Technology
Gablux technology – 99.9% repeatability, heavy-duty materials and bolted connections
Since the company was founded, we have continuously developed our own gabion basket technology: 20×8×1.8 mm C-profile, Ø 4.8 mm vertical rods, a welded construction and exclusively bolted connectors (cross braces). Production takes place using purpose-built welding frames and fixtures, ensuring 99.9% repeatability of the basket geometry.
- Steel sourced from Poland/the EU, from a long-term supplier
- Rods cold-drawn (repeatability and strength)
- Holes and bends are formed during C-profile production
- Every component is inspected three times
Introduction
A technology refined over many years – never by reducing steel thickness
It is easy to compromise gabion durability by using thin materials, weak connections and poor geometry control. At Gablux, development has always focused on new designs and repeatable manufacturing, rather than cutting costs. Testing and practical experience have shown that the key factors are: thicker rods, C-profiles with the correct rigidity and bolted connectors, which maintain the correct wall spacing under the pressure of the stone fill.
Repeatability
Welding on purpose-built frames and fixtures provides 99.9% repeatability and consistent basket geometry.
Rigidity
Ø 4.8 mm + 20×8×1.8 mm C-profile provide stability and premium proportions.
Safety
Only bolted connectors (cross braces) – no wire hooks or spirals.
4 pillars
What makes up Gablux technology?
1) Rigid geometry: Ø 4.8 mm rods + 20×8×1.8 mm C-profile
Years of experience have confirmed that with gabions, it is not enough to ask whether the basket is welded – what also matters is the size and strength of its load-bearing sections. Combining cold-drawn Ø 4.8 mm rods with a 20×8×1.8 mm C-profile provides high rigidity, keeps the basket upright and preserves clean proportions after filling with stone.
2) Welding on frames and fixtures: 99.9% repeatability
The baskets are welded by hand using purpose-built welding frames and fixtures. The frames are designed to provide 99.9% repeatability. For certain custom dimensions (for example, 183 cm instead of 185 cm), where the required vertical rod spacing is 50 mm, the length tolerance may be up to 3 mm.
3) Bolted connectors only – no hooks or spirals
Testing has shown that maintaining the correct wall spacing is critical to long-term durability and safe use. This is why we use only full-size bolted connectors (cross braces). Wire hooks and cost-cutting solutions drastically reduce rigidity, bringing the basket closer in quality to lightweight machine-welded mesh gabions. See also: why bolted connectors are essential.
4) Corrosion protection: hot-dip galvanizing to EN ISO 1461 (Pionart, Zabrze)
All components are galvanized at one galvanizing plant: Pionart (Zabrze). Coating thickness and quality tests show that on our mesh panels the coating not only meets the required ~70 µm, but often approaches ~100 µm. This materially extends the period of corrosion protection. Read more: hot-dip galvanizing vs electro-galvanizing.
Gablux technology is not about making the structure lighter or thinner. We develop new designs, geometry and manufacturing repeatability so that the baskets retain their clean appearance and rigidity after filling.
Manufacturing
Production process: roll-formed C-profiles, press-made holes and bends, and frame-based welding
Stage 1: C-profile forming and preparation
All mounting holes and bends are made at the beginning of the C-profile production process. The steel strip is first roll-formed into a C-profile. The required holes are then punched on presses, followed by trimming and forming the bends needed for the finished structure.
Stage 2: manual welding on frames and fixtures
The baskets are welded by hand on purpose-built frames and fixtures. This allows us to maintain geometry repeatability of 99.9%. For custom projects, the length tolerance may be up to 3 mm (due to the required vertical rod spacing of 50 mm).
What does this mean in practice?
Straight, even lines
The basket maintains its geometry before and after filling, without waviness or bulging.
Predictable component fit
Holes, bends and connectors align consistently, reducing installation time.
Premium appearance
The proportions and rigidity of the structure deliver a refined, factory-finished result without compromise.
Quality
Quality control: every component is inspected three times
| Stage | When? | What do we inspect? | Why? |
|---|---|---|---|
| 1) After welding | When removed from the welding frame (immediately after welding) | Geometry, dimensional accuracy, weld quality and component fit | To identify deviations before the component moves to the next stage |
| 2) Before galvanizing | After the components have been prepared as a complete set | Repeatability, installation details, holes and bends | To ensure correct galvanizing and installation |
| 3) After galvanizing | During preparation for collection or delivery | Coating quality, details, completeness and final conformity | To confirm quality before the order is handed over to the customer |
Three-stage inspection helps us maintain repeatable details and consistent quality throughout the production run. This is particularly important on long fence lines, where differences between individual components are immediately visible.
Materials
Raw materials: steel from Poland/the EU, a long-term supplier and cold-drawn rods
Consistent quality begins with consistent raw materials. We use steel sourced from Poland and the EU and work with a long-term supplier. The rods are cold-drawn, supporting dimensional consistency and predictable strength characteristics.
Why cold-drawn rods?
Cold drawing improves dimensional control and reduces variations that could affect mesh geometry and component fit.
Why use a long-term supplier?
Lower batch-to-batch variation, improved manufacturing repeatability and consistent long-term quality.
Corrosion protection
Hot-dip galvanizing: why coating thickness matters
The zinc coating provides both barrier and sacrificial protection: the zinc is consumed first, and only after that can the steel begin to corrode. Tests of components made using Gablux technology show coating thicknesses ranging from ~70 µm up to ~100 µm. All galvanizing is carried out at one plant: Pionart (Zabrze).
| Environment | Approximate zinc loss | Estimated protection at 70 µm | Estimated protection at 100 µm |
|---|---|---|---|
| Rural / low-corrosivity | ~0.7–1.0 µm/year | ~70–100 years | ~100–143 years |
| Urban | ~1.0–2.0 µm/year | ~35–70 years | ~50–100 years |
| Industrial | ~2.0–4.0 µm/year | ~17–35 years | ~25–50 years |
| Coastal / salt exposure | ~3.0–6.0 µm/year | ~12–23 years | ~17–33 years |
This is an indicative model, as the local microclimate also matters, but it clearly illustrates the principle: a thicker coating means longer protection. More about corrosion protection: hot-dip galvanizing vs electro-galvanizing.
Comparison
Gablux technology vs cost-cutting solutions
Some manufacturers, including certain companies in Slovakia and businesses competing primarily on price, use thinner rods (3.6–3.8 mm often marketed as “Ø 4 mm after galvanizing”), very thin steel strip for C-profiles, and wire hooks instead of full-size connectors. In terms of rigidity and performance, such a basket is closer to lightweight machine-welded mesh gabions than to durable welded baskets designed for long service life.
| Component | Price-first solutions | Gablux technology |
|---|---|---|
| Vertical rods | 3.6–3.8 mm (often marketed as “Ø 4 mm” after galvanizing) | Ø 4.8 mm (cold-drawn) |
| C-profiles | thin steel strip, lower rigidity | 20×8×1.8 mm – a proven balance of rigidity and clean aesthetics |
| Connections | hooks / spirals / clips | bolted connectors (cross braces) + A2 stainless steel bolts |
| Repeatability | batch-dependent, with greater variation | 99.9% repeatability (frames and fixtures) |
| Safety | risk of bulging and deformation, weaker wall-spacing control | rigidity under load, stable wall spacing |
With gabions, appearance in a photograph can be misleading. The real differences become visible after filling and over the first seasons of use: rigidity, wall spacing, geometry and corrosion resistance.
Applications
Where does Gablux technology make the greatest difference?
Long fence lines
Repeatability and rigidity are most visible across a continuous line, especially on long runs. See: gabion fencing.
Tall baskets (≥ 60 cm)
Here, cross bracing and correct wall spacing are critical. Bolted connector technology provides a clear advantage.
Retaining walls and slopes
Structures exposed to soil pressure require rigidity and correct geometry. See: gabion retaining walls.
FAQ
Gablux technology – frequently asked questions
Is Gablux technology only about welding?
What is the dimensional tolerance of the baskets?
Why do you not use hooks or spirals?
Where are the gabion baskets galvanized?
How does quality control work?
Need gabions selected for your project?
Tell us how the gabions will be used (fence, wall or planter), provide the dimensions and installation location, and we will select the appropriate variant, connectors and construction details based on Gablux technology.