2021
Maulden, Bedfordshire
Grand Union Housing Association
FJ Morris
Maccaferri
Gabion Retaining Wall Replacement in Constrained Residential Gardens
Finished gabion wall stretching along the line of properties
Steep scrubland largely unused and not maintained
The 6° batter and stepped face reportedly enhanced the feeling of increased area
Sleeves built into the wall for easy fitting of fence
Woven baskets easily form curves without losing strength
Challenge
A social housing development built in the early 2000s featured multiple retaining walls constructed from treated timber logs. Over time, these timber retaining structures deteriorated due to weathering and natural degradation, leading to structural concerns and the need for replacement. A simple like-for-like timber solution was deemed unsuitable, as it would not provide the long-term durability required for modern retaining wall systems.
The project presented significant challenges due to restricted site access. The retaining walls were located within occupied residential back gardens, where space was extremely limited. This created difficulties for material delivery, plant access, and safe construction practices. Traditional retaining wall construction methods, particularly for gabion walls, typically require substantial temporary works and working space—both of which were not feasible in this environment.
Although gabion retaining walls were identified as a durable and sustainable solution, the cost and complexity associated with conventional installation methods made the project economically unviable. Contractor FJ Morris therefore engaged Maccaferri to develop an innovative and cost-effective construction methodology that would reduce temporary works, maintain safety standards, and enable efficient installation within tight access constraints.
Solution
Maccaferri and FJ Morris collaborated to design a bespoke construction methodology tailored to the project’s logistical challenges. A short-section, end-on working approach was developed, allowing the phased removal of the existing timber walls and immediate installation of the new gabion retaining structures. This method significantly reduced the need for temporary works and enabled construction to proceed safely in confined residential spaces.
Given the limited access, smaller plant equipment was utilised instead of standard heavy machinery typically used in gabion wall construction. The modular nature of gabion baskets provided a key advantage, as units could be delivered flat-packed and assembled on-site. This reduced transportation difficulties, minimised disruption to residents, and allowed efficient working within restricted garden areas.
Maccaferri designed the retaining walls using high-performance double-twist woven mesh gabions. These systems are manufactured from steel wire with a zinc-aluminium coating and an additional PoliMac protective layer, ensuring exceptional durability and corrosion resistance. The solution offers a design life of up to 120 years, even in aggressive environmental conditions, and is supported by BBA certification—making it a reliable long-term retaining wall solution.
The gabions were filled with locally sourced stone, carefully hand-placed to create an aesthetically pleasing finish similar to traditional dry-stone walling. This not only enhanced the visual appeal of the installation but also ensured integration with the surrounding residential environment.
Overall, the project successfully delivered a cost-effective, durable, and low-maintenance gabion retaining wall solution, overcoming significant access and logistical challenges while ensuring minimal disruption to residents.
Used Products
