The mesh fabric is formed by weaving adjacent strands of wire by twisting them through one and a half turns at intervals, forming a hexagonal shaped mesh. The ends of the mesh wires are wrapped around a heavier transverse edge wire to form the panels. The tensile strength of the mesh in the direction of the weave is greater than across the weave.

The gabion box  is manufactured from a main panel that forms the face, base, rear and lid of the unit. The side panels and diaphragms are then jointed to the base section of the main panel. The unit is then folded flat for transportation.

On site, the unit can be opened out into the required position and the sides, diaphragm and end panels are rotated vertically. The vertical joints are formed by a continuous lacing operation with the wire supplied or with rings to form the box shape.

Once assembled the gabions are filled with stones or rocks and the lid secured to form a monolithic structure.