catalogo_gavion_ing.pdf

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PortugalPortugal


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PRODUCTOS DE ACERO CASSADO S.A., PRODAC, was

established in 1994 as a result of the merger

between INDUSTRIAS CASSADO S.A. and PROLANSA,

the two largest wire manufacturers in Peru.

This is how Prodac, the most ambitious wire

manufacturing projects ever created in Peru, started its

operations.

Nowadays, Prodac is the largest wire manufacturer in

Peru. Its sales have successfully expanded to South

America, Central America, the Caribbean, North America,Europe and Oceania. Prodac strives day to day to im-

prove its quality standards, and to become the

leading wire company of the region.

Prodac`s products meet international quality standards

as ASTM, Euronorm, British Standard, AFNOR and

others. This commitment to quality, andtechnological know how guarantee a quality product,

designed and produced with the latest technology.

All of our products are manufactured in accordance to a quality

management system certified by BVQI, which meets ISO 9001:2000

requirements with certificate number 133670. Our gabions also meet

the requirements of Bolivian standard IBNORCA: Standard NB 710-

00.

IBNORCANorma NB

710PRO

D

UCT

O C E RT

IF

I

C

A

DO

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Prodac gabion baskets and mattresses

represent an efficient technical - economical,

as well as aesthetic and ecological solution in

civil engineering works.

Prodac gabions are easy to install, and they

integrate and adapt in harmony to their

surroundings, allowing vegetation to grow. This

provides a pleasant landscape in contrast to

the rigid or semi-rigid solutions of concrete or

ripraps.

IntroducIntroducIntroducIntroducIntroductiotio

tiotiotionn

nnn

BoliviaBolivia

Portugal Mexico Bolivia

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Dominican Republic


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Prodac Gabion baskets and mattresses are

rectangular parallelepipeds composed of

meshes with particular characteristics which

form a base, vertical walls and a cover. The

cover can occasionally be formed separately.

According to the mesh type, they can be:

Hexagonal openings (woven).

Orthogonal openings (electrowelded).

Baskets are gabions whose height ranges

from 0.50 m to 1.00 m while mattresseshave a height range from 0.17 m to 0.30 m.

Gabions can be partitioned by internal

diaphragms forming cells whose length must

not be greater than 1 the width of the mesh.

Usually, this spacing is 1 meter.

DefiniDefiniDefiniDefiniDefinitiontiontiontiontion

There is a third type of gabion called sack which

is mainly used in emergency works or in placeswhere it is not possible to make an installation

in optimal conditions. Unlike gabion baskets

or mattresses, gabion sacks are assembled off-

site and they are mounted in their final

location with the use of heavy machinery.

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BoliviaBolivia

Bolivia

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Mattress

Sack

Basket

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Guatemala

MexicoMexico

PeruPeru


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FLEXIBILITY

Prodac gabions allow deformation of the

structures without losing their functionality.

This feature is very important when the work must

support high ground movements, it is set on

unstable soils, or is exposed to severe erosions.Unlike rigid structures, gabions collapses do not

occur suddenly, allowing adequate recovery

actions.

Characteristics and Advantages

PERMEABILITY

As Prodac gabions are composed of mesh and

rocks, they are highly permeable structures. This

prevents hydrostatic pressures from building up

in bank protection works. They form drains which

allow water discharge, avoiding movements tooccur from the dry face of the structure.

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AESTHETICS

Prodac gabions integrate with their surroundings,

naturally and in harmony, allowing the growth of

vegetation and preserving the existing

ecosystem.

Peru


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DURABILITY

The protective coating of the wires used for

manufacturing Prodac gabions ensures their useful

life. The triple zinc layer or heavy galvanization (BS

443-82 / ASTM A 641), as well as Aluzinco, ensures

protection against corrosion and abrasion. A PVCcoating protection, recommended in cases of severe

corrosion, can be added to these metallic coatings.

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ECONOMY

As Prodac Gabions are easy to assemble, they do

not require specialized labor. The tools required are

simple (shears, pliers, etc.), achieving high

performance in the installation. In many cases fill

stones are extracted from the site where the

installation is being performed which has a favorable

influence on the reduction of the final cost of the work.

RESISTANCE

The materials used for manufacturing gabions meet the

most exigent international standards, ensuring a 100%

reliable gabion, guaranteed by wire diameters and mesh

openings.

VERSATILITY

The type of materials used in the gabions allow their

construction either manually or mechanically in any

weather conditions, either in presence of water or in

places difficult to access. The gabion construction is

fast and it starts working immediately after the

construction is completed. It also allows working in

phases and a fast repair in the event of any failure.

Costa RicaBoliviaBolivia


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1.1 PRODAC HEXAGONAL GABIONS

GENERAL DESCRIPTION

Prodac gabion baskets are regular parallelepipeds of various sizes, manufactured with double twisted

metallic mesh (ASTM A 975 97) and filled on site with stones of appropriate hardness and weight.

HexagonalHexagonalHexagonalHexagonalHexagonalMeshMeshMeshMeshMesh GaGaGaGaGabbbbbionsionsionsionsions

Other sizes can be manufactured upon request. Tolerances meet ASTM A 975-97.

Table N 1 GABION BASKET

Length m

1.0

1.5

2.0

2.0

2.0

3.0

3.0

4.0

4.0

4.0

5.0

5.0

5.0

6.0

Width m

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.0

1.5

1.0

1.0

1.5

2.0

Height m

1.0

1.0

0.5

1.0

1.0

0.5

1.0

0.5

1.0

1.0

0.5

1.0

1.0

0.5

Diaphragms N

-

-

1

-

1

2

2

3

3

3

4

4

4

5

Volume m3

1.0

1.5

1.0

2.0

2.0

1.5

3.0

2.0

4.0

6.0

2.5

5.0

7.5

6.0

D I M E N S I O N S

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MESH

The mesh is a hexagonal double twisted wire net made by interweaving

two wire threads by three half turns. The mesh type is 8 x 10 cm (ASTM

A 975 97).

Since these structures are affected by differential ground settlements,external movements, etc., the use of gabions with openings bigger than8 x 10 cm is not recommended. A bigger mesh opening reduces the

gabions steel area and weakens the structure.

Mesh opening tolerance is +- 10%. Wire diameters will depend on theplanned structural building conditions.

1.2. PRODAC HEXAGONAL REVET MATTRESSES

GENERAL DESCRIPTION

Prodac Revet Mattresses are regular parallelepipeds of various sizesmanufactured with a double-twisted woven metallic mesh filled on site

with stones of appropriate hardness and weight.

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MESH

The mesh is a hexagonal woven net obtained by interweaving two wire threads by three half turns. Fieldexperiences have demonstrated that in this application mesh openings should be used from 6 x 8 cm to amaximum 8 x10 cm.

Since revet mattresses are generally in contact with water and solid elements carried by rivers, the designs

must consider characteristics that allow them to resist physical and mechanical forces such as impacts,

Table N 2 REVET MATTRESS

Other diameters upon request. Tolerance set by standard ASTM A 975-97.

D I M E N S I O N S

Length m Width m Height m Diaphragm N Volume m3

2.0

2.0

2.0

2.02.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

0.17

0.23

0.30

0.170.23

0.30

0.17

0.23

0.30

0.17

0.23

0.30

2

2

2

33

3

4

4

4

5

5

5

1.02

1.38

1.80

1.361.84

2.40

1.70

2.30

3.00

2.04

2.76

3.60

3.0

3.0

3.0

4.04.0

4.0

5.0

5.0

5.0

6.0

6.0

6.0

traction and abrasion.

To extend their useful life, Prodac produces revet mattresses

with 2.70 mm wire diameter and 8 x 10 cm mesh opening, inaddition to 6 x 8 cm with 2.20 mm wire diameter. Such

characteristics allow filling with up to 3 layers of stones as large

as 3 " diameter, enough for dissipating rivers hydraulic

energy and undermining effect.

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EDGE WIRE

All the edges of the unfolded gabion, including

the upper side of the diaphragms, must be thicker

than the mesh wire to provide increased

resistance and firmness.

LACING WIRE AND STIFFENERS

Lacing wires are used to assemble and

interconnect empty units, to close and secure

stone-filled units and for internal stiffeners.

Stiffeners are used to avoid deformations and

they are thinner than mesh wire.

1.3 WIRE PROPERTIES OF GABIONS AND REVET

MATTRESSES

Wires used in gabion baskets and revet mattresses

production, assembly and installation are mild annealed

steel SAE 1008 quality, according to the following

specifications:

b

a

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Base Material

CARBON : % C 0.06 - 0.10

PHOSPHORUS : % P max. 0.04

SULFUR : % S max. 0.05

Traction resistance must meet BS 443 - 82 / ASTM A 641

standard.


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BoliviaBolivia

Tolerances meet BS 443-82 standard. Other diameters can be produced upon request.

Table N 3 GABION BASKET WIRE DIAMETER

Wire type

2.40

3.00

2.20

2.70

3.40

2.20

3.00

3.90

2.20

3.50

4.10

3.20

Mesh wire

Edge wire

Tie Wires and Stiffeners

Tolerances meet BS 443-82 standard. Other diameters can be produced upon request.

Table N 4 REVET MARTES WIRE DIAMETER

3.50

4.10

3.50

2.20

2.70

2.20

2.70

3.40

2.20

3.00

3.90

2.20

Mesh Type 6 x 8 cmWire type

Mesh wire

Edge wire

Tie Wires and Stiffeners

3.70

4.10

3.20

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Dominican RepublicDominican Republic

Mesh Type 8 x 10 cm

Metallic coatingdiameter mm

PVC coatingdiameter mm

Metallic coatingdiameter mm

PVC coatingdiameter mm

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WIRE PROTECTION COATING

Wires used by Prodac in the production, assembly and

installation of gabions and revet mattresses are protected

by:

Heavy or triple galvanization recommended for severe

corrosion and abrasion, particularly in wet environments.

Aluzinco (Zn + Al), recommended in cases of

atmospheric corrosion.

PVC coating additional to the two types of protection

mentioned above.

2.20

2.40

2.70

3.00

3.40

3.90

240

260

260

275

275

290

244

244

244

244

244

244

Table N 5 METALLIC COATING

ASTM A 856/A 856M-98 Standard Class 80.

Wire diameter

mm

Heavy galvanized coating

Min. Weight

g/m

Minimum weight of

Aluzinco coating

Zn + Al g/m2

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For severe corrosive environments and additional PVC coating is mostly

recommended. PVC properties are:

Minimum PVC thickness: 0.38 mm .................................... ASTM A 975-97

Specific weight: between 1.30 and 1.40 Kg/dm.............. ASTM 792 - 66 (79)

Hardness between 50 and 60 shore D.......ASTM D 2240- 75 (ISO 868 - 1978)

Break load: greater than 210 Kg/cm2.............................. ASTM D 412 - 75

Elongation: greater than 200% .........................................ASTM D 412 - 75

Elasticity not less than 20.6 Mpa...........................................(ASTM 412-75)

Abrasion: weight loss less than 12%.........................ASTM D 1242 - 56 (75)

Fragility temperature: less than -9C ...................................... ASTM D 746

PVC sample must meet with accelerated aging tests, that consist on an

exposition to saline fog and UV light according to ASTM 975 standard.

TOLERANCES

Wire diameter tolerances will be as those indicated in the ASTM A 641-98 stand-

ard for triple galvanization.

The tolerances for gabion baskets and/or mattresses length, width and height

are indicated below:

Gabion baskets: length, width and height 5 %.

Gabion mattresses: length and width 5 %; and height 10 %.

STANDARDS AND TOLERANCES OF PVC COATING

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GENERAL DESCRIPTION

Prodac welded wire gabions are structures made

up by meshes electrically welded from heavy

galvanized wires. They are efficient, economic and

sound units. Our gabions are the perfect union of

steel, stone and soil, creating flexible and adequate

structures for resisting various conditions in thiskind of works.

TABLE N 6 ELECTROWELDED GABIONS

Dimensions

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Electrowelded GabionsElectrowelded GabionsElectrowelded GabionsElectrowelded GabionsElectrowelded Gabions

G-0.90 3.0 1.0 0.3G-1.00 2.0 1.0 0.5

G-1.35 3.0 1.5 0.3

G-1.50 3.0 1.0 0.5

G-1.80 3.0 2.0 0.3

G-2.00 2.0 1.0 1.0

G-2.25 3.0 1.5 0.5

G-3.00 3.0 1.0 1.0

G-4.50 3.0 1.5 1.0

Peru Peru

Type Length Width Height m m m


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MESH

Meshes are made with electrically welded wires,

creating orthogonal mesh openings. Modules

are 75 x 75 mm (3"x3") ASTM A 974 97 and 100

x 100 mm (4"x4"). Wire diameter will depend

on the construction's projected structural

conditions. Field experiences recommend the

following diameters:

BWG 11 (Diameter 3.05mm)



WIRES PROPERTIES

The wire used for manufacturing electrowelded

gabions is steel SAE 1008 quality with the

following specifications:

Tensile Strength meets ASTM standard A 641

Hard Temper, which demands tensile strength

greater than 550 N/mm2 (56 kg/mm2). Flow

degree is 5000 kg/cm2.TABLE N 7 ZINC COATING

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Minimum weightof zinc coating

g/m2

Wire diametermm

3.05 240

3.40 260

4.20 275

WIRE COATING

Coating used in Prodac electrowelded gabions is heavygalvanized (triple galvanized), which provides a

maximum protection against abrasion and corrosion,

meeting with ASTM Standard A 641, Class 3.

The following table indicates minimum zinc coating

weight:

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Width Length Wire Mesh type m m mm cm

During works demanding soil cutting, the use of retention struc-

tures is frequent. There are multiple structure

alternatives, such as those which avoid the loss of stability of

the slope (contention and retention structures), and those

which, without avoiding this, are used to guide the material

which may detach. Prodac rock falling netting is used to

resolve this kind of problems.

For slope stabilization, Prodac Rock Falling Netting allows

engineers to select, the best solution for their specific

problem, from a large variety of alternatives.

An important condition for reaching efficiency is choosing

accurately the wire protective coating.

There are three types of Prodac Rock Falling Netting:

Heavy galvanization or triple galvanization (BS 443-82).

Aluzinco (Zinc + Aluminum). ASTM A 856-98 Class 80. PVC coating additional to the heavy galvanization.

The hexagonal mesh twists guarantee that the mesh,because of a possible cut or rupture of the netting due to

TABLE N 8 ROCK FALLING NETTING

Note: other sizes can be manufactured upon request.

The measurements above described are nominal and aresubject to tolerances.

Rock Falling Netting

2 50 2.70 8 x 10

3 100 2.00 6 x 8

4 100 2.40 8 x 10

4 100 2.70 8 x 10

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Mexico

Mexico

traction, impact or other reason, will not unravel, thus

maintaining the netting's effectiveness.

The easy installation of Prodac Rock Falling Netting

allows to rapidly obtain a practical, economical and

efficient alternative in the solution of these geotechnical

problems.


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PRODAC Hog Rings are wire elements used in the assembly

and installation of gabions.

They can be applied by specially designed manual or

pneumatic tools.

Unlike traditional tie wire system, Hog Rings allow a greater per-

formance in the labor of assembly and

installation of gabions.

Hog Rings

Presentation

1600 units per box.

Manual Tool

AccesoriAccesoriAccesoriAccesoriAccesorieeeeesssss

Tools

Technical Specifications

Pneumatic Tool

1 1/2 3.0

Standard Dimension Diameterinches mm

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AplicaAplicaAplicaAplicaAplicatttttionsionsionsionsions

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1

2

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Photo 1Streambank satabilization - Peru

Photo 2Retention of falling rocks - Mexico

Photo 3Culvert headwall - Peru

Photo 4Channeling wall - Peru

Photo 5Pier - Peru

Photo 6Streambank satabilization - Peru

Photo 7Retaining wall - Bolivia

3 4

5

6

7

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Other aplications: Weirs - stepped, sloped or vertical, scour protection, architectural

features, sound barriers, etc


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GabionsGabionsGabionsGabionsGabions around the worldaround the worldaround the worldaround the worldaround the world

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Peru Bolivia Argentina Venezuela Costa Rica Honduras El Salvador Guatemala

Nicaragua Mexico Jamaica Santa Luca Portugal Spain New Zealand South Africa Australia

Haiti Panama France Puerto Rico Dominican Republic Ireland Italy United Kingdom United States

Poland

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Bolivia

Spain

Peru

BoliviaBolivia Peru


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Diseo

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