Gabion barrier assembly

Abstract

An automated method 100 of assembling a gabion barrier in which pre-assembled panels 106-110 are connected to one another to create a gabion compartment. The method may comprise the steps of arranging

Description

The present invention concerns an automated method of assembling a gabion barrier, a gabion barrier assembled using the method, a system for conducting the method and a kit for assembling the gabion barrier using the method. Gabion barriers are fortification structures which are commonly used to protect military or civilian installations from weapon or vehicle assault or from elemental forces, such as flood waters, sea water, avalanches, slope erosion and the like. They comprise a plurality of gabion compartments, connected in a line. Each gabion compartment is usually formed by connected wire mesh panels, into which a fill material is placed. Each gabion compartment may be formed from four or six panels. The wire mesh panels are usually lined with a material, such as a geotextile material. The geotextile is generally applied as a single piece of material to the gabion compartment after the panels are assembled. Thus, a two-step process is required in order to create a lined gabion compartment, namely a first step of assembling the gabion compartment and a second step of adding the lining material, which is difficult to automate. Conventionally, gabion barriers are therefore constructed manually, with each panel being connected to each other panel by hand. Not only is this inefficient, but it allows for human error in construction. This may result in inconsistencies in the gabion barrier produced and material waste. In addition, manual gabion barrier construction is labour-intense, and therefore expensive. There is therefore a need for an automated method of assembling a gabion barrier which reduces the requirement for manual labour. Few manufacturing machines have been proposed in the art, none of which provide an complete, automated method of assembling a gabion barrier. For example, JP2OO9185596A discloses a gabion manufacturing machine which folds a single panel into a U-shaped member. However, the remaining sides of the gabion require manual attachment to produce the resulting gabion. The present invention therefore aims to provide an improved, automated method of assembling a gabion barrier. According to a first aspect of the present invention, there is provided an automated method of assembling a gabion barrier in which pre-assembled panels are connected to one another to create a gabion compartment. The term "pre-assembledpanels" refers to the panels making up the gabion compartment which are already assembled to contain the major component parts. This may refer to a panel that already comprises a lining material. For example, each pre-assembled panel may comprise a wire mesh connected to a separate lining material, such as a geotextile. Thus, no second step is required to create the final panels once the gabion barrier has been assembled. For example, the second step of lining the gabion compartment with a lining material is not required, as the panels are already connected to the lining material before they are assembled. This allows for a simpler process, that is easier to automate. However, additional non-structural component parts may be added after the gabion barrier is assembled, such as tags or labels. The term "gabion compartment" refers to a compartment in the gabion barrier formed by opposed side walls and partition walls. The term "gabion barrier" refers to a structure formed from a plurality of gabion compartments. This may comprise a plurality of opposed side walls connected along the length of the gabion barrier, and a plurality of partition walls extending perpendicularly to and between the side walls, thereby forming a line of gabion compartments. The method may comprise the steps of: arranging a first panel on a first table and a second panel on an adjacent second table; connecting the first panel and the second panel to one another; rotating the second table towards the first table such that the second panel is rotated to be positioned on top of the first panel and lowering the height of the first table; and connecting at least another panel to the first and second panels to form a gabion compartment. The invention therefore provides a method of assembling a gabion barrier using a series of tables, some of which rotate to position the panels on top of one another to allow for assembly of the gabion barrier on the first table. The inventors have surprisingly found that assembling the gabion barrier using the method of the present invention reduces the requirement for manual labour, increases productivity and minimises costs. Further, the lowering of the first table means that the connection between the panels occurs at the same height, even as the height of the gabion barrier grows. This provide a simple and reliable method for assembling the gabion barrier, and allows all of the connections between the panels at the same height to be added simultaneously. While this method is intended for use with pre-assembled panels, such that the method results in the final product, it would also be possible to use the system and method described herein with panels such as unlined panels. It should be appreciated that more than one panel can be connected to the first and second panels to form a gabion compartment and that each of said panels does not need to be connected to both the first and second panels. For example, one further panel may be connected to the first panel and another further panel connected to the second panel, with these two then being connected to one another to form a compartment. Thus, the first and second panels are indirectly connected to one another using the additional panels to form a gabion compartment. Preferably, the first table is lowered after the second table is rotated. This maintains the assembly process at the same height (i.e. the height of the second table) as the gabion barrier grows in length. As the process proceeds, the first table may be lowered after each adjacent table is rotated. However, the first table may also be lowered simultaneously with the rotation of the adjacent tables, as this may be quicker, or even before the rotation of the adjacent tables. The method may comprise arranging a third panel on a third table. The third table may be located on the opposite side of the first table to the second table. The method may comprise connecting the third panel to a panel on the first table. The method may comprise the step of rotating the third table, such that the third panel is rotated to be positioned on top of a panel on the first table. This provides a simple way in which to add panels to the gabion barrier assembly from both sides thereof. The use of rotating tables in the method of the present invention means that workers are not required to manually lift and rotate the panels. This advantageously allows for more rapid gabion barrier assembly and prevents lifting-related injuries. The rotation of the panels on the second and / or third tables such that they are positioned on top of panels already on the first table reduces the space required for the assembly, as the entire gabion barrier may end up assembled in a folded configuration on the first table. The method may comprise arranging five panels next to one another. The five panels may be positioned at the same time as each other or sequentially. The first panel may be on the first table. The second panel may be on the second table. A third panel may be on a third table. A fourth panel may be on a fourth table, wherein the fourth table is on the opposite side of the second table to the first table. A fifth panel may be on a fifth table, wherein the fifth table is on the opposite side of the third table to the first table. The tables may be sized such that the second, third, fourth and fifth tables are smaller than, preferably half the width of, the first table. The panels may be sized such that the second, third, fourth and fifth panels are smaller than, preferably half the width of, the first panel. The fourth and fifth tables may not be rotatable. The method may comprise connecting the fifth panel to the third panel. The method may comprise connecting the third panel to the first panel. The method may comprise connecting the first panel to the second panel. The method may comprise connecting the second panel to the fourth panel. The panels are preferably connected to one another before the tables are rotated or lowered. The panels may be connected to one another at the same time or sequentially. Preferably, the panels are connected to each other at the same time, as this greatly increases the speed of assembly. This is in contrast to manual assembly, in which the panels have to be connected to one another sequentially. The method may comprise rotating the third and second tables towards the first table. This can be done sequentially but preferably, the third and second tables are rotated towards the first table at the same time. This results in the third and second panels being positioned on top of the first panel. The rotation of the third and second tables may result in the fifth and fourth panels being positioned on top of the third and second panels, respectively. The method may comprise lowering the first table. This can be done at the same time as the rotation of the third and / or second tables, before said rotation or after. Preferably, the first table is lowered after the third and second tables are rotated. Thus, the third panel is connected to the first panel on the first table and is rotated to be positioned on top of the first panel on the first table. The method may comprise arranging another five panels on the tables and / or on top of the existing panels. The five panels may be positioned at the same time as each other or sequentially. One of the five panels may be positioned on each table. The panels may be arranged such that a sixth panel is in line with the first table (and on top of the existing panels), a seventh panel may be on the second table, an eighth panel may be on the third table, a ninth panel may be on the fourth table and a tenth panel may be on the fifth table. Due to the lowering of the first table, the sixth panel is also in line with the seventh to tenth panels. The method may comprise connecting the tenth panel to the eighth panel. The method may comprise connecting the eighth panel to the sixth panel and the fifth panel. The method may comprise connecting the seventh panel to the fourth panel and the sixth panel. The method may comprise connecting the ninth panel to the seventh panel. The panels may be connected to one another at the same time or sequentially. Preferably, the panels are connected to each other at the same time, as this greatly increases the speed of assembly. The first, second, third, fourth, fifth and sixth panels may be connected such that a gabion compartment is created. The gabion compartment created comprises partition walls formed from the first and sixth panels, with a first side wall formed from the second and fourth panels and a second side wall formed from the third and fifth panels. This allows the gabion compartment to concertina as it folds, such that the first and sixth panels are on top of one another in the folded configuration, thereby reducing the size of the folded gabion. This method can then be repeated, such that the second and third tables rotate to move the seventh and eighth panels on top of the sixth panel and the ninth and tenth panels on top of the seventh and eighth panels respectively. The first table may lower again. A further five panels may then be placed on top of the arrangement and the process repeated, thereby forming a gabion barrier. In an alternative embodiment, the method may comprise arranging two panels on the first table. The two panels may be the first panel and a fourth panel. The method may comprise connecting the first panel to the fourth panel. The panels may all be the same size. The second and third tables may be smaller than, preferably half the width of, the first table. The second and third tables may be designed to hold one panel, while the first table is designed to hold two panels. The method may comprise arranging a fifth panel above the second panel after the second table has been rotated and the first table has been lowered. The first table may have been lowered such that the fifth panel is in line with the second and third tables. The method may comprise arranging a sixth panel above the fourth panel. This can be before or after the second table has been rotated and / or the first table has been lowered. Preferably, the fifth and sixth panels may be positioned at the same time as each other. The method may comprise arranging a third panel on a third table. The third table is on the opposite side of the first table to the second table. The third panel may be positioned at the same time as the fifth and sixth panels or afterwards. The method may comprise connecting the third panel to the sixth panel and the fourth panel. The method may comprise connecting the fifth panel to the sixth panel and the second panel. The panels may be connected to one another at the same time or sequentially. Preferably, the panels are connected to each other at the same time, as this greatly increases the speed of assembly. The first, second, fourth and sixth panels may be connected to create a first gabion compartment. The method may comprise the step of rotating the third table such that the third panel is positioned on top of the sixth panel, on the first table. The first table may be lowered after the third table is rotated. The first table may also be lowered as the third table is rotated, or before the third table is rotated. Thus, the third panel is connected to the fourth panel on the first table and is rotated to be positioned on top of the fourth and sixth panels on the first table. The method may comprise arranging an eighth panel on top of the third panel after the third panel has been rotated and the first table has been lowered. The eighth panel may be in line with the third and second tables. The method may comprise arranging a ninth panel on top of the fifth panel. This can be before or after the third table has been rotated and / or the first table has been lowered. Preferably, the eighth and ninth panels may be positioned at the same time as each other. The method may comprise arranging a seventh panel on the second table. The eighth, ninth and seventh panels may be positioned at the same time or sequentially. The method may comprise connecting the eighth panel to the third panel and the ninth panel. The method may comprise connecting the seventh panel to the ninth panel and the fifth panel. The panels may be connected to one another at the same time or sequentially. Preferably, the panels are connected to each other at the same time, as this greatly increases the speed of assembly. The third, fifth, sixth and ninth panels are connected to create a second gabion compartment. The gabion compartment created comprises partition walls formed from the first and sixth panels, with a first side wall formed from the second panel and a second side wall formed from the fourth panel. This is a simpler arrangement, as only four panels are needed to create a gabion compartment. A second gabion compartment is then formed with the sixth and ninth panels as partition walls and the third and fifth panels as side walls. This method can then be repeated, with sets of three panels being placed over the first table and alternatingly on the second and third tables, before being rotated to be positioned on top of the gabion barrier being formed. The table may lower with each rotation of the second and third tables. Arranging the panels may comprising sliding or dropping the panels into position. The panels may be connected via a helical wire member. Preferably, the helical wire member is a helical coil or spiral. The helical wire member may comprise any suitable material, for example steel, aluminium, titanium, any other suitable metal or alloy. The helical wire members may be twisted to connect at least two panels. Preferably, the helical wire members may be twisted to connect two or three panels. The helical wire members may be automatically twisted by a twisting device. More than one helical wire member may be twisted into position simultaneously. This advantageously reduces the time required to twist the helical wire members into position, allowing for more efficient gabion assembly. Alternatively, the helical wire members can be twisted into position sequentially. The end of the helical wire member may be bent after it has been twisted into position. This releasably secures the connection between the panels by preventing the helical wire member from untwisting. Advantageously, additional securing means are not required. Alternatively, the end of the helical wire member may be unbent such that the panels may be easily removed to facilitate replacement or repair of a section of the gabion, if required. The helical wire member may be sized to fit the panels. The helical wire member may be cut to size from a longer wire member after it has been positioned. Alternatively, the helical wire member may be cut to size before it has been positioned. The method may comprise repeating the steps to create a plurality of connected gabion compartments on the first table. This process therefore needs less space, as the gabion barrier is assembled in a folded configuration. Advantageously, the steps of the method can be repeated any number of times. This means that any number of gabion compartments can be created such that a gabion barrier of any length can be constructed. The first table may be lowered each time one or more tables are rotated towards the first table. The table may be lowered in a step-wise manner. This allows the gabion barrier to be assembled in a stack, which reduces the space required for the assembly, and lowers the top of the gabion barrier to the same height as the adjacent tables, so any panels being positioned can be added in a line. Additionally, this provides space for the next gabion compartment of the gabion barrier to be constructed such that construction of the gabion barrier is not interrupted between each gabion compartment. This provides a more efficient, continuous assembly method. The first table may be lowered after each time one or more tables are rotated towards the first table. The first table may be lowered before or at the same time as one or more tables are rotated towards the first table. The first table may be lowered by an amount that corresponds to the increase in height of the gabion barrier assembly caused by the addition of panels due to the rotation of the one or more tables. The first table may comprise a lowering means or may be positioned on a lowering means. For example, the first table may be a scissor lift table. The gabion compartments may comprise side walls and partition walls. The side walls may be opposed to one another and may connect to the side walls of adjacent gabion compartments along the length of the gabion barrier. The partition walls may extend perpendicularly to and between the side walls. The side walls may be connected to adjacent side walls and optionally also partition walls at the ends thereof. The partition walls may be connected to two adjacent side walls at each end thereof. Also disclosed herein are panels for use in the method of assembling the gabion barrier of the present invention. The partition walls and side walls may each comprise any number of panels. Preferably, each partition wall comprises one panel. Preferably, each side wall comprises one or two panels. The panels may be polygonal, preferably quadrangular. More preferably, the panels are square or rectangular. One panel may be a different height to the other panels. For example, the front panels of the gabion barrier may be taller than the partition wall panels and / or the rear panels. The panels may comprise wire mesh or may be formed from a solid material. Preferably, the panels comprise wire mesh. The panels may comprise any suitable material, for example steel, aluminium, titanium, any other suitable metal or alloy. Where the panels comprise wire mesh, the helical wire member may be wound between the wire mesh of adjacent panels to connect the panels. Where the panels comprise a solid material, the panels may comprise a row of apertures along an interconnecting edge through which the helical wire member can be threaded. The side walls of the gabion barrier may be pivotally connected to each other and / or to the partition walls. Preferably, each side wall panel may be connected to two other side wall panels and to at least one partition wall, except for in the gabion compartments at the end of the barrier. The helical wire member may provide the pivotal connection. The pivotal connection advantageously allows the walls of the gabion barrier to be moveable relative to one another. This improves the ease of both assembly and installation. Where the pivotal connection is provided between the two panels of each side wall of a gabion compartment, the pivotal connection may allow the gabion barrier to fold concertina-wise. This advantageously allows the gabion barrier to be easily folded for storage and transport, and easily unfolded for use. The gabion barrier may comprise a locking member. The locking member may releasably secure the pivotal connection. This allows the walls of the gabion barrier to be kept in a fixed position. This prevents the gabion barrier from folding when in use. The side wall panels and / or the partition wall panels may comprise a lining material, such as a geotextile. This can be used with solid material panels, but is particularly important for wire mesh panels. Each panel may comprise a separate portion of lining material. The lining material may extend all of the way around the gabion compartment, so as to help retain a fill material when in use. However, the panels may not be fully covered by the lining material, such that part of the wire mesh or solid material is not lined. The lining material may also extend beyond the edge of the wire mesh or solid material in some panels. This is entirely different to the arrangements in the prior art, in which the gabion compartment is lined with a single piece of lining material once it has been constructed. The use of individually lined panels allows the gabion barrier assembly process to be automated, as it removes the need for a two-step process. The lining material may line the inward facing surface of the panel when assembled into a gabion barrier. This advantageously reduces production costs and minimises the weight of the gabion barrier. Alternatively, the lining material may line both the inward and outward facing surfaces of the panel when assembled into a gabion barrier. The lining material may be stapled to the panel using one or more rows of staples. For example, the lining material may be stapled to the panels using four rows of staples comprising two rows at the top of the panel and two rows at the bottom. A hem may be created on at least one edge of the lining material before it is attached to the panel. This prevents the lining material from fraying. The lining material may extend beyond the sides of the wire mesh. The lining material may extend beyond at least one side of the wire mesh. Where the lining extends beyond at least one side of the wire mesh, it may overlap with the lining of an adjacent panel. This creates a continuous lining such that there are no gaps in the lining between adjacent panels. Where filling material is used, this advantageously prevents filling material from falling out of the gabion compartment. Additionally or alternatively, where the lining extends beyond at least one side of the wire mesh, it may extend over an adjacent helical wire member. Where filling material is used, this advantageously prevents the filling material from falling out through the gaps in the helical wire member. Additionally, where the helical wire member provides a pivotal connection between adjacent panels, this also prevents the filling material from becoming lodged in the helical wire member and obstructing the said pivotal connection. The helical wire member is preferably covered by a lining material as viewed from both of the adjacent gabion compartments that it connects together. In some panels, the lining material may not extend to the sides of the wire mesh. These can be used in combination with panels in which the lining material extends beyond the side of the wire mesh. This reduces the cost and minimises the weight of the gabion barrier produced as it reduces the parts of the panel that have two overlapping layers of lining material, while still ensuring the gabion compartment is fully lined. Each gabion compartment may comprise one or more wire mesh panels connected to a lining material in which the lining material does not extend to the sides of the wire mesh and one or more wire mesh panels connected to a lining material in which the lining material extends beyond one or both sides of the wire mesh. The side wall of the gabion compartment may comprise a wire mesh panel connected to a lining material in which the lining material does not extend to the sides of the wire mesh or a wire mesh panel connected to a lining material in which the lining material extends beyond both sides of the wire mesh. These two types of side wall panel may alternate along the length of the gabion barrier, with adjacent gabion compartments having different side wall panels. Preferably, opposed side walls within a gabion compartment have the same type of panel. In this embodiment, the partition wall panels may comprise a wire mesh panel connected to a lining material, in which the lining material extends beyond the edges of the panel. The lining material of the partition wall may then extend over the unlined part of the side wall panel in compartments in which the lining material does not extend to the edges of the wire mesh. This therefore entirely lines said gabion compartment. The adjacent side wall panel, in which the lining material extends beyond the edges of the wire mesh, then covers the helical wire member between the partition wall and said adjacent side wall panel in the adjacent gabion compartment. Alternatively, the side walls of each gabion compartment may comprise two wire mesh panels, each connected to a lining material, wherein the lining material extends beyond one side of the wire mesh but does not extend to the other side of the wire mesh. These can be connected to one another such that the lining material that extends beyond one side of one side wall panel covers the unlined portion of the adjacent side wall panel in a gabion compartment. The lining material that extends beyond the edge of the adjacent panel can then cover the helical wire member connecting said panel to a partition wall. These can be used with partition wall panels comprising a wire mesh panel connected to a lining material in which the lining material extends beyond both edges of the panel. The lining material on the partition wall covers the unlined portion of the side walls adjacent to the partition wall, thereby also covering the helical wire member from the adjacent gabion compartment. Each of these two side panels may be narrower than the partition wall panel. The width of the two side panels combined may be the same as the wide of the partition wall. According to a second aspect of the present invention, there is provided a gabion barrier assembled using the method of the present invention. The gabion barrier may comprise at least one gabion compartment. The gabion barrier may be multicompartmental. The gabion barrier according to this aspect of the invention differs from conventional gabion barriers in that the panels used are each lined with a separate portion of lining material. Conversely, conventional gabions tend to use a single piece of lining material to line the inside of each gabion compartment, the single piece of lining material extending over all of the panels. However, this then makes it difficult to automate the process. The use of individually lined panels also means that each panel can be more easily replaced or repaired if damaged. According to a third aspect of the present invention, there is provided a system for conducting the method of the present invention. The system comprises a first table that can be lowered in a step-wise manner; a second table that can be rotated towards the first table; and a means for supplying a helical wire member to the position between the first and second tables. The system may comprise a third table on the opposite side of the first table to the second table. The third table can be rotated towards the first table. The system may comprise a further means for supplying a helical wire member to the position between the first and third tables. This may share a reservoir of helical wire members with the means supplying helical wire members to between the first and second tables, or it may have its own. The system may comprise a fourth table on the opposite side of the second table to the first table. The system may comprise a fifth table on the opposite side of the third table to the first table. The fourth and fifth tables may not rotate. The system may comprise a further means for supplying a helical wire member to the position between the fifth and third tables, and / or between the fourth and second tables. Thus, there may be two further means for supplying helical wire members, one positioned between the fifth and third tables and one between the fourth and second tables. These may share a reservoir of helical wire members with the means supplying helical wire members to between the first and second tables, or they may have their own. Each of the means for supplying a helical wire member may comprise an indent between the tables into which the helical wire member can be rotated. The distance between the indents may be adjustable. Each indent between the tables may comprise one or more notches at the edge thereof, to hold the horizontal wires of the mesh panels. There may be notches on both edges of the indent, aligned with one another. This allows the panels to be held in position as the helical wire members are being twisted into position. The means for supplying a helical member may comprise a means for twisting the helical wire member into position. This may be a twisting device. This means that the helical wire members do not need to be positioned manually. The helical wire members can therefore be positioned in a quicker and safer manner, and allows the helical wire members to be positioned along the tables simultaneously. The system may comprise a means for sliding or dropping the panels into their positions. This may comprise one or more reservoirs of panels, which may be positioned above or adjacent to the tables. As the panels are pre-assembled, the system may not comprise any further means for assembling the panels, such as lining said panels. The tables may comprise one or more grooves to hold the wire mesh panels in position. The one or more grooves may be sized to fit a wire of the wire mesh panels. The one or more grooves may hold one or more vertical wires of the mesh panel. The grooves advantageously ensure that the wire mesh panels do not move from their intended positions on the tables during the gabion barrier assembly. One or more grooves may hold one or more of the horizontal wires of the mesh panel, in order to hold the panel in position as the helical wire members are being twisted into position. The first table may comprise an indent to hold a helical wire member. Where the method comprises arranging two panels on the first table, and the two panels are connected by a helical wire member, this allows the panels to sit flush against the table. This also provides a flat base on which the gabion barrier can be assembled. This prevents the gabion barrier from being constructed at an angle and therefore from falling to one side during construction. The system may comprise an exit table. The exit table may extend from the first table. Once the gabion barrier has been assembled, it may be slid on to the exit table. This frees the first table such that it can immediately be used to assemble another gabion barrier. This reduces the time required between assembling gabion barriers such that production of the gabion barriers is more efficient. The one or more grooves holding a vertical wire of the panel on the tables may extend to the edge of the table closest to the exit table, such that the panels can slide along the grooves to the exit table. The exit table may comprise an indent to hold a helical wire member, as in the other tables. Where both the first table and the exit table comprise indents to hold the helical wire member, the gabion barrier can be more easily slid from the first table to the exit table. The exit table may be moveable. This means it may function as a trolley to easily transport the assembled gabion. Also disclosed herein is a means for manufacturing the panels discussed above, preferably the panels comprising a wire mesh and a lining material. The system for conducting the method of the present invention may comprise the means for manufacturing panels. The means for manufacturing panels may be positioned before the tables in the system. The means for manufacturing the panels may comprise a reel of lining material, such as geotextile, that can be unrolled; a means for arranging a wire mesh on a portion of unrolled lining material; a means for connecting the lining material to the wire mesh; and / or a means for cutting the lining material. The reel of lining material may be unrolled continuously or in sections. The reel of lining material may be unrolled on to a conveyor means. The conveyor means may be a roller conveyor or a conveyor belt. The means for arranging a wire mesh on a portion of unrolled lining material may be a means for sliding or dropping the wire mesh panels on to the lining material. For example, the means may comprise a reservoir of panels positioned above or adjacent to the lining material, as well as a means for moving the panels from said reservoir. The wire mesh panel may be narrower or wider than the lining material. The wire mesh panel may be positioned on the lining material such that the lining material does not extend to the edges of the wire mesh. Alternatively, the lining material may extend beyond one or both edges of the wire mesh. The means for creating the panels may be programmable to create all of these types of lined panel. The means for connecting the lining material to the wire mesh may be a stapler. The means may be automated. A programmable logic controller (PLC) may control the means. The means may be pre-programmed to attach the wire mesh to the lining material in a specific way. For example, the wire mesh may be stapled to the lining material using four rows of staples, two on the right hand side of the wire mesh, and two on the left hand side. The number of rows of staples or the position of the rows may be adapted depending on the size of the panel. The means for cutting the lining material may be a movable blade, such as an X&Y moving cutting head. A PLC may control the means for cutting the lining material. The means for manufacturing the panels may comprise a means for creating a hem in the lining material. Preferably, the means for creating a hem is a hemming device. The hem may be created before or after the wire mesh panel is attached to the lining material. The hem may be created on either side of the unrolled lining material. Preferably, the hem is created on the side of the material that will be positioned at the top end of the panel when the gabion barrier is assembled. According to a fourth aspect of the present invention, there is provided a kit for assembling the gabion barrier using the method of the present invention. The kit comprises a plurality of helical wire members and a plurality of panels comprising a wire mesh connected to a lining material. As discussed above, the use of pre-assembled panels is not conventional in the art and instead, the lining material is generally added to the gabion compartment after it has been assembled. The kit may also comprise either (a) a plurality of panels comprising a wire mesh connected to a lining material, wherein the lining material extends beyond both sides of the wire mesh of some of the panels and does not reach either side of the wire mesh of some of the panels, or (b) a plurality of panels comprising a wire mesh connected to a lining material, wherein the lining material extends beyond both sides of the wire mesh some of the panels and extends beyond one side of the wire mesh but does not extend to the other side of the wire mesh of some of the panels. The plurality of panels may all be the same width, particularly in embodiment (a) above. Alternatively, the panels wherein the lining material extends beyond one side may be narrower than the panels wherein the lining material extends beyond both sides in embodiment (b) above. The lining material may extend beyond the top of all of the wire mesh panels. The lining material may be folded over the panel. The lining material may be connected on the opposite side, for example by staples. This may create a hem. Any of the features discussed above in relation to one of the aspects of the present invention can equally apply to the other aspects of the present invention. The invention will now be more particularly described with reference to the following examples and figures, in which; Figure 1 illustrates a first embodiment of the system for conducting the method of assembling a gabion barrier; Figure 2 illustrates a second embodiment of the system for conducting the method of assembling a gabion barrier; Figure 3 illustrates a plan view of the first embodiment of the system for conducting the method of assembling a gabion barrier; Figure 4 illustrates a plan view of the second embodiment of the system for conducting the method of assembling a gabion barrier; Figure 5 illustrates an embodiment of the means for creating the panels for the gabion barrier of the invention; and Figure 6 illustrates a plan view of two embodiments of the gabion barrier of the invention. Figure 1 illustrates a first embodiment of a system 100 for conducting the method of assembling a gabion barrier of the present invention. As shown in row A, the first embodiment of the system 100 comprises five tables 101-105. The first table 101 is a scissor table and is positioned between the second and third tables 102,103. A fourth table 104 is positioned on the opposite side of the second table 102 to the first table 101. A fifth table 105 is positioned on the opposite side of the third table 103 to the first table 101. Panels 106-110 are dropped on to the tables 101-105, as indicated by the arrows 111, such that a first panel 106 is positioned on the first table 101, a second panel 107 is positioned on the second table 102, a third panel 108 is positioned on the third table 103, a fourth panel 109 is positioned on the fourth table 104 and a fifth panel 110 is positioned on the fifth table 105. The tables are sized such that the second, third, fourth and fifth tables 102-105 are half the width of the first table 101. The panels are sized such that the second, third, fourth and fifth panels 107-110 are half the width of the first panel 106. Each panel 106-110 is a pre-assembled panel that comprises a wire mesh and a geotextile lining 112-116. Each lining comprises at least one overlap portion 117-122, which extends beyond the edge of the wire mesh. In the first embodiment of the system 100, the geotextile lining 112 of the first panel 106 comprises two overlap portions 117, 118. The geotextile linings 113-116 of the second, third, fourth and fifth panels 107-110 each comprise one overlap portion 119-122. As shown in row B, four helical coils 123-126 are twisted into position simultaneously, as shown by the arrows 127, between the panels 106-110 such that the helical coils 123-126 hingedly connect adjacent panels. Specifically, a first helical coil 123 hingedly connects the first panel 106 to the second panel 107. A second helical coil 124 hingedly connects the first panel 106 to the third panel 108 on the opposite side of the first panel 106 to the second panel 107. A third helical coil 125 hingedly connects the fourth panel 109 to the second panel 107 on the opposite side of the second panel 107 to the first panel 106. A fourth helical coil 126 hingedly connects the third panel 108 to the fifth panel 110 on the opposite side of the third panel 108 to the first panel 106. The second and third tables 102, 103 are rotatable. The second and third tables 102, 103 rotate towards the first table 101 as shown by the arrows 128. As shown in row C, the rotation of the second and third tables 102,103 causes the second and third panels 107, 108 to hinge at the helical coils 123, 124 that connect the second and third panels 107, 108 to the first panel 106. The second and third panels 107,108 therefore fold towards the first panel 106 such that the second and third panels 107,108 are positioned on top of the first panel 106. The folding of the second and third panels 107,108 causes the fourth and fifth panels 109,110 to hinge at the helical coils 125,126 which connect the second and third panels to the fourth and fifth panels 109, 110. The fourth and fifth panels 109,110 fold towards the first panel 106 such that the fourth and fifth panels 109, 110 are positioned on top of the second and third panels 107, 108, respectively. In this manner, concertina folds are created by the second, third, fourth and fifth panels 107-110. As indicated by the arrow 129, the first table 101 is lowered relative to the second, third, fourth and fifth tables 102-105. As indicated by the arrow 130, the second and third tables 102, 103 rotate outwards from the first table 101 to realign with the fourth and fifth tables 104,105. As shown in row D, five new pre-assembled panels 131-135 are dropped on to the tables 102-105 and panels 109,110 as indicated by the arrows 136, such that a sixth panel 131 is positioned on top the fourth and fifth panels 109,110, a seventh panel 132 is positioned on the second table 102, an eighth panel 133 is positioned on the third table 103, a ninth panel 134 is positioned on the fourth table 104 and a tenth panel 135 is positioned on the fifth table 105. The seventh, eighth, ninth and tenth panels 107-110 are half the width of the sixth panel 131. The lowering of the first table 101 means that the sixth panel 131 is in line with the other panels. As shown in row E, four additional helical coils 137-140 simultaneously twist into position, as shown by the arrows 141, between the panels 131-135 such that the additional helical coils 137-140 hingedly connect adjacent panels. Specifically, a fifth helical coil 137 hingedly connects the sixth panel 131 to the seventh panel 132. A sixth helical coil 138 hingedly connects the sixth panel 131 to the eighth panel 133 on the opposite side of the first panel 131 to the seventh panel 132. A seventh helical coil 139 hingedly connects the ninth panel 134 to the seventh panel 132 on the opposite side of the seventh panel 132 to the sixth panel 131. A eighth helical coil 140 hingedly connects the tenth panel 135 to the eighth panel 133 on the opposite side of the eighth panel 133 to the sixth panel 131. A first gabion compartment is created in the space between the first, second, third, fourth, fifth and sixth panels 106-110,131. The steps shown in rows C to E as described above are then repeated to create a gabion barrier having a plurality of connected gabion compartments. Figure 2 illustrates a second embodiment of a system 200 for conducting the method of assembling a gabion barrier of the present invention. As shown in row A, the first embodiment of the system 200 comprises three tables 201-203. The first table 201 is a scissor table and is positioned between the second and third tables 202, 203. Panels 204-206 are dropped on to the tables 201, 202, as indicated by the arrows 207, such that a first panel 204 is positioned on the first table 201, a second panel 205 is positioned on the second table 202 and a fourth panel 206 is positioned on the first table 201 on the opposite side of the first panel 204 to the second panel 205. The first, second and fourth panels 204-206 are the same width. The second and third tables 202,203 are each half the width of the first table 201 such that one panel can fit on each of the second and third tables 202, 203. Each panel 204-206 is a pre-assembled panel which comprises a wire mesh and a geotextile lining 208-210. The geotextile lining of the second and fourth panels 205, 206 each comprise two overlap portions 211-214, which extend beyond the edge of the wire mesh. The geotextile lining of the first panel 204 does not extend to the edges of the wire mesh. As shown in row B, two helical coils 215, 216 twist simultaneously into position, as shown by the arrows 217, between the panels 204-206 such that the helical coils 215,216 hingedly connect adjacent panels 204-206. Specifically, a first helical coil 215 hingedly connects the first panel 204 to the second panel 205. A second helical coil 216 hingedly connects the first panel 204 to the fourth panel 206 on the opposite side of the first panel 204 to the second panel 205. The second and third tables 202, 203 are rotatable. The second table 202 rotates towards the first table 201 as indicated by the arrow 218 (but not shown). The first table 201 is lowered. As shown in row C, the rotation of the second table 202 causes the second panel 205 to hinge at the helical coil 215 that connects the second panel 202 to the first panel 201. The second panel 202 therefore folds towards the first panel 201 such that the second panel 202 is positioned on top of the first panel 201. The second table 202 then rotates outwards from the first table 201 such that it realigns with the third table 203, leaving the second panel 202 on top of the first panel 201. Three additional panels 220-222 are dropped on to the tables and panels, as shown by the arrows 223, such that a sixth panel 220 is positioned on top of the fourth panel 206, a fifth panel 221 is positioned on top of the second panel 205, and a third panel 222 is positioned on top of the third table 203. Each panel 220-222 is a pre-assembled panel which comprises a wire mesh and a geotextile lining 224-226. The geotextile lining of the fifth and third panels 221, 222 each comprise two overlap portions 227-230, which extend beyond the edges of the wire mesh. The geotextile lining of the sixth panel 220 does not extend to the edges of the wire mesh. Due to the lowering of the first table 201, the panels are positioned in line with one another. As shown in row D, two additional helical coils 231, 232 simultaneously twist into position, shown by the arrows 233, between the three additional panels 220-222 such that the helical coils 231, 232 hingedly connect adjacent panels. Specifically, a third helical coil 231 hingedly connects the sixth panel 220 to the second panel 205 and the fifth panel 221. A fourth helical coil 232 hingedly connects the sixth panel 220 to the third panel 222 on the opposite side of the sixth panel 220 to the fifth panel 221, and to the fourth panel 206. A first gabion compartment is created in the space between the first, second, fourth and sixth panels. As indicated by the arrow 234, but not shown, the third table 203 then rotates towards the first table 201. The first table 201 lowers. As shown in row E, the rotation of the third table 203 causes the third panel 222 to hinge at the helical coil 232 that connects the third panel 222 to the fourth panel 206 and the sixth panel 220. The third panel 222 folds towards the sixth panel 220 such that the third panel 222 is positioned on top of the sixth panel 220. The third table 203 then rotates outwards from the first table 201 such that it realigns with the second table 202, leaving the third panel 222 on top of the sixth panel 220. As shown in row F, three additional panels 235-237 are dropped on to the tables and panels, as shown by the arrows 238, such that there is an eighth panel 237 on top of the third panel 222, a ninth panel 235 on top of the fifth panel 221 and a seventh 236 panel on the second table 202. The steps shown in panels B to F as described above are then repeated to create a plurality of gabion compartments. The connection of the sixth panel 220, the third panel 222, the ninth panel 235 and the fifth panel 221 creates a second gabion compartment. Figure 3 illustrates a plan view of the first embodiment of the system 100 for conducting the method of assembling a gabion barrier of Figure 1. In line with row B of Figure 1, five panels 106-110 are positioned on five tables 101-105. Four helical coils 123-126 are twisted into position, in the direction shown by the arrow 142, between the panels 106-110 such that the helical coils 123-126 hingedly connect adjacent panels. The helical coils 123-126 are each twisted into position by twisting devices 143. The system also comprises an exit table 144 extending from the first table 101. Once the gabion has been assembled, it is slid from the first table 101 onto the exit table 144, as indicated by the arrow 145. Figure 4 illustrates a plan view of the second embodiment of the system 200 for conducting the method of assembling a gabion barrier of Figure 2. In line with row A of Figure 2, the first table 201 can hold two panels 206 and 204. The first table 201 is positioned between the second table 202 and the third table 203, each of which can hold a single panel. A helical coil 216 connects the panels 206, 204 on the first table 201 and so the first table 201 comprises an indent 240 to accommodate said helical coil. Helical coils 215,232 can also be positioned between the first table and the second and third tables, respectively. The helical coils 216, 215, 232 are each twisted into position by twisting devices 243. The system also comprises an exit table 244 extending from the first table 201. Once the gabion has been assembled, it is slid from the first table 201 onto the exit table 244, as indicated by the arrow 245. Figure 5 illustrates an embodiment 300 of the means for creating the panels of the gabion barrier of the invention. The means for creating the panels comprises a geotextile reel 301. The end of the geotextile reel is fed through a first pair of rollers 302 in the direction indicated by the arrow 303, and continuously unrolled along the roller conveyor system 304. Panels are dropped on to the unrolled geotextile, as indicated by the arrow 305 from a reservoir of panels 306 positioned above the geotextile. A hem is then created on one side of the geotextile material by a hemming device 307. The panels are then stapled to the geotextile material by an automatic stapler 308 controlled by a PLC (not shown). The geotextile material stapled to the panel is then fed through a second pair of rollers 309. The geotextile material is then cut on either side of the panel by an X&Y moving cutting head 310 controlled by a PLC (not shown). A lined panel is thereby created. Figure 6 illustrates a plan view of two embodiments of the gabion barrier of the invention, 400 and 500, shown in rows A and B, respectively. The gabion barrier 400 shown in row A comprises three gabion compartments numbered 1-3. Each gabion compartment comprises four walls, namely two side walls 401-406, and two partition walls 407-410. Each wall comprises a single pre-assembled panel, formed from a wire mesh and a geotextile lining. The side walls of the first and third compartments 401,402, 405,406 comprise geotextile linings 411-414 that do not extend to the sides of the wire mesh adjacent to the partition walls 407-410. The partition walls of the first and third compartments 407,408,409, 410 comprise geotextile linings 415-418 comprising overlap portions at both of the sides adjacent to the side walls, which extend beyond the edge of the wire mesh. Each overlap portion overlaps with the adjacent unlined portion of the side walls 401, 402, 405, 406 and covers the helical coil 415-422 as viewed from the first and third compartments. The side walls of the second gabion compartment 403, 404 comprise geotextile linings 423, 424 which comprise overlap portions at both edges of the panels. The overlap portions extend beyond the sides of the wire mesh adjacent to the partition walls 408, 409 such that they overlap with the helical coil 416, 417, 420,421, as viewed from the second compartment. The partition walls are not lined on the inside of the second compartment. Thus, the gabion compartments are entirely lined. The gabion barrier 500 shown in row B comprises three gabion compartments numbered 1-3. Each gabion compartment comprises four walls, namely two side walls 501-506, each comprising two side wall panels labelled a and b, and two partition walls 507-510, each comprising a single panel. The side wall panels 501a, 502a, 503a, 504a, 505a, 506a are pre-assembled panels comprising a wire mesh lined with a geotextile lining 511-516 comprising an overlap portion at one edge thereof, but not extending to the other edge of the wire mesh. The overlap portions overlap the helical coil 517-522 that are present in the middle of each side wall and overlap the unlined portion of the adjacent panel in the same side wall, namely 501b, 502b, 503b, 504b, 505b, 506b. The side wall panels 501b, 502b, 503b, 504b, 505b, 506b are pre-assembled panels comprising a wire mesh lined with a geotextile lining 523-528 comprising overlap portions at one edge thereof, but not extending to the other edge of the wire mesh. These overlap portions overlap with the adjacent partition wall 508, 509, 510 and the helical coil connecting the side wall panels 501b, 502b, 503b, 504b, 505b, 506b to the respective partition walls 508, 509, 510. The partition walls 507-509 are pre-assembled panels comprising a wire mesh and geotextile linings 529-531 which comprise overlap portions that extend beyond both of the edges of the wire mesh and so extend over the unlined portions of the adjacent side wall panels 501a, 502a, 503a, 504a, 505a, 506a. The partition wall 510 is a pre-assembled panel comprising a wire mesh and a geotextile lining 532 which does not extend to the sides of the wire mesh adjacent to the side wall panels 505b and 506b, as it is at the end of the gabion barrier.

Claims

1. An automated method of assembling a gabion barrier in which pre-assembled panels are connected to one another to create a gabion compartment.

2. The method of Claim 1 comprising the steps of:arranging a first panel on a first table and a second panel on an adjacent second table;connecting the first panel and the second panel to one another;rotating the second table towards the first table such that the second panel is rotated to be positioned on top of the first panel and lowering the height of the first table; andconnecting at least another panel to the first and second panels to form a gabion compartment.

3. The method according to Claim 2, further comprising arranging a third panel on a third table located on the opposite side of the first table to the second table, and connecting the third panel to a panel on the first table.

4. The method according to Claim 3, further comprising rotating the third table such that the third panel is rotated to be positioned on top of a panel on the first table.

5. The method according to any one of Claims 2 to 4, further comprising arranging five panels next to one another, namely the first panel on the first table, the second panel on the second table, a third panel on a third table, a fourth panel on a fourth table on the opposite side of the second table to the first table and a fifth panel on a fifth table on the opposite side of the third table to the first table.

6. The method according to Claim 5, further comprising connecting the fifth panel to the third panel, the third panel to the first panel, the first panel to the second panel and the second panel to the fourth panel.

7. The method according to Claim 6, further comprising rotating the third and second tables towards the first table such that the third and second panels are positioned on top of the firstpanel and the fifth and fourth panels are positioned on top of the third and second panels, respectively, and lowering the first table.

8. The method according to Claim 7, further comprising arranging another five panels with one on each table, such that there is a sixth panel in line with the first table, a seventh panel on the second table, an eighth panel on the third table, an ninth panel on the fourth table and a tenth panel on the fifth table and connecting the tenth panel to the eighth panel, the eighth panel to the sixth panel and the fifth panel, the seventh panel to the fourth panel and the sixth panel and the ninth panel to the seventh panel, such that a gabion compartment is created from the first, second, third, fourth, fifth and sixth panels.

9. The method according to any one of Claims 2 to 4, further comprising arranging two panels on the first table, namely the first panel and a fourth panel, and connecting the first panel to the fourth panel.

10. The method according to Claim 9, further comprising arranging a fifth panel above the second panel and a sixth panel above the fourth panel after the second table has been rotated and the first table has been lowered, as well as arranging a third panel on a third table, connecting the third panel to the sixth panel and the fourth panel and connecting the fifth panel to the sixth panel and the second panel to create a first gabion compartment.

11. The method according to Claim 10, further comprising the step of rotating the third table such that the third panel is positioned on top of the sixth panel on the first table and lowering the first table.

12. The method according to Claim 11, further comprising arranging an eighth panel on top of the third panel, a ninth panel on top of the fifth panel and a seventh panel on the second table, connecting the eighth panel to the third panel and the ninth panel, and connecting the seventh panel to the ninth panel and the fifth panel to create a second gabion compartment.

13. The method according to any preceding claim, wherein the panels are connected via a helical wire member.

14. The method according to any one of Claims 2 to 13, comprising repeating the steps to create a plurality of connected gabion compartments on the first table.

15. The method according to any one of Claims 2 to 14, wherein the first table is lowered each time one or more tables are rotated towards the first table.

16. The method according to any preceding claim, wherein each panel comprises a wire mesh connected to a lining material, such as a geotextile.

17. The method according to Claim 16, wherein the gabion compartments comprise side walls and partition walls, wherein each side wall of each gabion compartment comprises:a wire mesh panel connected to a lining material in which the lining material does not extend to the sides of the wire mesh or a wire mesh panel connected to a lining material in which the lining material extends beyond both sides of the wire mesh, optionally wherein these two types of panel alternate along the length of the gabion barrier; ortwo wire mesh panels, each connected to a lining material, wherein the lining material extends beyond one side of the wire mesh but does not extend to the other side of the wire mesh, optionally wherein each of these two wire mesh panels are narrower than the partition wall panel.

18. A gabion barrier assembled using the method of Claim 16 or Claim 17.

19. A system for conducting the method according to any one of Claims 2 to 17, comprising:a first table that can be lowered in a step-wise manner;a second table that can be rotated towards the first table; anda means for supplying a helical wire member to the position between the first and second tables.

20. The system according to Claim 19, further comprising a third table on the opposite side of the first table to the second table that can be rotated towards the first table and a means for supplying a helical wire member to the position between the first and third tables.

21. The system according to Claim 20, further comprising a fourth table on the opposite side of the second table to the first table and a fifth table on the opposite side of the third table to the first table, as well as means for supplying a helical wire member to the position between the fifth and third tables and between the fourth and second tables.

22. The system according to any one of Claims 19 to 21, wherein the means for supplying a helical wire member comprises a reservoir of helical wire members and an indent between the tables into which the helical wire member can be rotated, optionally wherein the distance between the means is adjustable.

23. The system according to any one of Claims 19 to 22, further comprising a means for creating the panels, which comprises:a reel of lining material that can be unrolled;a means for arranging a wire mesh on a portion of unrolled lining material;a means for connecting the lining material to the wire mesh; and a means for cutting the lining material.

24. A kit for assembling the gabion barrier using the method of any one of Claims 1 to 17, comprising a plurality of helical wire members and a plurality of panels each comprising a wire mesh connected to a lining material.

25. The kit of Claim 24, wherein the lining material extends beyond the top of all of the wire mesh panels, is folded over the panel and is connected on the opposite side, and / or whereina. the lining material extends beyond both sides of the wire mesh of some of the panels and does not reach either side of the wire mesh of some of the panels, optionally wherein all panels are the same width; orb. the lining material extends beyond both sides of the wire mesh some of the panels and extends beyond one side of the wire mesh but does not extend to the other side of the wire mesh of some of the panels, optionally wherein the panels wherein the lining material extends beyond one side are narrower than the panels wherein the lining material extends beyond both sides

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