Coastal erosion costs global economies over $500B annually, with saltwater corrosion accelerating infrastructure degradation. JOESCO’s Galfan-coated HESCO baskets, engineered with Zn95/Al5 alloy and EN 10244-2 certification, deliver unmatched protection for seawalls, harbors, and tidal zones. Validated by 2024 UAE trials, these systems reduce erosion by 92% while cutting maintenance costs by 60% vs. traditional gabions.
Why Galfan Coating Dominates Saltwater Environments
1. Material Science Breakthrough
- Zn95/Al5 Alloy Composition: 95% zinc + 5% aluminum-mischmetal coating provides 3× the corrosion resistance of standard galvanized steel.
- Salt Spray Test Results: ≤0.002 mm/year coating loss (ASTM B117) in simulated marine conditions.
2. 2025 Engineering Standards
- EN 10244-2 Class A Compliance: Guarantees 245 g/m² minimum coating mass for 50+ year coastal service life.
- NATO STANAG 4569 Alignment: Meets ballistic protection requirements for dual-use military/civilian zones.
Technical Specifications
| Parameter | Value |
|---|---|
| Wire Diameter | 4.0mm (mesh), 5.5mm (edges) |
| Coating Thickness | 85–100µm |
| Saltwater Lifespan | 50–70 years |
| Max Wave Force | 6 kN/m² (2.5m/s velocity) |
Case Study: Dubai Coastal Reinforcement (2024)
Challenge
- Site: 8km shoreline facing 4.2m/year erosion.
- Threats: 5.8% annual salinity increase + Category 3 storm surges.
Solution
- Tiered HESCO Configuration:
- Base Layer: 200–300mm limestone aggregate (35% voids for drainage).
- Upper Tiers: 50–150mm granite fill + coconut fiber bio-layers.
- Anchoring: 316L stainless steel stakes at 45° intervals.
Results
- Erosion Reduction: 92% post-installation (12-month monitoring).
- ROI: $1.2M saved vs. concrete seawall over 10 years.
Installation Protocol for 2025
Phase 1: Site Preparation
- Soil Analysis: Ensure chloride content <800 ppm (per ASTM D512).
- Geotextile Layering: Install non-woven 400g/m² polypropylene fabric.
Phase 2: Basket Deployment
- Stacking:
- Max 5 tiers (2.8m height) with 0.5m overlap.
- Alternate fill sizes (100mm → 50mm) for interlocking.
- Compaction: Use vibratory plates to achieve 98% Proctor density.
Maintenance & Monitoring
- Biannual Inspections:
- Ultrasonic thickness gauges to measure coating wear.
Alert Threshold: <70µm remaining coating.
- Post-Storm Actions:
- Replace displaced stones within 72hrs to prevent voids.
FAQs
Q: How does Galfan compare to PVC coating in tidal zones?
A: Galfan lasts 3× longer (50 vs. 15 years) and resists UV degradation.
Q: Cost per linear meter for 2025 projects?
A: 300/m depending on:
- Fill material density
- Water depth (intertidal vs. subtidal)
