contact us today for a custom gabion machine solution that fits your project’s exact needs.