Mac Guide
Mac Guide
Introduction Maccaferri SA (Pty) Ltd, formerly known as African Gabions, a subsidiary of the Maccaferri Group
founded in Italy in 1879, is an ISO 9001 & 14001 company and specialises in providing products
and solutions for the preservation of the environment. Our traditional double-twist wire mesh
products are typically used for flood protection, landslide control, channel linings, embankment
stabilisation and erosion control all over the world. In addition, Maccaferri SA provides a range of
geotextile and erosion control blankets to compliment our existing core products. Other services
offered by Maccaferri SA include technical design assistance, design software, training and on-
site assistance.
The Wire Mild steel wire to SANS 675:2009 is used in the manufacture of all our wire mesh products. The
heavy duty Class A zinc coating is applied by hot-dip galvanising to SANS 675:2009 and SANS
10244-2:2003. Mesh used in the manufacture of gabions and mattresses are produced with wire
coated to SANS 1580:2005. The additional 0.5mm PVC coating, when required, is extruded
onto the zinc or Galfan wire to comply with SANS 1580:2005.
Galfan is a eutectic Zn-Al mischmetal: a combination resulting in a more uniform crystalline
microstructure and improved mechanical characteristics. It consists of a steel wire corrosion
protection with a 95% Zinc and 5% Aluminium Alloy. Small additions of Cerium-Lanthanum
rare earths to of the improve the reliability of the coating process.
Mild Steel
WIRE TOLERANCE
Galfan / Zinc Coating Nominal Diameter (mm) 2.2 2.5 2.7 3.0 3.4 3.9 4.4
Tolerance SANS 675:2009 (mm) 0.08 0.08 0.08 0.08 0.10 0.10 0.10
Zinc/Galfan Coating SANS 675:2009 SANS 1022-2:2003 g/m2 230 230 245 255 265 275 275
Zinc/Galfan Coating SANS 1580:2009 g/m2 240 260 275 275 275 290 290
PVC Coating
The Mesh Woven wire mesh is a non-ravelling mesh made by twisting continuous pairs of wires through
three one-half turns (commonly known as double-twist) which are then interconnected to adjacent
wires to form hexagonal openings. Maccaferri SA manufactures woven mesh to comply with the
requirements of SANS 1580:2005.
MESH CHARACTERISTICS
Wire Diameter (mm)
Mesh Tollerance Mesh Selvedge
b (mm) Galv Galv/ Galv Galv/
Type (mm)
b Galfan Galfan PVC Galfan Galfan PVC
60 60 -4 +10 2.2 2.2 / 3.2 2.7 2.7 / 3.7
80 80 -4 +10 2.7 2.7 / 3.7 3.4 3.4 / 4.4
Specifications: All lacing wire - 2.2mm for galvanised mesh
Specifications and 2.2 / 3.2mm for PVC coated mesh
Accessories
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MacMat MacMat is a three-dimensional erosion control mat manufactured from
entangled polypropylene mono-filaments. For lighter applications, MacMat
may be used without reinforcement.
MacMat can be combined with the range of Maccaferri double-twist wire
mesh or a geogrid reinforcement (MacGrid) to form MacMat-R. This
is used for long-term root reinforcement, erosion control, re-vegetation
and when used with soil nails and shotcrete, for slope stabilisation. This
unique combination marries the excellent anti-erosion properties of the
3-dimensional MacMat geomat with the strength of double-twist mesh
and the geogrid reinforcement.
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Biojute BioJute is a biodegradable short-term erosion control blanket manufactured
from fabric woven into an open mesh from rugged, heavy jute yarn. BioJute
is used for erosion control and re-vegetation where partial protection of the
river banks, streams and slopes is required. BioJute is available in packs
and rolls, and in 2 different grades.
BIOJUTE
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Rockfall Netting Double twist wire mesh rolls are used for the protection of slopes and cliffs
where there may be danger of falling rocks. When used in conjunction
with erosion control blankets they assist with environmental rehabilitation
and erosion control. All wire is mild steel to SANS 675:2009, zinc coated
by hot-dip galvanising to SANS 675:2009 and, for PVC coated wire mesh,
heat bonded through extrusion with a 0,5mm heavy duty PVC coating to
ROCKFALL SANS 1580:2005. Mesh Rolls are manufactured in both Mesh Type 60
NETTING and 80.
Galfan
Galfan/PVC
Galfan
Galfan/PVC
Gabions Gabions are double-twist hexagonal wire mesh baskets of various sizes, uniformly
partitioned into internal cells. They are manufactured to SANS 1580:2005 from
mild steel produced to SANS 675:2009 zinc or Galfan zinc alloy coated to SANS
1580:2005, SANS 675:2009 and SANS 20244-2:2003. PVC Units have a 0.5mm
heavy-duty PVC coating heat bonded and extruded over the zinc or Galfan coated
wire to SANS 1580:2005. All gabions are manufactured in Mesh Type 80 to SANS
1580:2005, having 3.4mm frame wire and 2.7mm mesh wire. The PVC units
GABIONS have an additional 1mm added to all the wire diameters. They are filled with stone at
the project site to form flexible, permeable, monolithic structures, such as retaining
walls, bridge abutments, sea walls, weirs, culverts and river bank protection.
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Mattresses Mattresses are double-twist (60mm) wire mesh (2.2mm - SANS 1580:2005)
baskets, filled with rock to form flexible, permeable, monolithic structures for river
bank and scour protection, channel linings for erosion control and underwater
pipeline protection. The steel wire used is heavily zinc or zinc alloy (Galfan) coated
and if required, a PVC coating is extruded over the coated wire to provide added
protection for use in aggressive environments. In Castoro Mattresses, the base,
diaphragms, front, end and sides are manufactured from one continuous panel of
CASTORO RENO mesh. The base is folded onto itself at 1.0m intervals to form double diaphragms
MATTRESSES MATTRESSES
that are automatically secured with spirals, prior to folding up the sides and securing
to the diaphragms. Castoro Mattresses have loose lids. In Reno Mattresses the lids
are pre-attached and the diaphragms are loose and need to be secured to the base
on site.
MATTRESSES
Nominal Dimensions Units per Bundle
Number Capacity
Length (L) Width (W) Height (H) of cells (m3) Galv Galv/PVC
(m) (m) (m)
2,0 1,0 0,30 2 0,60 80 60
3,0 1,0 0,30 3 0,90 60 40
6,0 2,0 0,17 6 2,04 25 20
6,0 2,0 0,23 6 2,76 25 20
6,0 2,0 0,30 6 3,60 25 20
Binding Wire : Sufficient wire is supplied for lacing and bracing operations.
Tolerances : Height (H), Width (W) : 5%; Length (L) : 10%
Sack Gabions Sack Gabions are double twist hexagonal wire mesh units consisting of a
single mesh panel laced to form a cylindrical unit. Sack Gabions are filled
with rock at the project site to form flexible, permeable, monolithic structures
used for emergency and river training works, where local conditions
require fast installation or the water does not allow easy access to the site
(underwater installations). All wire is mild steel to SANS675:2009, zinc
SACK GABIONS or Galfan coated by hot-dip galvanising to SANS 675:2009 and, for PVC
coated units, heat bonded through extrusion with a 0,5mm heavy duty PVC
coating to SANS 1580:2005. All Sack Gabions are manufactured in Mesh
Type 80 to SANS 1580:2005, having 3,4mm frame wire and 2,7mm
mesh wire and an additional 1mm to all wire diameters for PVC coated
units.
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MacTex MacTex N is a non-woven geotextile, manufactured from double needle-
punched continuous polyester filament. Its high-energy absorption, and
resistance to de-tangling of fibres make the MacTex N range ideal for
functions of filtration, separation and protection.
MacTex W is a woven geotextile manufactured from UV stabilised weaving
polypropylene yarns. The high strength of MacTex W combined with its
separation function, make the MacTex W a unique product when a single
product is required for separation and ground stabilisation.
MACTEX N
Units N 15.2 N 20.2 N 30.2 N 40.2
Tensile Strength 9 12 22 26
Opening Pore Size O90 208 195 166 155
CBR Static puncture resistance 1500 2400 3500 4000
Permeability at 100mm head 235 200 150 145
Roll sizes: Widths - 1.73m, 2.60m, 5.2m Length: 150m
MACTEX W
2S 4S 8S 10S
Tensile Strength - both directions kN/m 27 41 83 108
Opening Pore Size O90 m 200 250 120 470
CBR Static puncture resistance kN 3.0 5.0 10.0 10.5
Permeability - Normal to plane m/sec 0.015 0.021 0.022 0.033
Roll sizes: Width - 4m to 5.3m Length: 200m
MACDRAIN
Units M1111 M111M W1061 W1091
Thickness at 2kPa mm 11 11 7 9
In-plane flow capacity (at 100kPa and i=1) l/m.s 0.41 0.41 0.7 2.65
Roll Width m 25 25 75 75
Roll Length m 30 30 4.15 4.15
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TerraMesh System The TerraMesh System is a modular system that forms one of four mechanically
stabilised earth wall (MSEW) technology systems on offer by Maccaferri
SA. The TerraMesh System is a completely assembled unit made of double twist
heavily galvanised and PVC coated wire mesh, where a continuous double twist
wire mesh panel forms the reinforcement as well as the front and top of a gabion
style facing section. The back panel, ends and diaphragm of the facing section are
connected to the unit during manufacture. This creates rectangular shaped cells
used for stone confinement. All wire is mild steel to SANS 675:2009, zinc coated
by hot-dip galvanising to SANS 675:2009 and heat bonded through extrusion with
a 0,5mm heavy duty PVC coating to SANS1580:2005. All Terramesh System
units are manufactured in Mesh Type 80 to SANS 1580:2005, having 4,4mm
frame wire and 3,7mm mesh wire. ParaMesh is the combination of the TerraMesh
system used as a facing and secondary reinforcement in combination with the
ParaProducts family range used as a primary reinforcement.
Green TerraMesh Green TerraMesh is an environmentally friendly modular system that forms one
of four mechanically stabilised earth wall (MSEW) technology systems on
offer by Maccaferri SA. Green TerraMesh is a completely assembled unit made
of double twist heavily galvanised and PVC coated wire mesh lined with BioMac
and strengthened with a welded steel panel. Two pre-formed steel brackets incline
the front face at an angle of 70 to the horizontal. The angled front face and the
BioMac facilitate the establishment of natural vegetation of the units. All wire is
mild steel to SANS 675:1997, zinc coated by hot-dip galvanising to SANS 675:1997
and heat bonded through extrusion with a 0,5mm heavy duty PVC coating to SANS
1580:2005. All Green Terramesh units are manufactured in Mesh Type 80 to SANS
1580:2005, having 4,4mm frame wire and 3,7mm mesh wire. The welded steel
panel is manufactured from 6mm mild steel bars with aperture size 160mm x
200mm. ParaMesh is the combination of the Green TerraMesh system used as a
facing and secondary reinforcement in combination with the ParaProducts family
range used as a primary reinforcement.
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MacGrid MacGrid WG & EG geogrids are ideal for ground stabilisation and soil
reinforcement applications where they can be used in conjunction with
TerraMesh System and Green TerraMesh. MacGrid WG is a geogrid
made from high-molecular weight, high-tenacity polyester, multifilament
yarns. The yarns are woven on tension in machine direction and finished
with a polymeric coating. MacGrid EG is a high-modulous polypropylene
MACGRID WG MACGRID EG geogrid, produced by an extrusion process characterised by a rigid strip in
both directions.
MACGRID WG MACGRID EG
Units 5 5S 8 8S 11 11S 15 20 Units 15S 20S 30S 40S
Tensile Strength - Length Direction kN/m 60 60 90 90 130 130 170 220 Tensile Strength* kN/m 15.0 20.0 30.0 40.0
Tensile Strength - Cross Diretion kN/m 35 60 35 90 35 130 35 25 Tensile Strength at 2% Strain* kN/m 5.0 7.0 10.5 14.0
Strain at Max strength - Length Direction % 10 10 10 10 10 10 10 12 Tensile Strength at 5% Strain* kN/m 7.0 14.0 21.0 28.0
Polymer Coating Standard - PVC Roll Dimensions - Width: 4m Length: 100m *Length & Cross Direction Roll Dimensions - Width: 3.95m Length: 50m
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MacGrid AR MacGrid AR.7 and the composite AR G.7 (geogrid in combination with a
non-woven geotextile) are planar structures consisting of glass fibre strands
arranged in a grid shape with squared polymeric coated mesh. On request,
the MacGrid AR.7 can be supplied with a pressure-sensitive adhesive.
The full range of MacGrid AR materials has been specially developed for
asphalt reinforcement (i.e. highways and airports) and industrial pavement
applications.
MACGRID AR
Units 5A.7 5G.7 10A.7 10G.7 20A.7 20G.7
Tensile Strength - Length Direction kN/m 50 50 100 100 120 120
Strain at Max Load - Length Diretion % 2.51 2.51 2.51 2.51 2.51 2.51
Tensile Strength - Cross Direction kN/m 50 50 100 100 200 200
Strain at Max Load - Cross Direction % 2.51 2.51 2.51 2.51 2.51 2.51
Geogrid Structure Glass Fibre Strands
Polymeric Coating Bitumen Compatible Polymer
Roll Dimensions - Width: 2.2m to 5.3m Length: 100m
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RoadMesh RoadMesh is typically used as a reinforcement from the sub-base to the
wearing coarse of asphalt pavements, consists of double twist woven
mesh manufactured from heavily galvanised mild steel, and transversely
reinforced at regular intervals with steel rods. All wire is mild steel to
SANS675:1997 and zinc coated by hot-dip galvanising to SANS675:1997.
RoadMesh is manufactured in Mesh Type 80.
RMC Rockfall Barriers RMC Rockfall Barriers able to resist a minimum impact load of between
500kJ and 5000kJ depending on the type of barrier. This system has the
catch net downhill of the barrier. The posts act independently from the net.
If a post is hit by a falling rock and damaged, then the remaining posts take
the additional forces, ensuring that the catching performance of the system
is not compromised. During impact, the system ensures that the energy
RMC ROCKFALL of the falling rock is dispiated and the rock is prevented from moving any
BARRIERS further. The height of the barrier ranges from 3m - 7m, and the optimum
barrier length is between 30m and 70m, with the minimum length being
30m. The barrier has been designed and produced to comply with the UNI
EN ISO 9001 standard.
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HEA Panels The new HEA Panel (High Energy Absorption) combines high strength
features of the wire rope with the steel knot. The new knot is made by
two bindings, each one obtained by looping a pair of steel 3.0mm wires
coated with a 95% Zinc-Aluminium, 5% Mischmetal alloy. The two bindings
tightly envelope the ropes crossing each other. The panel is made of
square meshes manufactured with a single continuous rope, closed by an
HEA PANEL aluminium pressed spinning cot, with resistance not less than 90% of the
rope-breaking load.
HEA PANELS
400 x 400
Panel Dimensions - Mesh 300 x 300
Panel Height 3.0
Panel Length 6.0
Knot - Binding rods
Breaking load of wire (bars) 380-500
Diameter - UNI EN 10218 3
Tear Resistance
Max Load of tear break 24.4
Min breaking load of the rope 11.9
Steelgrid MO & BO Maccaferri SA has developed SteelGrid, a new double twist woven
mesh into which steel cables are woven within the double twisted
mesh.
SteelGrid MO (Mono Oriented) consists of woven mesh where
the conventional selvedge wires are replaced by 8 mm diameter
steel ropes. An additional 8 mm diameter steel rope is inserted
STEELGRID
longitudinally midway between the selvedges in the woven mesh.
SteelGrid BO consists of 8mm diameter steel ropes, in place
of the conventional selvedge wire, with a further 8mm diameter
steel rope inserted longitudinally midway between the selvedges.
During production, steel ropes are also inserted transversely in
the cross direction through the mesh twist and secured to the
edge ropes with clips.
MO
STEELGRID MO & BO
Length Width L Spacing* T Spacing**
Steelgrid MO 25m / 50m 3.0m 1.5m 1.5m
Steelgrid BO 150 24.5m / 49.5m 3.0m 1.5m 1.5m BO
Steelgrid BO 200 25m / 50m 3.0m 1.5m 1.5m
Steelgrid BO 300 24.5m / 49.5m 3.0m 3.0m 3.0m
* Longitudinal rope spacing ** Transversal rope spacing
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MacForce MacForce is the T-shaped concrete panel that forms one of four mechanically
stabilised earth wall(MSEW) technology systems on offer by Maccaferri SA.
This technology focuses on providing a retaining-wall solution, based on
soil reinforced materials, that obey friction criteria to develop a gravity
structure. These structures are a continuous homogenous block, capable
of performing in mining, industrial, residential and marine applications. It
has proved itself well able to perform with high loads, robust and critical
MACFORCE structures, where durability and reliability was required. All four MSEW
systems are being expanded with on-going research and adaptation to
Panel Thickness: 140mm - 160mm suit new and problematic site conditions.
Effective common area: 3.2m
MACFORCE
Facial Dimensions - Top 2100 x 785
Facial Dimensions - Bottom 1820 x 785
Thickness 14.0 - 16.0
Effective wall area 3.2
Reinforcement
50T Panel - Steel 18.86
Diameter 8
Spacing 160
50T Panel - Steel 26.70
Diameter 8
Spacing 100
MacRes MacRes is the square-shaped concrete panel that forms one of four
mechanically stabilised earth wall(MSEW) technology systems on offer by
Maccaferri SA. This technology focuses on providing a retaining-wall solution,
based on soil reinforced materials, that obey friction criteria to develop a
gravity structure. These structures are a continuous homogenous block,
capable of performing in road, residential and retaining-wall applications.
It has proved itself well able to perform with high loads, robust and critical
MACRES structures, where durability and reliability was required. Due to its regular-
shaped panels it lends itself to decortive and aesthetically pleasing
Panel Thickness: 140mm - 160mm patterns and surfaces with greater ease and application. All four MSEW
Effective common area: 2.25m systems are being expanded with on-going research and adaptation to
suit new and problematic site conditions.
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ParaWeb ParaWeb strips are planar structures consisting of a core of high-tenacity
polyester yarn tendons encased in a polyethylene sheath. The strips
are suitable for reinforcement applications in combination with concrete
MacForce and MacRes panels.
PARAWEB 2D
PARAWEB Units 30 40 50 70 75 100
Ultimate Tensile Strength kN 30.16 40.20 50.27 70.38 75.40 100.54
Long Term Tensile Tcr (72.4% of UTS at 20C) kN 21.86 29.13 36.43 51.00 54.64 72.86
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Software
MacStars W
The MacStars W software assists in the design
of Reinforced Soil Structures (RSS), Mechanically
Stabilised Earth Walls (MSEW), Mass Gravity Walls as
well as natural slopes. A wide library of products help the
user to chose the right products along with the principle
stability analysis: global, internal, sliding, overturning,
bearing capacity and settlement analysis. MacStars
W incorporates the most common design standards with
the equilibrium method.
Macra 2 - Weirs
Macra 2 was developed to provide the user with a rapid
and efficient tool to design vertical (dropped), stepped
and sloped (spillway) weirs. The general design criteria
makes the data input and the output intuitive for most of
the gabions weirs.
GawacWin
The GawacWin program was developed to provide
designers with a quick and reliable tool to analyse and verify
mass-gravity gabion walls in accordance with the mechanical
characteristics of gabions manufactured by the Maccaferri
Group. The user-friendly interface allows GawacWin to be
one of the best software platforms to check mass-gravity
gabion walls.
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Website: www.maccaferri.co.za
ZAF / MCG: Eng - Rev. 02, July 2011 - Maccaferri SA (Pty) Ltd, Durban, South Africa - Designed by: Branden Grant