Product

Guide

INTRODUCTION
Maccaferri SA (Pty) Ltd, formerly known as African Gabions, a subsidiary of the Maccaferri Group founded in Italy in 1879, is a company that specialises in providing products and solutions for the preservation of the environment. Our traditional double-twist wire mesh products are typically used for flood protection, landslide control, channel linings, embankment stabilisation and erosion control all over the world. In addition, Maccaferri SA provides a range of geotextile and erosion control blankets to compliment our existing core products. Other services offered by Maccaferri SA include technical design assistance, design software, training and on-site assistance.

THE WIRE
Mild steel wire to SANS 675:1997 is used in the manufacture of all our wire mesh products. The heavy duty Class A zinc coating is applied by hot-dip galvanising to SANS 675:1997. The additional 0.5mm PVC coating is extruded onto the zinc coated wire to comply with SANS 1580:2005.

Mild Steel Zinc Coating

WIRE TOLERANCE
Nominal Diameter Tolerance * Zinc Coating Galfan Coating ** (mm) (mm) g/m2 g/m2 2,2 0,08 245 230 2,5 0,08 260 230 2,7 0,08 275 245 3,0 0,8 275 245 3,4 0,1 275 265 3,9 0,1 290 265 4,4 0,1 290 265

PVC Coating

* According to SANS 675:1997 ** According to EN 10244-2 Table 2 Class A

THE MESH
Woven wire mesh is a non-ravelling mesh made by twisting continuous pairs of wires through three one-half turns (commonly known as double-twist) which are then interconnected to adjacent wires to form hexagonal openings. Maccaferri SA manufactures woven mesh to comply with the requirements of SANS 1580:2005. Galfan is a eutectic Zn-Al mischmetal: a combination resulting in a more uniform crystalline microstructure and an improved mechanical characteristics. Consists of steel wire corrosion protection with a 95% Zinc and 5% Aluminium Alloy. Small additions of Cerium-Lanthanum rare earths to of the improve the reliability of the coating process.
MESH CHARACTERISTICS
Wire Diameter (mm) Mesh Type 60 80 Tollerance b (mm) (mm) 60 80 -4 +10 -4 +10 Mesh Galv 2.2 2.7 Galfan 2.7 Galv/PVC Glafan/PVC 2.2 / 3.2 2.7 / 3.7 2.7 / 3.7 Galv 2.7 3.4 Selvedge Galfan 3.4 Galv/PVC Glafan/PVC 2.7 / 3.7 3.4 / 4.4 3.4 / 4.4

Specifications: All lacing wire - 2.2mm for galvanised mesh and 2.2 / 3.2mm for PVC coated mesh MESH TOLERANCE The tolerance on the opening of mesh b being the distance between the axis of two consecutive twists according to SANS1580:2005.

SPECIFICATIONS
SOUTH AFRICAN SPECIFICATIONS
Wire Specifications Zinc Coating * PVC Coating ** Mesh Specifications SANS 675:1997 SANS 675:1997 SANS 1580:2005 SANS 1580:2005

BIOMAC
BioMac is a biodegradable erosion control blanket manufactured from randomly arranged coconut husk fibres layered between photosensitive polypropylene netting to produce a coir mat. When contained with Galvanised and PVC coated wire mesh, BioMac is used for erosion control and re-vegetation of river banks, streams and slopes. For light applications, BioMac may be used without the mesh containment. All Mesh Rolls are manufactured in both Mesh Type 60 and 80 and conform to the specifications detailed under Double Twist Wire Mesh Rolls.

BIOJUTE
BioJute is a biodegradable erosion control blanket manufactured from fabric woven into an open mesh from rugged, heavy jute yarn. BioJute is used for erosion control and re-vegetation where partial protection of the river banks, streams and slopes is required. BioJute is available in packs and rolls.

MACMAT
MacMat is a three-dimensional erosion control mat manufactured from entangled polypropylene mono-filaments, heat bonded at the contact points. When combined with Galvanised and PVC coated wire mesh, MacMat is used for long term root reinforcement, erosion control and re-vegetation. For lighter applications, MacMat may be used without the mesh combination. All Mesh Rolls are manufactured in both Mesh Type 60 and 80 and conform to the specifications detailed under Double Twist Wire Mesh Rolls.

MACMAT-R
MacMat can be combined with double-twist wire mesh reinforcement to form MacMat-R. This is used for long-term root reinforcement, erosion control, re-vegetation and when used with soil nails and shotcrete, for temporary slope stabilisation. This unique combination marries the excellent anti-erosion properties of the 3-dimensional MacMat geomat and the well-known strength properties of double-twist mesh.

GEOTEXTILES
The AG range of non-woven geotextiles are manufactured from double needle-punched continuous polyester filaments. The AG geotextile has been specifically developed for use with double twist mesh and gabion products and has excellent mechanical and filtration characteristics. Their high energy absorption, initial modulus and resistance to de-tangling of fibres make the AG range ideal for functions of filtration, separation, abrasion and protection.

MACDRAIN 2L
2L
MacDrain 2L is a light and flexible geocomposite material which has a drainage core of looped polypropylene filaments. It is covered with a nonwoven polyester geotextile on both sides providing a high drainage capacity. The three components are thermally welded along the surface. Each side of the geotextile exceeds the edge of the drainage core by 100mm. A continuous surface filtering is achieved by overlapping the butt-joints of the adjacent MacDrain 2L strips.

2LFP

1L

REINFORCED ECOLOGS
Reinforced EcoLogs are cylindrical biodegradable sleeves manufactured from BioMac, bound together with twine and reinforced with Galvanised or PVC coated wire mesh. Reinforced EcoLogs are used to reduce sheet erosion and create a micro-climate for vegetation establishment. All wire is 2,2mm mild steel to SANS675:1997, zinc coated by hot-dip galvanising to SANS 675:1997 and, for PVC coated units, heat bonded through extrusion with a 0,5mm heavy duty PVC coating to SANS 1580:2005. Reinforced EcoLogs are manufactured in Mesh Type 60. For lighter applications, EcoLogs may be supplied without the mesh reinforcement.

SACK GABIONS
Sack Gabions are double twist hexagonal wire mesh units consisting of a single mesh panel laced to form a cylindrical unit. Sack Gabions are filled with rock at the project site to form flexible, permeable, monolithic structures used for emergency and river training works, where local conditions require fast installation or the water does not allow easy access to the site (underwater installations). All wire is mild steel to SANS675:1997, zinc coated by hot-dip galvanising to SANS 675:1997 and, for PVC coated units, heat bonded through extrusion with a 0,5mm heavy duty PVC coating to SANS 1580:2005. All Sack Gabions are manufactured in Mesh Type 80 to SANS1580:2005, having 3,4mm frame wire and 2,7mm mesh wire and an additional 1mm to all wire diameters for PVC coated units.

GABIONS
Gabions are double twist hexagonal wire mesh baskets of variable sizes, uniformly partitioned into internal cells. All wire is mild steel to SANS 675:1997, zinc coated by hot-dip galvanising to SANS 675:1997 and, for PVC units, heat bonded through extrusion with a 0,5mm heavy duty PVC coating to SANS 1580:2005. All gabions are manufactured in Mesh Type 80 to SANS 1580:2005, having 3,4mm frame wire and 2,7mm mesh wire and an additional 1mm to all wire diameters for PVC coated units. Gabions are filled with stone at the project site to form flexible, permeable, monolithic structures, such as retaining walls, bridge abutments, sea walls, weirs, culverts and river bank protection.

RENO MATTRESSES
Reno Mattresses are double twist hexagonal wire mesh baskets of variable sizes, uniformly partitioned into internal cells at typically 1m centres. All wire is mild steel to SANS675:1997, zinc coated by hot-dip galvanising to SANS 675:1997 and, for PVC units, heat bonded through extrusion with a 0,5mm heavy duty PVC coating to SANS 1580:2005. All Reno Mattresses are manufactured in Mesh Type 60 to SANS1580:2005, having 2,7mm frame wire and 2,2mm mesh wire and an additional 1mm to all wire diameters for PVC coated units. Reno mattresses are typically used for the protection of culverts, bridge abutments, river banks and shorelines, channels and spillways.

CASTORO MATTRESSES
Castoro Mattresses are double-twist hexagonal wire mesh (2.2mm SANS 1580:2005) baskets, filled with rock to form flexible, permeable, monolithic structures for river bank and scour protection, channel linings for erosion control and underwater pipeline protection. The steel wire used is heavily Galfan coated and if required, a PVC coating is extruded over the Galfan wire to provide added protection for use in aggressive environments. The base, diaphragms, front, end and sides are manufactured from one continuous panel of mesh. The base is folded onto itself at 1.0m intervals to form double diaphragms that are automatically secured with spirals, prior to folding up the sides and securing to the diaphragms.

CATCH FENCES
OM250, OM1000 & OM2000 Catch Fences are rockfall barriers able to resist a minimum impact load of 250kj, 1000kj and 2000kj respectively. This system has the catch net downhill of the barrier. Since the posts work independently from the net, a direct impact on the posts would not impede the immobilisation of the rock boulder by the net. The barriers components are designed to be easily transported and assembled in extreme conditions. The barrier has been designed and produced to comply with the norm UNI EN ISO 9001.

CATCH FENCES
Units OM250 OM1000 OM2000 Height Post Distance Top Edge Border Lateral Edge Border Uphill Anchor Load Lateral Anchor Load Downhill Anchor Load m m cm cm kN kN kN 4 5-10 50 500 200 300 4 10 70 500 415 415 195 5 10 70 500 140 200 195

ROCKFALL NETTING
Double twist wire mesh rolls are used for the protection of slopes and cliffs where there may be danger of falling rocks. When used in conjunction with erosion control blankets they assist with environmental rehabilitation and erosion control. All wire is mild steel to SANS 675:1997, zinc coated by hot-dip galvanising to SANS 675:1997 and, for PVC coated wire mesh, heat bonded through extrusion with a 0,5mm heavy duty PVC coating to SANS1580:2005. Mesh Rolls are manufactured in both Mesh Type 60 and 80.

HEA PANELS
The new HEA Panel (High Energy Absorption) combines high strength features of the wire rope with the steel knot. The new knot is made by two bindings, each one obtained by looping a pair of steel 3.0mm wires coated with a 95% Zinc-Aluminium, 5% Mischmetal alloy. The two bindings tightly envelope the ropes crossing each other. The panel is made of square meshes manufactured with one rope, closed by an aluminium pressed spinning cot, with resistance not less than 90% of the rope-breaking load.

HEA PANELS Panel Dimensions - Mesh Panel Height Panel Length Knot - Binding rods Breaking load of wire (bars) Diameter - UNI EN 10218 Tear Resistance Max Load of tear break Min breaking load of the rope

400 x 400 3.0 6.0 380-500 3 24.4 11.9

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TERRAMESH SYSTEM
The Terramesh System is a modular system used for soil reinforcement applications such as mechanically stabilised earth walls and slopes. The Terramesh System is a completely assembled unit made of double twist heavily galvanised and PVC coated wire mesh, where a continuous double twist wire mesh panel forms the reinforcement as well as the front and top of a gabion style facing section. The back panel, ends and diaphragm of the facing section are connected to the unit during manufacture. This creates rectangular shaped cells used for stone confinement. All wire is mild steel to SANS 675:1997, zinc coated by hot-dip galvanising to SANS 675:1997 and heat bonded through extrusion with a 0,5mm heavy duty PVC coating to SANS 1580:2005. All Terramesh System units are manufactured in Mesh Type 80 to SANS 1580:2005, having 4,4mm frame wire and 3,7mm mesh wire.

GREEN TERRAMESH
Green Terramesh is an environmentally friendly modular system used for soil reinforcement such as mechanically stabilised earth slopes and embankments. Green Terramesh is a completely assembled unit made of double twist heavily galvanised and PVC coated wire mesh lined with BioMac and strengthened with a welded steel panel. Two pre-formed steel brackets incline the front face at an angle of 70 to the horizontal. The angled front face and the BioMac facilitate the establishment of natural vegetation of the units. All wire is mild steel to SANS 675:1997, zinc coated by hot-dip galvanising to SANS 675:1997 and heat bonded through extrusion with a 0,5mm heavy duty PVC coating to SANS 1580:2005. All Green Terramesh units are manufactured in Mesh Type 80 to SANS 1580:2005, having 4,4mm frame wire and 3,7mm mesh wire. The welded steel panel is manufactured from 6mm mild steel bars with aperture size 160mm x 200mm.

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ROADMESH
RoadMesh is typically used as a reinforcement to the wearing coarse of asphalt pavements, consists of double twist woven mesh manufactured from heavily galvanised mild steel, and transversely reinforced at regular intervals with steel rods. All wire is mild steel to SANS 675:1997 and zinc coated by hot-dip galvanising to SANS 675:1997. RoadMesh is manufactured in Mesh Type 80.

FLEXMESH
FlexMesh is typically used for beach front vehicular deployment, emergency roadways and temporary roadway stabilisation. FlexMesh consists of hexagonal double twist woven mesh manufactured from heavily galvanised mild steel wire, transversely reinforced at regular intervals with steel rods and, on one side of the wire mesh panel, lined with a pre-attached geotextile for separation. All wire is mild steel to SANS1580:2005, zinc coated by hot-dip galvanising to SANS 675:1997. FlexMesh is manufactured in Mesh Type 80. The geotextile is a nonwoven, compact, needle-punched polyester type AG300, with a minimum weight of 265g/m.

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MACFORCE
The Maccaferri system of vertical walls with a concrete facing geared towards an ever increasing market for civil engineering applications. It is a tried and tested system used extensively. This system is ideal for the construction of a wall where high loads, durability and robustness is the requirement. Maccaferri SA has adopted both the MacForce and MacRes cladding panels and developed the technology to provide innovative solutions for both products.

MACFORCE
Facial Dimensions - Top Facial Dimensions - Bottom Thickness Effective wall area Reinforcement 50T Panel - Steel Diameter Spacing 50T Panel - Steel Diameter Spacing 2100 x 785 1820 x 785 12.4 3.2 18.86 8 160 26.70 8 100

PARAWEB
ParaWeb strips are planar structure consisting of a core of high-tenacity polyester yarn tendons encased in a polyethylene sheath. The strips are suitable for reinforcement applications in combination with concrete wall-facing panels.

ParaWeb ParaWeb ParaWeb ParaWeb

MD ME MS 2D
PARAWEB
Tensile and Mechanical Properties Units 27 27.14 17.51 27.14 17.51 27.14 17.51 30.16 19.46 36 36.18 23.34 36.18 23.34 36.18 23.34 40.20 25.94 45 45.22 29.17 45.22 29.17 45.22 29.17 50.27 32.43 54 54.27 35.01 54.27 35.01 54.27 35.01 75.40 48.65 63 63.31 40.85 63.31 40.85 63.31 40.85 100.54 64.86

ParaWeb MD Ultimate Tensile Strength Long term tensile (64.5% of UTS) ParaWeb ME Ultimate Tensile Strength Long term tensile (64.5% of UTS) ParaWeb MS Ultimate Tensile Strength Long term tensile (64.5% of UTS) ParaWeb 2D Ultimate Tensile Strength Long term tensile (64.5% of UTS)

kN kN kN kN kN kN kN kN

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MACGRID WG
MacGrid WG is a woven high-strength geogrid composed of high-tenacity, multifilament polyester yarns woven in tension and PVC coated to form a stable fabric. MacGrid WG is ideal for applications where reinforcement of soils is essential and has been tested internally and independently, in accordance with published standards.

MACGRID WG
Mechanical Properties Units Tensile Strength - Length Direction Tensile Strength - Cross Diretion Elongation - Length Direction
EN ISO 10319 EN ISO 10319

WG2

WG6 WG11 WG15 WG20 70 35 10 24 28 240 3.9 100 130 35 10 21 28 320 3.9 100 170 35 10 20 28 400 3.9 100 220 25 10 19 28 500 3.9 100

25 25 EN ISO 10319 10 Physical Properties 27 Grid Aperture Size (MD(1)) 28 Grid Aperture Size (XD(2)) 190 Unit Weight 3.9 Roll Width 100 Roll Length (1) MD = Machine Direction (2)XD = Cross Mchine Direction

PARARIB
ParaRib mining grids have been developed from ParaGrid geogrids and are made from ParaWeb which is based on strips of a planar structure consisting of high-tenacity polyester filament yarns encased in a tough and durable flame-retardant, white polymeric sheath. ParaRib has been designed specifically for use in underground mining where flameretardancy is a requisite. The white polymer used enhances light reflectance and visibility when used in areas of limited illumination. ParaRib is suitable for lining tunnel walls and for salvage applications.

PARARIB
Units Roll width m Roll length m kN/m-1 Strength - length kN/m-1 Strength - width Warp element pitch mm Weft element pitch mm gm-2 Mass 10/10 4.5 55 10 10 75 150 300 30/24 4.5 55 30 24 75 75 460 100/100 4.5 55 100 100 75 75 820

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PARALINK
ParaLink geocomposites are planar structures consisting of a regular array of composite geosynthetic straps, nominally interconnected laterally to form soil reinforcement materials with high unidirectional strength.

PARALINK
Units Roll width Roll length Roll Diameter Roll gross weight Warp element pitch Weft element pitch Warp element width Breaking Load(BL) Extension at BL m m m kg mm mm mm kN/m-1 % 100 4.5 100 0.38 270 180 1000 82 100 12 400 4.5 100 0.61 590 180 1000 90 400 12 800 4.5 100 0.56 580 180 1000 91 800 12

ACCESSORIES
Ring Fastening Tool
To assist with fastening operations of double-twist mesh products, fastening tools and ring fasteners are available. The rings are supplied in boxes of 1600 and are available in galvanised or stainless steel.

Closing Tool
To assist with closing of the Gabion box and TerraMesh System lids, Closing tools are available from our offices.

Pre-formed Braces
Pre-formed braces are available as a substitute for bracing wire. Pre-formed braces are supplied in 3.4mm Class A Galvanised wire or 4.4mm Class A Galvanised and PVC coated wire. Pre-formed braces are sold separately.

Steel Pegs
Steel pegs are used to secure erosion control blankets such as BioMac, BioJute and MacMat to the soil interface beneath. Steel pegs are available in packs of 100.

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SOFTWARE
GawacWin
The GawacWin program was developed to provide designers with a quick and reliable way to analyse and verify mass gravity gabion walls through a user-friendly Windows graphics interface. The program takes into account the mechanical characteristics of gabions manufactured by the Maccaferri Group.

Macra 1 - Bank Protection

Through a user-friendly Windows graphics interface, Macra 1 conducts the stability analysis of water course cross-sections, with respect to water flow by checking the hydraulic stability of different bank protection linings given an allowable shear stress and roughness coefficient for that material.

Macra 2 - Weirs
Macra 2 was developed to provide engineers with a rapid and efficient tool with which to conduct the hydraulic and static analysis of different type of gabion weirs. The software operates through a user-friendly Windows graphics interface.

MacStars 2000
MacStars 2000 provides wall designers with a reliable way to execute the correct analysis for the stability verification of reinforced soil walls and slopes.

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SOFTWARE cont.
Macro 1
The Macro 1 program evaluates the behaviour of unstable surficial revetments constrained with cable panel systems and is able to design both the mesh and nail. The program chooses the appropriate mesh and takes the characteristic of the nails into account. Using a friendly interface, it is possible to customise a lot of input like the rock-face geometry, geotechnical model and the most dangerous joint.

Macro 2
The Macro 2 program evaluates the stability of the chosen drapery system based on debris volume vs allowable tensile stress. The program allows calculation of the total stress on an Adherence Mesh System on a slope due to debris weight at the slope toe, weight of the mesh structure, and weight of snow over the structure.

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Quality System Guarantees production, certified internal management and technical assistance in compliance with ISO 9001:2000
JOHANNESBURG, SOUTH AFRICA: P O Box 2285, North Riding, 2162 Tel: +27-11-704 0160 Fax: +27-11-704 0159 e-mail: jhbsales@maccaferri.co.za CAPE TOWN, SOUTH AFRICA: P O Box 22150, Fish Hoek, 7974 Tel: +27-21-702 1416 Fax: +27-21-702 2977 e-mail: cptsales@maccaferri.co.za EAST LONDON, SOUTH AFRICA: P O Box 5481, Greenfields, 5208 Tel: +27-43-731 1580 Fax: +27-43-731 1584 e-mail: ecsales@maccaferri.co.za MADAGASCAR: BP 168, Antananarivo 101, Madagascar Tel: +261-20-22-231 02 Fax: +261-20-22-553 90 e-mail: maccaferri@moov.mg

MACCAFERRI SA (PTY) LTD

HEAD OFFICE - DURBAN, SOUTH AFRICA: P O Box 15777, Westmead, 3608 Tel: +27-31-700 8456 Fax: +27-31-700 8469 e-mail: dbnsales@maccaferri.co.za

Website: www.maccaferri.co.za
ZAF / PRODUCT GUIDE: Eng - Rev. 04, Apr 2009 - Maccaferri SA (Pty) Ltd, Durban, South Africa - Designed by: Branden Grant - Printer: Pro-Print (Pty) Ltd.

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