The Allware Warehouse Gabion Walls Project

Gabion Baskets recently completed an exciting upgrade to the main entrance of the Allware Warehouse in Newcastle’s industrial area. The client sought to improve vehicle access and enhance perimeter security as part of a broader fencing upgrade. The old entrance was too narrow for two vehicles to pass simultaneously, and the outdated fence and boom gate needed replacement. Our solution? Installing two large, curved gabion walls that combine durability, functionality, and aesthetic appeal.

Project Timeline:

Start Date: 29 May 2025
End Date: 20 June 2025
Duration: 3 Weeks

before

Materials and Equipment

To bring this project to life, we used the following materials:

Gabion Baskets (50x50mm, 3mm Welded Mesh):
- 6 Units – 1.0 x 0.5 x 0.8m
- 18 Units – 2.0 x 0.5 x 0.8m
- 6 Units – 1.5 x 0.5 x 0.8m
Welded Mesh Roll: 2.1m x 34m (50x50mm, 3mm) for shaping curved sections
Binding Wire: 60kg (Galvanized 2.2mm)
Gabion Stone: 57 tons
Support Posts: 26 Units of 75x75mm square tubing, reinforced with welded rods and end caps
Concrete Base: 150mm thick slab
Excavation & Backfill: G2 crusher dust and general backfill for leveling

Equipment Hired:

Jack Hammer
Rammer

Installation Process

Site Clearance & Preparation:
The existing fence and boom gate were removed—a task originally outside our scope but handled to prevent delays. The right-hand side of the site was uneven and crossed by a small water stream. We diverted the stream and leveled the area using backfill and G2 crusher dust.
Marking & Excavation:
Site lines were marked, and a 150mm deep trench was excavated for the concrete base. Additionally, 800mm-deep holes were dug for 13 structural support beams on each side, spaced 1m apart.
Support Structure Installation:
75x75mm square tube supports were installed into the holes, each reinforced with welded base rods and capped to prevent water ingress. Concrete was mixed on-site and poured to secure the foundation.
Basket Placement & Rock Packing:
Pre-fabricated baskets were placed for the straight sections, with their bottoms cut to fit the support posts. Gabion rock was hand-packed in layers as baskets were stacked to the full 2.4m height.
Curved Section Fabrication:
The 2.1m x 34m welded mesh roll was used to create custom curved cages on-site. These were packed in layers and braced internally for structural integrity.
Final Touches:
Once packing was complete, the baskets were securely closed, and the site was cleaned and neatened.

during

Challenges & Solutions

Uneven Terrain & Water Stream: Diverted the stream and leveled the area with backfill and G2 crusher dust.
Scope Changes: Handled the removal of the old fence and boom gate in-house to avoid delays.
Material Logistics: Coordinated carefully with suppliers to manage delivery delays due to the remote location.
Travel Time: Alternating drivers ensured productivity and reduced fatigue for our team.

Final Outcome

Despite the challenges, the project was completed on schedule. The new gabion walls provide a robust, visually striking entrance that enhances both security and vehicle flow. The client was highly satisfied with the result, which aligns perfectly with their broader security upgrades.