HAPAS 5mm certification

HAPAS Fine Mesh Metals Ltd Unit B4 Halesfield 11 Telford Shropshire TF7 4PH Tel: 01902810310 e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it. website: www.finemeshmetals.co.uk HAPAS Certificate 24/H7283 Product Sheet 2 Issue1

FMM WELDED MESH GABION BASKETS

5MM FMM GALFAN/4-LIFE COATED WELDED MESH GABION BASKETS

This Product Sheet(1) is issued by the British Board of Agrément (BBA). The Highways Authorities Product Approval Scheme (HAPAS) is supported by National Highways (NH) (acting on behalf of the Overseeing Organisations of the Department for Transport; Transport Scotland; the Welsh Government; and the Department for Infrastructure, Northern Ireland), the Association of Directors of Environment, Economy, Planning and Transport (ADEPT), the Local Government Technical Advisers Group and industry bodies. (1) Hereinafter referred to as ‘Certificate’.

This Certificate relates to FMM Welded Mesh Gabion Baskets, constructed from a 3” x 3” mesh with a 5 mm wire diameter and Galfan / 4-Life coating, supplied with lacing wire for final assembly for ease of installation and improved efficiency, for use as forming mass retaining walls, in accordance with the Manual of Contract Documents for Highway Works (MCHW), Volumes 1, Series 600, and Volume 2, Series NG 600, BS EN 10223-3 : 2013, BS EN 10218-2 : 2012, BS EN 10244-1 : 2009, BS 6031 : 2009, BS 8002 : 2015, BS EN 10244-2 : 2009, BS EN 10245-1 : 2011, BS EN 10245-2 : 2011 and BS EN 10223-8 : 2013, BS EN 1997-1 : 2004and its UK National Annex.

The BBA has awarded this Certificate to the company named above for the product described herein. This producthas been assessed by the BBA as complying with the requirements of the BBA HAPAS Certification Scheme according to the assessments set out in this Certificate. On behalf of the British Board of Agrément Date of issue: 15 January 2025 Hardy Giesler Chief Executive Officer

This BBA HAPAS Certificate is issued under the BBA’s accreditation to ISO/IEC 17065 (UKAS accredited Certification Body Number 0113). Clauses marked † are additional information outside the scope of accreditation. Readers MUST check the validity and latest issue number of this BBA HAPAS Certificate by referring to the BBA website or contacting the BBA directly. The Certificate should be read in full as it may be misleading to read clauses in isolation. Any photographs are for illustrative purposes only, do not constitute advice and should not be relied upon

 

1. Product Description

1.1 The Certificate holder specifies the product under assessment, FMM Welded Mesh Gabion Baskets, constructed from a 3” x 3” mesh with a 5 mm wire diameter and Galfan / 4-Life coating, supplied with lacing wire for final assembly or optional Helicoils and pre-made braces for ease of installation and improved efficiency, for use as forming mass retaining walls, in accordance with the Manual of Contract Documents for Highway Works (MCHW)(1), Volumes 1, Series 600, and Volume 2, Series NG 600, BS EN 10223-3 : 2013, BS EN 10218-2 : 2012, BS EN 10244-1 : 2009, BS 6031 : 2009, BS 8002 : 2015, BS EN 10244-2 : 2009, BS EN 10245-1 : 2011, BS EN 10245-2 : 2011 and BS EN 10223-8 : 2013, BS EN 1997-1 : 2004 and its UK National Annex. (1) The MCHW is operated by National Highways (NH) (acting on behalf of the Overseeing Organisations of the Department for Transport; Transport Scotland; the Welsh Government; and the Department for Infrastructure, Northern Ireland).

1.2 The FMM Welded Mesh Gabion Baskets comprise a 3” x 3” mesh with a 5 mm wire diameter as shown in the
Table 1.

Table 1 Nominal dimensions of FMM Welded Mesh Gabion Baskets

2. Requirements

Requirements for the product are outlined in the BBA HAPAS Certification Scheme and Technical Specifications Documents, and have been established from the following specification documents:

• the MCHW, Volume 1, Series 600
• the MCHW, Volume 2, Series NG 600
• BS EN 10223-3 : 2013
• BS EN 10223-8 : 2013
• BS EN 10218-1 : 2012
• BS EN 10218-2 : 2012
• BS EN 10244-1 : 2009
• BS EN 10244-2 : 2009
• BS 6031 : 2009
• BS 8002 : 2015
• BS EN 1997-1 : 2004
• BS EN 10245-1 : 2011
• BS EN 10245-2 : 2011

3. Summary of Product Assessment

The product was assessed on the basis of the following characteristics in accordance with HAPAS requirements.

3.1 Tensile Strength of Mesh

Table 2 contains the test results for tensile resistance of the mesh. 

Table 2 Tensile strength of mesh

_{(1) Mean values.}

3.2 Tensile Strength and Elongation at Rupture of Wires

Table 3 contains the test results for tensile strength and elongation of wires. 

Table 3 Tensile strength and elongation at rupture of wires

_{(1) Mean values.}

3.3 Brace Tensile Strength

Table 4 contains the test results for brace tensile strength.

Table 4 Brace tensile strength

_{(1) Premade brace deformed under load, releasing from the mesh.
(2) Mean values.}

3.4 Helicoil Spring Tensile Strength

Table 5 contains the test results for helicoil spring tensile strength

Table 5 Helicoil spring tensile strength

_{(1) Mean values.}

3.5 Dimensional Accuracy of Wire Diameter

Table 6 contains the test results for dimensional accuracy of wire diameter. 

Table 6 Dimensional accuracy of wire diameter

_{(1) Mean values.}

3.6 Dimensional Accuracy of Mesh

Table 7 contains the test results for dimensional accuracy of mesh. 

Table 7 Dimensional accuracy of mesh

_{(1) Mean values.}

3.7 Wrapping Test

Table 8 contains the test result for the wrapping test.

Table 8 Wrapping test

3.8 Mass of Coating

Table 9 contains the test result for mass of coating.

Table 9 Mass of coating

_{(1) Mean values.}

3.9 Sulphur Dioxide Exposure

Table 10 contains the test results for sulphur dioxide exposure.

Table 10 Sulphur dioxide exposure

3.10 Resistance To Salt Spray

Table 11 contains the test results for resistance to salt spray.

Table 11 Resistance to salt spray

 

3.11 Durability

3.11.1 The potential mechanisms for degradation and the known performance characteristics of the materials in the product were assessed. For every installation environment, the suitability of the product must be assessed by a suitably experienced and competent individual in accordance with BS EN 10223-3 : 2013, Annex A, to satisfy the required project service life.

3.11.2 The life of a gabion structure is dependent on the specification of the mesh wire and the durability of the stone and, in the longer-term, the stability of the consolidated mass of the infill material and the conditions of exposure encountered during its service life.

3.11.3 The product is resistant to the chemicals normally encountered in earth-retaining structures. 

3.11.4 The life expectancy of the product used in river erosion and coastal protection schemes will also be affected by the scouring effects of fast-flowing water.

3.11.5 Data were assessed from tests relating to the common degradation methods prevalent in the environments in which the product will be used. 

4. Summary of Process Assessment

4.1 Manufacture

4.1.1 The BBA has undertaken the following tasks for the assessment of product manufacture and has established that the manufacture complies with BBA HAPAS Certification Scheme requirements:

• the BBA has recorded and evaluated the manufacturer’s documentation of the methods adopted for quality control procedures and product testing against HAPAS requirements
• the BBA has assessed the quality control operated over batches of incoming materials and formulations against HAPAS Requirements
• the BBA has evaluated the process for management of non-conforming work
• the BBA has audited the production process and verified that it is in accordance with the documented process
• the BBA has checked that equipment has been properly tested and calibrated

4.1.2 The BBA has undertaken to review the above measures on a regular basis through a surveillance process, to verify that the specifications and quality control operated by the manufacturer are being maintained.

† 4.1.3 The management system of the manufacturer has been assessed and registered as meeting the requirements of ISO 9001 : 2015 by IGQ (Certificate IGQ 2J05).

4.2 Delivery and site handling

† 4.2.1 The Certificate holder states that the FMM Welded Mesh Gabion Baskets end users must follow the Certificate holder’s delivery and site handling guidance.

4.2.2 To achieve the performance described in this Certificate, delivery and site handing must be performed in accordance with the Certificate holder’s instructions and this Certificate, including:

• the Policy of the Company for domestic customers is to deliver kerbside which means that the components will be delivered to the nearest access point possible to the intended address and the customer will be required to collect from there
• customers are requested to inform the Company of any specific difficulties in delivery eg no parking areas, steep slopes, confined access etc
• wherever practicable a tail lift will be used to lower the components to the ground. Where this is not practicable then the components will need to be manually handled off the lorry. This is the responsibility of the customer
• goods will either be delivered palletised or in a parcel determined by the size and weight of the consignment
• prior to the commencement of assembly the customer should check that all of the components as per the given inventory are present
• prior to assembly the customer should also ensure that the ground is suitable for the structure
• the product must be constructed to the layout provided by Fine Mesh Metals Ltd.

4.3 Design

† 4.3.1 5 mm FMM Welded Mesh Gabion Baskets, used with selected fill materials, are satisfactory for use as retaining wall structures, river training and erosion control, in both short- and long-term applications. Where required by the overseeing authority, the gabions must be protected by the use of environmental barriers, as recommended in HE
85/01.

† 4.3.2 The design of structures using 5 mm FMM Welded Mesh Gabion Baskets must be carried out by a suitably experienced and competent individual in accordance with BS EN 1997-1 : 2004, BS 8002 : 2015 and BS 6031 : 2009.

4.3.3 The design of the gabion structures must be based on the principle of mass gravity earth-retaining walls. Additional allowances may be made to account for the effect of the wire mesh.

4.3.4 The magnitude and distribution of the earth pressures and earth resistance should be calculated in accordance with current design practices and available guidelines.

† 4.3.5 The designer must specify the relevant properties of both the gabion stone fill and backfill material (placed behind the cages) as deemed ‘acceptable’ for the purpose of the design. ‘Acceptable’ materials must meet the requirements of the MCHW, Volume 1 SHW.

4.3.6 The density of filled gabions depends on both the granulometric curve of the filling stones and the installation procedures: generally, it should be taken as 60 to 70% of the density of the solid material. A higher value may be appropriate in certain circumstances, but this will be the responsibility of the consulting engineer who must ensure that the design value is achieved on site.

† 4.3.7 The stone infill of the gabions is normally sized between 100 and 200 mm and will depend on the mesh size, the lower limiting size being controlled by the dimensions of the mesh. The fill should satisfy the requirements of the MCHW, Volume 1 SHW, Class 6G⁽¹⁾. The fill must be a hard, durable material, eg stone as quarried or naturally occurring rounded stone (in accordance with BS EN 13383-1 : 2002). 

_{(1) The MCHW, Volume 1, Series NG 600 Earthworks.}

4.3.8 Gabion walls can be constructed with a minimum radius of curvature of 25 m on plan without modification of the gabion structure.

4.3.9 Watercourse linings, weirs and/or other hydraulic or erosion protection structures may require special consideration in regard to scour, uplift, wave action, seepage, etc.

4.3.10 The specification of the mesh for the gabions should be chosen to achieve the required service life (see section 3.4).

4.4 Installation

4.4.1 The Certificate holder’s instructions for installation of the product were confirmed as meeting the BBA HAPAS Certification Scheme requirements.

4.4.2 To achieve the performance described in this Certificate, the product must be installed by competent ground engineering contractors, familiar with these types of products, in accordance with the product specifications and construction drawings.

4.4.3 To achieve the performance described in this Certificate, Installation of forming mass retaining walls incorporating 5 mm FMM Galfan/4-Life Coated Welded Mesh Gabion Baskets must be in accordance with the Certificate’s holder’s installation instructions, Manual of Contract Documents for Highway Works (MCHW), Volumes 1, BS EN 10223-3 : 2013, BS EN 10218-2 : 2012, BS EN 10244-1 : 2009, BS 6031 : 2009, BS 8002 : 2015, BS EN 1997-1 : 2004, BS EN 10244-2 : 2009, BS EN 10245-1 : 2011, BS EN 10245-2 : 2011 and BS EN 10223-8 : 2013.

† 4.4.4 The Certificate holder’s instructions advise the following:

Ground preparation

4.4.4.1 Ground should be prepared in accordance with design documents provided.

Assembly

4.4.4.2 The appropriate Personal Protective Equipment (PPE) must be worn by all persons involved with handling and installation. This includes, but is not limited to, safety glasses, ear defenders, cut proof gloves, hard hat, steel toe cap boots and high-visibility vest.

4.4.4.3 All gabions come flat packed. Panels are attached together using stainless steel clips.

4.4.4.4 Using the lacing wire supplied, lace the corners of the baskets, tying the ends off with a pair of pliers. There is no need to lace the sides already clipped.

4.4.4.5 When filling the baskets, it is necessary to insert a brace in the middle of the basket. This is important to stop the face bulging when filling. The higher the wall, the more important this is, as more force is exerted on the face. Fill a 1/3 and then create a windlass. Make a loop from the back to the front of the basket and join the ends with pliers. Put a sturdy flat stone in this loop and turn in a circle, creating a tourniquet effect, which pulls the front tight. Fill on top of this, which will hold the stone in place. Repeat 2/3 of the way up. Finally, lace the lids down with the lacing wire provided. Remember to attach all higher rows to the lower ones as well.

4.4.4.6 Gabions should be arranged in accordance with the design documents provided.

Gabion filling

4.4.4.7 Choosing the correct stone fill is important as gabions are a mass retaining system. The fill should be 100-200 mm and angular. The stone should be laid flat, and action taken to avoid voids. The gabions can be machine filled, but again, action must be taken to avoid voids by hand picking at regular intervals. For the best finish, the fronts of the
baskets should be faced by hand.

4.4.4.8 Gabions are normally machine filled in layers, the stone is picked to eliminate any voids. The faces are hand laid to give the appearance of a dry stone wall. This can be more easily achieved using the hand laying partitions option, which is an extra panel to make a narrow filling compartment at the front.

4.4.4.9 A building rubble , such as crushed concrete or brick can be used at the rear of your basket, but this should be crushed to 100-200 mm. Mobile Crushers can be hired for this purpose to be used on site.

4.4.4.10 The rock fill should be tightly packed, minimising voids. If possible, the fronts should be hand-packed. Using the lacing wire, all corners and the lid should be joined, making a continual seam. Bracing wire should be used to create a 1/3 and 2/3 high on a 1 m basket,, and half way up on a 0.5 m high basket. The baskets should be filled to a level where the lid bears down on the rock fill.

4.4.4.11 Rows should be laced to the row below them with lacing wire. 

4.5 Maintenance

4.5.1 No ongoing maintenance is required.

5 Fulfilment of Requirements

5.1 The conclusion of this BBA assessment is that 5mm FMM Welded Mesh Gabion Baskets, when used in accordance with the provisions of this Certificate, complies with the BBA HAPAS Certification Scheme requirements. 

5.2 In order for the product to continue to meet Scheme requirements, it must be installed, used and maintained as per the Certificate holder’s instructions and as detailed in the Certificate.

6 Validity of Certificate

Continuing validity of this Certificate is dependent on the following factors:

• continuing compliance with product or process requirements, as described in the HAPAS Scheme document, and the specification documents referred to therein
• ongoing BBA surveillance of factory production control, to verify that the specifications and quality control being operated by the manufacturer are being maintained
• acceptable results from long-term exposure monitoring
• acceptable data to confirm durability
• formal triennial Review of the Certificate, and Reissue for required technical or non-technical updates
• compliance with ongoing Certificate obligations by the Certificate holder and manufacturer(s).

†7 Additional Regulations

Construction (Design and Management) Regulations 2015
Construction (Design and Management) Regulations (Northern Ireland) 2016

Information in this Certificate may assist the client, designer (including Principal Designer) and contractor (including Principal Contractor) to address their obligations under these Regulations.

8 Bibliography

BS 6031 : 2009 Code of practice for earthworks

BS 8002 : 2015 Code of practice for earth retaining structures

BS EN 1670 : 2007 Building hardware — Corrosion resistance — Requirements and test methods

BS EN 1997-1 : 2004 + A1 : 2013 Eurocode 7 — Geotechnical design — General rules

BS EN 10218-1 : 2012 Steel wire and wire products – General – Test methods

BS EN 10218-2 : 2012 Steel wire and wire products — General — Wire dimensions and tolerances

BS EN 10223-3 : 2013 Steel wire and wire products for fencing and netting — Hexagonal steel wire mesh products for civil engineering purposes

BS EN 10223-8 : 2013 Steel wire and wire products for fencing and netting — Welded mesh gabion productsBS EN 10244-1 : 2009 Steel wire and wire products — Non-ferrous  metallic coatings on steel wire — General principlesBS EN 10244-2 : 2009 Steel wire and wire products — Non-ferrous metallic coatings on steel wire — Zinc or zinc alloy coatings

BS EN 10245-1 : 2011 Steel wire and wire products — Organic coatings on steel wire — General rules

BS EN 10245-2 : 2011 Steel wire and wire products — Organic coatings on steel wire — PVC finished wire

BS EN 13383-1 : 2002 Armourstone — Specification

BS EN ISO 6892-1 : 2019 Metallic materials — Tensile testing — Method of test at room temperature

BS ISO 7802 : 2013 Metallic materials — Wire — Wrapping test

ISO 22479 : 2019 Corrosion of metals and alloys — Sulfur dioxide test in a humid atmosphere (fixed gas method)

BS EN ISO 9001 : 2015 Quality management systems— Requirements

BS EN ISO 9227 : 2017 Corrosion tests in artificial atmospheres — Salt spray tests

Manual of Contract Documents for Highway Works, Volume 1 Specification for Highway Works

Manual of Contract Documents for Highway Works, Volume 2 Notes for guidance on the specification for highway works series NG 600 Earthworks

9 Conditions of Certification

9.1 This Certificate:

• relates only to the product/system that is named and described on the front page
• is issued only to the company, firm, organisation or person named on the front page – no other company, firm, organisation or person may hold or claim that this Certificate has been issued to them • is valid only within the UK
• has to be read, considered and used as a whole document – it may be misleading and will be incomplete to be selective
• is copyright of the BBA
• is subject to English Law.

9.2 Publications, documents, specifications, legislation, regulations, standards and the like referenced in this Certificate are those that were current and/or deemed relevant by the BBA at the date of issue or reissue of this Certificate.

9.3 This Certificate will remain valid for an unlimited period provided that the product/system and its manufacture and/or fabrication, including all related and relevant parts and processes thereof:

• are maintained at or above the levels which have been assessed and found to be satisfactory by the BBA
• continue to be checked as and when deemed appropriate by the BBA under arrangements that it will determine
• are reviewed by the BBA as and when it considers appropriate.

9.4 The BBA has used due skill, care and diligence in preparing this Certificate, but no warranty is provided.

9.5 In issuing this Certificate the BBA is not responsible and is excluded from any liability to any company, firm, organisation or person, for any matters arising directly or indirectly from:

• the presence or absence of any patent, intellectual property or similar rights subsisting in the product/system or any other product/system 
• the right of the Certificate holder to manufacture, supply, install, maintain or market the product/system 
• actual installations of the product/system, including their nature, design, methods, performance, workmanship and maintenance 
• any works and constructions in which the product/system is installed, including their nature, design, methods, performance, workmanship and maintenance 
• any loss or damage, including personal injury, howsoever caused by the product/system, including its manufacture, supply, installation, use, maintenance and removal
• any claims by the manufacturer relating to UKCA marking and CE marking.

9.6 Any information relating to the manufacture, supply, installation, use, maintenance and removal of this product/system which is contained or referred to in this Certificate is the minimum required to be met when the product/system is manufactured, supplied, installed, used, maintained and removed. It does not purport in any way to restate the requirements of the Health and Safety at Work etc. Act 1974, or of any other statutory, common law or other duty which may exist at the date of issue or reissue of this Certificate; nor is conformity with such information to be taken as satisfying the requirements of the 1974 Act or of any statutory, common law or other duty of care.