BUDGET GUIDE FOR ESTIMATING AND PLANNING FOR WOVEN MESH PRODUCTS

1.

Estimating and Planning for Gabion Works

The cost of gabion and mattress work will depend on the physical conditions on site. Costs will vary
between a river wall, where some underwater work may be required, and a dry land retaining wall with good
access. Also labour,
plant hire and stone costs tend to vary with geographical location. The
following rates are based on a 4 man gang assisted by a 360o slew tracked excavator working a seven
hour day with good site access. Strict adherence to Hy-Ten Installation Guidelines is assumed.

2.

3.

Materials
a.

Gabions: An up-to-date quotation should be obtained. The major differences in price will be between
galvanised units and galvanised units with additional HDPE coating.

b.

Stone: From practical experience, figures of 1.6 to 1.7 Tonnes per m3 for gabion works and 2.0
3
Tonnes per m for mattress work will allow for slight over filling and normal wastage on site. Stone
should be placed as close to the works as practical, double handling may have to be considered.
(The grading for use in box gabions should be between 100 and 150mm, and between 75 and
150mm for Reno Mattress units).

Site Preparation
Excavation and grading of the ground cannot be determined here and should be assessed on site and
according to site conditions.

4.

Mechanical Plant
Use a loading shovel on structures not exceeding 2m in height with free access along the whole length.
Use 360o excavator similar to a 15-18 Ton Kamatsu/Hitachi on high structures where access is restricted.
N.B. There are conditions where other types of machinery are required, e.g. long reach booms,
cranes etc, but this is not very common.

5.

Labour
3-4 men plus a machine operator are suggested as the ideal Gabion gang. For large contracts or if high
production is required, the figures should be 8 men plus 2 machine operators. For economical working the
number of men should match the output of the machine.

6.

Production
6.1.

Dry Land Gabion Retaining Walls

1. Based on a 3m high gabion retaining wall with three 1m deep courses, 2m, 1.5m and 1m wide
3
respectively. Average production: 20-25 m per day per gang.
2.

6.2.

Based on a 1.5m high retaining wall with two courses, each 1m wide with the second course
stepped back 0.5m. Average Production: 15-20m3 per day per gang.

Reno Mattresses
2

Based upon a total square metreage of 1,000m or more.

2

Average production: 100-150m per day per gang.

6.3.

Working in Water
(i)

Water less than 0.5m deep:

Gabions can be placed in the normal manner with production only reduced by approximately
10-15% if lacing is done above water only.
Mattresses placed in this depth can still be filled in-situ, but the men are lacing with their
hands under water and production can be slowed by 30%. This can be countered by
increasing the gang size by two men to help place empty units under water and lace up the
filled ones.

(ii) Water greater than 0.5m deep

Depending on the scheme, this usually means prefilling the gabions on dry land, transporting
them to site and then lifting them by crane into position. Divers may be required to lace under
water. This is an expensive operation and very difficult to quantify, but production is unlikely to
exceed 10m3/12m3 per day. Tidal conditions will decrease this.
Mattresses have to be laid by crane in the same manner. Again, positioning and lacing under
2
2
water by divers is expensive. Production can be estimated at 20m /40m per day.

7.

Aesthetic Appearance
The above figures for gabion walls assumes that all the outer vertical faces have been hand-placed or
pitched to present a neat coursed finish.

8.

Installation Tools, although not essential are available for hire/purchase:

3

Pneumatic Fixing Tool. For contracts >200m of gabions a pneumatic tool produces a saving.

9.

Packaging
For ease of handling and transportation the gabions are supplied folded flat and tied in compressed
bundles.
The maximum weight of a bundle is about 700kgs.
Gabions

* HDPE only

Standard
sizes
2x1x1m
2x1x0.5m
3x1x1m
3x1x0.5m
1.5x1x1m
2x0.5x0.5*

Volume
3

2m
3
1m
3m3
3
1.5m
3
1.5m
0.5m3

Mattresses

Standard
sizes
6x2x0.170m
6x2x0.230m
6x2x0.300m
3x2c0.170m
3x2x0.230m
3x2x0.300m

Volume
3

2.04m
3
2.76m
3.60m3
3
1.02m
3
1.38m
1.80m3

ALL IN COST OF GABION WORK

The question is invariably asked Please can you give us an all in budget price cost per m3 for gabion work?
Hopefully the following examples will assist in Planning and Estimating for gabion works:EXAMPLE 1: The following assumptions are made:
(i) The gabions shall be the HDPE coated type generally in accordance with the 1987 Department of Transport
Specification.
(ii) The cost of stone delivered to the working area is 12.50 per Tonne.
(iii) A360o excavator including driver will cost 1,000 per week to hire.
(iv) Labour will cost on average 65.00 per man day.
3
(v) The whole gang will produce on average 20m of finished gabion work per day.
GABIONS
1a 2m x 1m x 1m HDPE coated gabions complete with tying wire @ 41.50 each (2m3)

STONE
1b 1.6 Tonnes per m3 @ 12.50 per Tonne
MECHANICAL PLANT

Cost Per m
20.75 20.75

20.00

1c. Typical 15-18 Tonne Kamatsu/Hitachi plus driver @ 200.00 per day with output of 20m3 per day
10.00
LABOUR
1d. 3 men @ 65.00 per day total 195.00 with output of 20m3 per day
9.75
60.50
Basic cost per m3
Add say 15% for Contractors OH & P
3
TOTAL per m 69.58
EXAMPLE 2
2
MATTRESSES
Cost Per m
2
2a 3mx2x0.3m deep HDPE coated mattresses complete with tying wire @ 55 each (12m )
9.16m2
STONE
2b 2.0 Tonnes per m2 @ 12.50 per Tonne (6x2x0.170 = 2.04m2) (2.04x2.0x12.50) 12

MECHANICAL PLANT
2c. Typical 15-18 Tonne Kamatsu/Hitachi plus driver @ 200.00 per day with output of 100m2 per day
LABOUR
3
2d. 3 men @ 65.00 per day total 195.00 with output of 100m per day
2
Basic cost per m
Add say 15% for Contractors OH & P
All information is given in good faith but without warranty!

4.25

2.00
1.95
18.03