1 Introduction – protect and survive

2 Basic construction guidelines

3 Design of Concertainer structures

4 Fill selection and characteristics

5 Preconfigured structures

6 Improvised structures

7 Maintenance and repair

8 Product technical information

9 Trial information

10 Packing and shipping

11 Conversion tables

12 Contacts
1
Introduction –
protect and
survive
 Introduction – protect and survive
HESCO® Concertainer® has
been a key component in
providing Force Protection since
the 1991 Gulf War.
Concertainer units are used
extensively in the protection of
personnel, vehicles, equipment
and facilities in military,
peacekeeping, humanitarian
and civilian operations.
They are used by all major
HESCO Construction Guide for Engineers
military organisations around
the world, including the UK
MOD and the US Military.
It is a prefabricated, multi-
cellular system, made of
Alu-Zinc coated steel welded
mesh and lined with non-woven
polypropylene geotextile.
1.01
Delivered flat-packed on standard
timber skids or pallets, units
can be joined and extended
using the provided joining pins
and filled using minimal
manpower and commonly
available equipment.
Concertainer units can be
installed in various configurations
to provide effective and
economical structures, tailored
to the specific threat and level
of protection required. Protective
structures will normally be
designed to protect against
ballistic penetration of direct fire
projectiles, shaped charge
warheads and fragmentation.
Introduction – protect and survive
Protection is afforded by the fill
material of the structure as a
consequence of its mass and
physical properties, allied with
the proven dynamic properties
of Concertainer units.
Users must be aware that the
protection afforded may vary
with different fill materials, and
may be further varied by
moisture content. This guide will
provide general guidance, with
an emphasis on the design and
construction practices
applicable to structures built
from Concertainer units. More
detailed reference material may
be required for information on
weapon-effects data and
comparison of fill material.
1.02
In constructing protective
structures, consideration must
HESCO Construction Guide for Engineers
be given to normal structural
design parameters.
The information included in this
guide is given in good faith,
however local conditions may
affect the performance of
structures. HESCO Bastion Limited
cannot be held responsible for
failures of structures beyond the
existing material warranty against
manufacturing defects.
As with any structure,
maintenance may be required
to ensure continued effective
long-term service.
HESCO Bastion Ltd can provide
design, training, supervisory
and consultancy services.
 Introduction – protect and survive 1.03

A 10m long wall can be built

from a Mil® 1 Concertainer unit
by two men with suitable
material-handling equipment,
in less than 20 minutes.
An equivalent wall of 1,500
HESCO Construction Guide for Engineers

sandbags would take 10 men

seven hours to build.
Introduction – protect and survive 1.04
The Mil range

HESCO Construction Guide for Engineers

 Introduction – protect and survive 1.05
Using this manual
Warning
This guide was published in
2010; it replaces all previous Statements presented in
this style warn of the danger
versions of the HESCO
of a particular action or lack
Construction Guide for Engineers of action. These statements
and the HESCO Bastion should be followed, as
Technical Information booklet. failure to do so could result
in injury or death.
Amendments to this guide will
be issued from time to time.
Please see the next page for
instructions. Safety
HESCO Construction Guide for Engineers

This guide includes statements
on safety issues and information
on correct procedure. Examples
of how these statements
appear and what they constitute
are shown to the right.
Statements presented in
this style advise certain
actions or approaches to
tasks. Failure to follow the
advice could result in a
failure of the product
and/or danger to users.

Note: Statements that provide

general information about an
issue or that draw attention to
a point of detail are presented
in this style, as emboldened
text preceded by ‘Note:’.
Introduction – protect and survive 1.06
Amendments

Amendments to this guide will

be posted at:

www.hesco.com/amends

Please ensure that once

amendments are incorporated
into this document they are
recorded as such in the table
below.

HESCO Construction Guide for Engineers

Amendment record

Amendment number By whom amended Date of insertion

 Introduction – protect and survive 1.07

Notes
5mm
HESCO Construction Guide for Engineers
2
Basic
construction
guidelines
 Basic construction guidelines
Health and safety
Task commanders must ensure
that all relevant and practical
health and safety precautions are
taken. The main risks to health
and safety during the building of
Concertainer structures, in
addition to any tactical risks
that may be present, are:
- working at height.
- personnel working in close
HESCO Construction Guide for Engineers
proximity to plant equipment.
- manual handling injuries, back
strain, cut hands etc.
- risk of injuries from the elements,
cold or heat injuries.
- collision between personnel
and loading equipment/
crushing injury.
Simple precautions should be
taken to ensure a safe build,
such as:
- Only qualified and properly
trained equipment operators
should operate the loading
equipment, when used.
- Ladders, when used, should
be secured at the top and
bottom and be fit for purpose.
2.01
- A minimum number of persons
should be employed when
carrying out tasks at height.
- Keep good site organisation.
- Ensure personnel only lift the
weight that they are safely
able to.
- Provide a properly briefed and
competent banksman for the
loading equipment. He is to
ensure correct employment of
the loading equipment, correct
placement of the fill material
and that working areas for the
loading equipment are free
from personnel.
All personnel should be fully
briefed on the task, including:
- safe methods of work.
- safety around moving loading
equipment.
- manual handling techniques.
- work positions when working
above ground level.
Site supervisors must ensure
that they have sufficient control
measures in place to protect
their personnel from the risks
that may be present on the site.
Basic construction guidelines 2.02
Basic equipment
There is little need for special
tools when building structures
and walls from Concertainer
units. The following list shows
basic items which are either
required or are useful:

- shovels (must have)

- multi-tool (desirable)

- tape measure (desirable)

HESCO Construction Guide for Engineers

- string line (desirable)

- small jemmy bar (desirable)

- bolt croppers (desirable)

- knife (must have, supplied on

pallet)
 Basic construction guidelines
General
A Concertainer unit is a simple
product that is used to create
effective and economical
protective structures. The
guidelines contained in this
publication will refer to “normal”
conditions of expected use in
operational situations.
The tactical and operational
situation may however dictate
that speed of build is more
HESCO Construction Guide for Engineers
important than properly prepared
foundations and the use of a
carefully selected fill. In this case
the life of the structure may be
reduced. The use of a poor fill
material may require the
structure to be wider to ensure
that it provides the level of
protection required.
Once erected the service life of
structures built from Concertainer
units depends upon how well they
were built, local environmental
conditions and the maintenance
regime implemented.
The building of Concertainer walls
is a relatively simplistic operation.
However, to get the best from
the material it is imperative that
2.03
Warning
Structures built in a hasty
manner due to operational
circumstances must be
routinely inspected to ensure
that they are structurally
sound and do not present a
hazard to those working or
living around them.
a number of simple steps are
followed during the construction:
- firm level foundations
- adequate drainage
- use of appropriate fill
- Concertainer units laid out,
line and level checked
- correct joining of units
- tucking in geotextile flaps
- bottom centre of the units
pulled out after the first
150mm of fill is placed
- fill material placed in layers
of 150mm max depth for first
layer and 300mm max for
subsequent layers
- fill material is spread and
compacted before placing
further layers
Basic construction guidelines
Site considerations,
foundations and drainage
The location where the
structure will be built will
normally be dictated by
operational requirements in
response to the nature of the
threat and the position of
assets to be protected.
In most cases site preparation will
be required. The level will depend
on local conditions, wall design
and/or time that the wall is
expected to be in service.
The most basic requirement is
a relatively level surface with a
base of sufficient strength to
support the structure. Where
ground preparation is required
the minimum procedure would
be to strip all organic or topsoil
material and replace with a
granular fill material.
2.04
An improved foundation may be
required when:
- the planned structure is large.
- the structure is to be in place
for more than six months.
- the soil to be built on is weak
and is unlikely to support the
weight of the wall to be built.
The strength of the ground can
be confirmed by using a cone
HESCO Construction Guide for Engineers
penetrometer to ascertain the
CBR1.
1
CBR, or California Bearing
Ratio – measure of the ground’s
ability to support loads.
 Basic construction guidelines 2.05

For long walls, the inherent

flexibility of Concertainer units
will allow the structure to
conform to moderate ground
contours.
HESCO Construction Guide for Engineers
Basic construction guidelines 2.06
Foundations - Line the trench with a
Local conditions may vary, but geotextile (minimum weight
a basic foundation for those 200 g/m2) or preferably a
without the resources to design Geogrid1.
one can be constructed, as
- Backfill the trench in layers
shown in Figure 1.
with coarse graded fill and
compact well.
- Excavate a trench 0.5m (1'8")
deep, extending at least 0.5m
(1'8") beyond the footprint of
the structure all around.

HESCO Construction Guide for Engineers

0.5m
(1'8")
| |
|

0.5m (1'8")
|

Base Fill Geogrid

Figure 1 Diagram showing improved foundation layout

1
Geogrid – adds strength to
a weak subgrade and will
enable it to support much
heavier loads.
 Basic construction guidelines
Drainage
HESCO Concertainer units form
a very effective dam so care
must be taken to ensure that
drainage is provided where
required. Correct drainage will
also ensure the base that the
wall is built on will retain its
strength and will not be
HESCO Construction Guide for Engineers
2.07
weakened by excessive moisture.
The issue of drainage should
not be ignored.
Culvert pipes can be placed
through the units to allow water
to be passed from one side
of a wall to the other in a
controlled manner (see Figure 2).

HESCO Wall

Ground level

Culvert pipe fitted with welded

mesh (optional)

Culvert pipe bedding

Figure 2
Basic construction guidelines
Basic construction techniques
Whether the structure is a
simple, single-course wall or a
more complex structure, basic
construction techniques are still
the same:
- layout
- joining
- forming corners and curves
- filling
Layout
- Units are delivered to site,
flat-packed on pallets.
- Units are lifted off the pallet
and placed in the desired
location.
- Concertainer unit placed on
the ground horizontally with
the arrow pointing away from
the desired direction the wall
is to be erected (Figure 3).
- Two men each grasp the end
panel and together move in
the desired direction. The unit
will concertina from the horizon-
tal to the vertical and become
self supporting (Figure 4).
2.08
- Pull the unit out to its full
length. Check it is in the
correct position (Figure 5).
- Adjust the outer walls of the
unit so that they are parallel.
- Make any joints or extensions
required before filling the unit
(see Joining).
Note: A number of Concertainer
units can be split into two
segments whilst still on the
HESCO Construction Guide for Engineers
pallet. This is achieved by
removing the orange tagged
pins. This facilitates easier man
handling of the units.
Safety
Ensure all personnel are
properly briefed on the
correct method of lifting
and carrying weight.
Persons should only lift
and carry the weight that
they feel comfortable with.
Basic construction guidelines
Figure 3
Place the unit in the
desired location
2.09 Basic construction guidelines 2.10
Joining vertically
stacked units
Joining is achieved using the
supplied hog rings.

- Fill the bottom unit to within

approximately 100mm (4")
from the top (Figure 10).

- Place the upper units and

pull out (Figure 11).
Figure 10
Figure 4
Pull up and out Suggested positions for hog rings

HESCO Construction Guide for Engineers

Figure 5
Pull out and check position

Figure 11

Note: Hog rings should be fitted every 150 – 200mm (6 – 8")

approximately. This would require two hog rings per Mil 2 side panel
and four per Mil 1 side panel.
 Basic construction guidelines
Joining Figure 9
Most walls will require
Concertainer units to be joined
end to end. This is achieved by
using the supplied joining pins.

- Butt together the units to be

joined and overlap and
interlock the coils on each
butted corner (Figure 6).
Figure 6 Butt together and
- Insert the supplied joining pin
overlap coils
through the overlapped coils,
HESCO Construction Guide for Engineers

ensuring that it connects the

coils fully and that it is fully
inserted (Figure 7).

Note: The joining operation must

be carried out prior to placing
fill in any of the cells to be joined. Pull out panel centres around 100mm (4")
Care should be taken to ensure after fill placement (see page 2.14)
that units are horizontally
aligned before joining.
Figure 7 Place joining pins
Before filling, ensure all
geotextile flaps at the base of
the unit are tucked in (Figure 8).

If a single tier is required, filling

can start after all units in a
run are aligned and joined.
Compacting must be undertaken,
as shown in Figure 9, for every
300mm (1') lift of fill. See p. 2.14 Spread and compact
for the correct approach to filling. Figure 8 Tuck in flaps at base each layer of fill
Basic construction guidelines 2.10
Joining vertically
stacked units
Joining is achieved using the
supplied hog rings.

- Fill the bottom unit to within

approximately 100mm (4")
from the top (Figure 10).

- Place the upper units and

pull out (Figure 11).
Figure 10

Suggested positions for hog rings

HESCO Construction Guide for Engineers

Figure 11

Note: Hog rings should be fitted every 150 – 200mm (6 – 8")

approximately. This would require two hog rings per Mil 2 side panel
and four per Mil 1 side panel.
 Basic construction guidelines
Figure 12
HESCO Construction Guide for Engineers
Figure 14
- Line up the upper cells with
the lower ones (Figure 12).
- Locate the top welded mesh
strut under the stapled
geotextile of the lower cell.
Make a small, horizontal cut
under it and a vertical cut up
through the geotextile with
the supplied knife (Figure 13).
2.11
Figure 13
Figure 15
- Tuck the welded mesh of the
upper unit into the lower. Fit
and rotate a hog ring enclosing
the top strut of the lower cell
and bottom strut of the upper
cell (Figure 14).
- Tuck any geotextile from the
upper unit into the lower prior
to filling (Figure 15).
Basic construction guidelines 2.12
Corners and curves
There are various methods of
making corners and curves with
Concertainer units.

Where a curve is required, pull

out the centre coils on each cell
until you achieve the desired
curve – see Figures 16 and 17.

Note: Only pull the centre Figure 16

coils outward when creating
curved sections of wall;

HESCO Construction Guide for Engineers

pushing the centre coils
inward creates a wall section
with less than the minimum
protective thickness.

Figure 17 Pulling out the centre coils to create curved walls

 Basic construction guidelines 2.13
Alternatively, for angled corners,
fold in one complete side panel
and secure by overlapping the
coils and inserting a joining pin
(Figure 18).

Note: This method is only

applicable to units with a
split side panel, such
as the Mil 1.
HESCO Construction Guide for Engineers

Figure 18 Folding the centre coil in to create a 45 degree corner

Where a right angled corner is

required, join two units at 90
degrees by meshing the coils
and inserting the joining pins, as
previously described (Figure 19).

Figure 19
Basic construction guidelines
Filling
The filling of a basic Concertainer
wall should be commenced with
placing no more than 150mm
(6") of material in the order
shown in the diagram below.
2.14
It is important that the unit is
checked for correct position,
line and level prior to filling. The
diagram assumes that the
loading equipment will straddle
two cells at once.

Note: It is important that the

bottom centre of each cell is
pulled out after the first layer of
material has been placed and
spread, as shown at the
bottom of the diagram. 150mm

HESCO Construction Guide for Engineers

max.

End cells

End cells

On longer walls
centre cells next

Place 150mm (6")

of fill in all others Pulling out
bottom
centre
 Basic construction guidelines
Once the centre coils are pulled
outward subsequent layers of
fill should be placed in depths
no greater than 300mm. Fill must
be spread inside each cell and
then manually compacted by foot
(see page 2.09). Placement of
this layer should start at the cell
indicated in diagram A below
and then continue along the full
length of the wall. Once 300mm
(12") has been placed in the full
length, filling should recommence
HESCO Construction Guide for Engineers
from the very end cell, as
shown in diagram B.
2.15
Walls which will have another
unit placed on top should be
filled to approximately 100mm
(4") of the top of the unit. This
allows for the subsequent
joining of the units and ensures
that the geotextile flap at the
base of the unit forms a seal.
Units should be filled to the top
when they will form the top
layer or where subsequent
layers to be built on top form a
pyramid. See Building Higher
Walls, later in this section.
Note: No cell should
ever contain more
than 300mm (12") of
material than its
neighbour. Failure to
comply will result in
deformation of
Concertainer walls.
Note: Stand-alone
walls which will not
be subjected to a
subsequent load need
not be compacted.
Basic construction guidelines
Further construction
techniques
Dividing and shortening
It is likely when building walls
and structures that the
Concertainer unit may have to
be shortened. Units are easily
modified to suit this requirement.
The majority of units arrive on site
with the in-built ability to be split
into two. This is achieved by
removing the orange tagged pins,
as described earlier. With the
Mil 1 unit, for example, this will
result in two segments: one of
four cells and the other of five.
Segments can be further
shortened simply by folding in
the end cells and securing by
overlapping the coils and fitting
pins. This can reduce the
segment length by either one
or two cell lengths. A unit can
be further shortened using the
procedure below:
- Erect the unit as shown on
page 2.09, but do not fill.
- Open the coil hinges by
bending at the desired location
of the cut (Figure 20), this will
2.16
normally be at the centre coil
if one is fitted. The coil must
be opened at the top and
bottom to facilitate its removal.
- Remove the coil by unscrewing,
counter-clockwise, completely
(Figure 21). Repeat on the
opposite side.
- Cut the geotextile. Leave a
150mm (6") overlap if
incorporating into a wall (see
page 2.18).
HESCO Construction Guide for Engineers
- Separate the shortened
segments (Figure 22).
- The coil can then be re-
inserted to secure the loose
side panels if required;
alternatively, the loose ends
can simply be incorporated
into the wall.
Note: If available, bolt croppers
can be used to cut the welded
mesh to speed the above
operation.
Note: All of the above methods
result in the loss of a cell.
Shortening the EPW 1 unit can
be achieved by removing the pin
securing the side panels.
 Basic construction guidelines 2.17

Figure 20 Figure 21

Note: Whenever possible

HESCO Construction Guide for Engineers

the end of a segment

that has been split
should be incorporated
into the wall.

Figure 22
Basic construction guidelines
Half segments
Walls built up to existing
structures may not fit exactly,
therefore it may be necessary to
split an end segment in half or
add an extra half segment to
the end to fill the gap (see
Figure 23).
- To shorten a segment by half,
unwind the two centre coil
hinges from the end cell of
the unit.
2.18
The EPW 1 unit is split by remov-
ing the pins at the centre of the
side panel and then refastening
the half cell to the end of the
unit. To add half a cell, remove
half a cell from a spare unit and
fix it to the end of the unit in use.
Figure 23

HESCO Construction Guide for Engineers

- Cut the geotextile, leaving a
150mm (6") overlap, as
shown. Fold in the two panels
still attached to the unit and
secure using hog rings.

- Rewind the hinges, butt the

three loose panels up to the
end panel of the unit.

- Fasten using joining pins.

To add a half segment to the end

of a unit, remove a half segment
from a spare unit and fit it to the
unit to be lengthened by following
the last two steps above.

Note: This method is only

applicable to units with a
split side panel, as shown.
 Basic construction guidelines 2.19
Thicker walls
Thick walls are formed by
placing units side by side.
Any width of wall can be
constructed using this
method.

- Secure the adjacent units at

the ends using joining pins
(see Figure 24).

- Cut away a small section of

geotextile to expose the top
HESCO Construction Guide for Engineers

welded mesh strut of each

side panel to be joined
(Figure 25).

- Place a hog ring around the Figure 24

struts and twist the ring to
ensure it encloses both struts
(Figure 26). Repeat the process
for further hog ring connections
along the run (Figure 24).

Figure 25 Figure 26
Basic construction guidelines 2.20
Building higher walls
The building of higher walls will
normally require a pyramid type
structure to be formed. This is by
far the best means of creating a
competent high structure.

- Make sure the ground is level

and firm before proceeding to
build a tall wall. Figure 27

- Deploy lower units and fill

completely to the top

HESCO Construction Guide for Engineers

(Figure 27).

- Place and join the units for

the second layer and fill them
completely (Figure 28).

- Place and join the units for

the third layer and fill them
completely (Figure 29).

Figure 28
Note: There is very little vertical
joining required on a structure
of this type.

Examples of pyramid type walls

and possible use are shown on
page 2.21.

Figure 29
 Basic construction guidelines 2.21

Mil 1 – 2 1. Mil 1 and Mil 5 on top. Protective

Typical perimeter wall. wall around accommodation units.
HESCO Construction Guide for Engineers

Mil 3 – 2 1. Mil 3 – 3 2 1.
ECP or perimeter wall. Perimeter wall.

Mil 1 – 3 2 1. Mil 7, 8 and 9.

Perimeter wall. Aircraft revetment kit.
Basic construction guidelines
Building multistorey
vertical walls
Multistorey vertical walls are
sometimes required for a
number of reasons, such as:
- the desire to present a
vertical wall on the hostile
side.
- a high wall being required,
but a very small footprint
available to build on.
The main rule regarding the
building of these walls is that
the height of the wall must
never exceed 2 x the width of
the base. For example, a wall
with a 1m (3'3") wide base
should not exceed 2m (6'6")
high.
The sequence for building a
multistorey vertical wall is as
previously described in this
section:
2.22
- Lay out, join and fill the lower
unit to around 100mm (4")
from the top.
- Place and join the upper unit
using the hog rings.
- Ensure the welded mesh from
the upper unit is inside the
mesh of the lower unit.
Warning
Wall height should not
HESCO Construction Guide for Engineers
exceed two times the base
width. Failure to comply
with this requirement may
result in an unstable and
dangerous structure.
Warning
Mil 1, Mil 1.9, EPW 1, Mil 7
and Mil 10 should not be
stacked vertically.
Basic construction guidelines 2.23 Basic construction guidelines
Increased stability of Construction planning basics
thinner walls
Due to a number of factors you Fill material
may be required to build a tall, The fill material used in building
thin wall. In order to increase Concertainer walls has a
the stability of thinner defence significant bearing on the walls’
walls, various alternative layouts protective qualities. Generally,
can be used, as shown. the ideal fill is a sand/gravel mix.
This offers good construction
For example, if a Mil 2 wall, characteristics, but, more
three storeys high, is adopted, importantly, offers a high degree
then the wall should be laterally of protection, with little
braced by intersecting walls or incidence of secondary
in-built stiffeners at no more fragmentation.
than 3.6m (11'10") centres.
Fine material such as silt and
clay do not offer the same
protection and may, indeed,
require the wall to be wider.
They are also not reliable
construction materials.
Large clumps of earth should
be avoided, as these may
damage the unit, as can
large stones.
|
")
'10
(11
m
3.6
um
xim
Ma
|
2.24
In the main, large rocks or
stones should be avoided as
during a large blast they may
present a secondary
fragmentation risk. However,
large rocks have been used
where the threat has been
accurately defined and there is
no risk from secondary
fragmentation.
Table 1 provides a brief outline
of potential fill materials.
HESCO Construction Guide for Engineers
Table 2 provides a guide to
quantities of fill required per
unit. It is a guide only and
actual figures will depend on
type of fill, construction methods
and control, amount of loss etc.
Fill material is discussed in
more detail in Section 4.
Note: The figures in Table 2
account for expansion of the
unit, compaction of the fill and
loss of fill.
 Basic construction guidelines
Increased stability is important if
you believe the wall may be
struck face on by a hostile
vehicle or the wall is close to
where personnel live or work.
HESCO Construction Guide for Engineers
Mil 5 units in ‘zig-zag’ formation
Mil 5 units in ‘lozenge’ formation
The stability of the walls can be
further increased by the use of
“anchor sections” in the
alignment where space permits.
3rd cell is folded in to create right angle
Mil 5 units joined at right angles
Anchor unit increases
wall stability
Mil 5 units joined at right angles
Basic construction guidelines
Construction planning basics
Fill material
The fill material used in building
Concertainer walls has a
significant bearing on the walls’
protective qualities. Generally,
the ideal fill is a sand/gravel mix.
This offers good construction
characteristics, but, more
importantly, offers a high degree
of protection, with little
incidence of secondary
fragmentation.
Fine material such as silt and
clay do not offer the same
protection and may, indeed,
require the wall to be wider.
They are also not reliable
construction materials.
Large clumps of earth should
be avoided, as these may
damage the unit, as can
large stones.
2.24
In the main, large rocks or
stones should be avoided as
during a large blast they may
present a secondary
fragmentation risk. However,
large rocks have been used
where the threat has been
accurately defined and there is
no risk from secondary
fragmentation.
Table 1 provides a brief outline
of potential fill materials.
HESCO Construction Guide for Engineers
Table 2 provides a guide to
quantities of fill required per
unit. It is a guide only and
actual figures will depend on
type of fill, construction methods
and control, amount of loss etc.
Fill material is discussed in
more detail in Section 4.
Note: The figures in Table 2
account for expansion of the
unit, compaction of the fill and
loss of fill.
 Basic construction guidelines 2.25
Table 1 – brief outline of fill materials

Very good Good Poor Do not use

Well graded Sand Fluid solids Large rocks

sand and gravel (i.e. snow)
Concrete Naturally Clay Large clumps
occurring soils of earth or soil
Organic
materials

Table 2 – fill material requirement per unit

HESCO Construction Guide for Engineers

Unit Type Unit Length No. of Cells Material Material

Per Unit Per Unit
Mil 1 10m 9 Cells 22m3 29yd3

Mil 1.9 3.3m 3 Cells 13m3 17yd3

Load Bearing

Mil 2 1.22m 2 Cells 0.5m3 0.6yd3

Mil 3 10m 10 Cells 13m3 16yd3

Mil 4 10m 10 Cells 20m3 26yd3

Mil 5 3.05m 5 Cells 1.2m3 2yd3

Mil 6 3.05m 5 Cells 4m3 5.6yd3

Mil 7 27.74m 13 Cells 190m3 248yd3

Mil 8 10m 9 Cells 25m3 33yd3

Mil 9 9.14m 12 Cells 9m3 12yd3

Mil 10 30.5m 9 Cells 66m3 87yd3

EPW 1 33m 30 Cells 103m3 135yd3

Basic construction guidelines
Manpower
A crew of four to six is ideal to
support a mechanical loading
shovel during filling operations.
The crew-members’ tasks are:
- unpacking of materials and
laying out of units.
- joining units.
- spreading and compacting fill
material.
2.26
The above figures equate to
around one minute per cubic
metre (1.35yd3) of fill material to
be placed.
On the rare occasions when
manual filling is required, it will
take four men around 14
minutes to fill one cell of a Mil 1
unit. As height increases then
an allowance must be made for
additional time.

HESCO Construction Guide for Engineers

- pulling out the bottom centres
This equates to one man
of cells.
placing approximately two cubic
- the direction of loading metres per hour. This does not
equipment. account for those persons
required to carry the fill to him.
Construction Time
Given ideal conditions, a basic
linear construction of a 10m
(32'10") length of Mil 1 will take
approximately 20 minutes using
one loading shovel and 4 men.
This will include removal of the
unit from the pallet, layout and
placement of the unit, and filling.

The above figure is with fill

material close by to the site of
use and with a wheeled loading
shovel with a bucket capacity
somewhere in the region of
1 – 2m3 (1.35 – 2.7yd3).
 Basic construction guidelines
Plant
Many different types of
equipment may be used for
placing the fill material.
The type of equipment selected
will depend on a number of
factors, not least:
2.27
The selected equipment must
be able to raise the fill to the
required height and place it with
sufficient accuracy for efficiency,
safety and economy.

- the type of equipment

available.

- the space available to

HESCO Construction Guide for Engineers

manoeuvre.

- the height that the fill must be

lifted to.
For lower levels, wheeled front-
- the type of terrain.
end loaders are ideal, especially
- the distance that the fill must those fitted with 4:1 buckets.
be hauled. This also includes skid steer
loaders.
- the type of Concertainer unit
being filled.

Safety
Only qualified and properly trained equipment operators
should operate the loading equipment. Also, provide a properly
briefed and competent banksman for the loading equipment.
He is to ensure correct employment of the loading equipment,
correct placement of the fill material and that working areas for
the loading equipment are free from personnel.
Basic construction guidelines 2.28

For higher levels, excavators, Telehandler/shooting boom type

particularly those with loading equipment has proved
articulated or clamshell buckets, to be very effective and versatile

HESCO Construction Guide for Engineers

are effective. when loading Concertainer units.

Concrete skips, or elevated conveyor-type equipment have proved

successful for filling very high structures.
 Basic construction guidelines
Removal
There may be a requirement to
remove Concertainer protective
structures. This operation is
often undertaken using heavy
earthmoving plant to topple the
walls and rip the welded mesh
away from the fill material. While
this method works, it results in a
mass of welded mesh that is very
difficult to handle and dispose of.
The following pages, describe two
alternative methods for removal.
HESCO Construction Guide for Engineers
Warning
Any demolition work can
be dangerous. It is
imperative that a safe
system of work is adopted
and followed, as described
on this page.
The following risks may be
present during demolition work:
- working at height
- premature collapse of
structure
- manual handling injuries
- collisions between
earthmoving plant and
pedestrians
2.29
A safe system of work must be
adopted and followed and
should include the practices
described below:
- Working at height should be
minimised.
- When cutting the welded
mesh always cut from the
bottom up.
- Wear gloves and protective
eye wear when handling cut
and removed welded mesh.
- Competent banksmen to be
appointed to manage
earthmoving equipment and
to ensure the operating area
is kept clear of personnel.
- Ensure dump trucks are
supervised whilst reversing.
- When an electric angle
grinder or disk cutter is used
it should be supplied with
site-safe electricity.
Basic construction guidelines 2.30
Removal – method 1
This method uses earthmoving
equipment fitted with a
demolition grab, grapple
attachment, orange peel grab
or timber grab attachment.
Orange peel
- Identify and remove all material
and equipment from the area
that is not to be disposed of.

- Cut all hog rings by bolt

croppers, angle grinder or

HESCO Construction Guide for Engineers

abrasive cutting tool.
- Cut all units into two-cell
lengths by bolt croppers or
angle grinder.
- Ensure all personnel are
removed from the area prior
to using the grab or grapple.
- Remove each two-cell length
at a time with the demolition
equipment. As the segment is
removed it should be shaken
to remove as much of the fill
as possible.
- The removed welded mesh
should be stockpiled at the
site for later removal or placed
immediately into a dump truck
or skip for transportation to
the disposal area.
Clamshell Demolition grab
- Work in a methodical and
logical manner removing
two-cell segments, but
ensuring that remaining cells
do not become buried in
dislodged fill.
- Surplus fill material may be
removed from the area by
means of a loading shovel
once the grapple has
progressed a sufficient
distance.
- The above process should
continue until the site is
cleared.
Note: The welded mesh can be
recycled where facilities exist.
 Basic construction guidelines 2.31
Removal – method 2
This method involves removing
the welded mesh by hand and
is only suitable for low walls.

- Identify and remove all

material and equipment that
is not to be disposed of.

- Use bolt croppers or an angle - Remove all accessible panels

grinder to cut off all hog rings. on a cell, as described in the
previous step. The welded
mesh of the diaphragm wall
HESCO Construction Guide for Engineers

(between each cell’s geotextile)

should be removed as and
when it becomes free.
Do not cut the geotextile.

Direction of cut

- Beginning at the bottom, cut

the welded mesh all the way
up both sides adjacent to the
corner coils. Then cut the
welded mesh across the top
just under the stapled flap.
Continue cutting until the
welded mesh panel can be
removed.
- Use earthmoving equipment
to remove the fill (this will still
be contained in the geotextile).
The removal of the fill, where
possible, should be carried
out cell by cell.
- Continue until the site is
cleared.
Basic construction guidelines 2.32
Removal – method 3

Removal of EPW 1 units for

reuse or disposal
Identify and remove all material
and equipment that is not to be
disposed of. This method
involves extracting the removable
pins from the centre of one The plain end of the Y-shaped
side panel, splitting each cell. strap is fed around the cell then
MHE will be required to remove joined to the ratchet strap, which
the pins. is then hooked onto the far
corner coil of the cell adjacent to

HESCO Construction Guide for Engineers

the one being removed. Tighten
the straps, using the ratchet,
without distorting the coils.
Ensure only the pin on the
opposite panel to the ratchet
mechanism is removed. After
removing this pin, release the
ratchet strap, upon which the
cell will swing open to release
the fill material. All personnel
The ratcheted cell-removal must stand clear at this point.
straps must be fitted to each
cell, in turn, prior to pin
removal. The hooks on the ends
of the Y-shaped strap are
attached to the corner coil of
the cell to be removed, 1/3rd
from the top and bottom, on
the same side as the pin
selected to be removed, as
shown above.
 Basic construction guidelines 2.33
Bulldoze the released fill material
away from the wall. Continue
this process until the wall
has been completely
removed. Remove the
EPW material, and clean,
inspect and repair any
damaged panels, as required.
Reassemble and re-palletise
the units ready for transportation
or storage.

Plan view of strap arrangement for removal of EPW 1 unit

HESCO Construction Guide for Engineers

Ratchet release Strap

operator Ratchet

EPW 1 unit
Pin to be removed
Safety
The ratchet must be on
the side opposite the pin
which is to be removed.
All other personnel to
stand clear before the
ratchet’s release.

Note: It is important the area around the cell to be split is free from
obstruction. This allows the cell to be opened freely.
Basic construction guidelines
In many instances HESCO
Concertainer units may be
delivered to site in RAID®
configuration.
RAID has been designed to
reduce the logistics burden of
supporting force-protection
missions on expeditionary
operations. In some cases
double the length of wall can be
carried inside one RAID shipping
container than can be carried
when units are transported
using conventional methods,
such as the units laid onto
timber pallets and then loaded
into a normal 20ft ISO container.
The Concertainer units arrive
on site stood vertically inside a
specially modified and configured
20ft container.
The concertainer unit carried
inside the container is a
continuous length for Mil 7 and
Mil 10 types and two continuous
lengths in the case of a RAID 1
unit. The units are made up of
five cell segments; each
segment is joined to the next by
means of two joining pins.
2.34
Concertainer units provided in
RAID configuration using a
specially modified and
HESCO Construction Guide for Engineers
configured 20ft container.
This arrangement allows the
easy splitting of the unit if a
shorter length is required or,
indeed, breaks and corners are
required.
The deployment of the
Concertainer unit from the RAID
Container can be achieved
using two methods or a
combination of each.
The first method is to use the
container as a storage unit.
The container is opened up, the
unit pulled out by hand and
each five cell segment split from
the next. The segments can
 Basic construction guidelines
then be placed onto a pallet or
into the bucket of an earthmoving
tractor for carriage to their
place of use. This process
continues until the required
amount of Concertainer unit has
been removed. The remainder
of the unit is left on board for
future use and the container
resecured.
The second method is achieved
by pulling out the first 2 – 3 cells
HESCO Construction Guide for Engineers
2.35
required for the construction of
walls using Concertainer units,
the use of RAID can reduce this
to as little as two.
Detailed instructions on how to
use the system are provided
with each container.
The container complies with all
normal ISO standards with
regard to transportation,
stacking and shipping.

of the unit, anchoring those

cells and then proceeding to Further explanation on all these
pull the container forward using topics can be found on the
a suitably sized vehicle, such as HESCO Training DVD. If you
an earthmoving tractor or require a copy, free of charge,
armoured vehicle. As the please email:
container moves forward the
unit is pulled out from the back technical@hesco.com
of the container against its own
weight. Splitting of the unit, to
allow the forming of breaks and
corners in the wall, is carried
out as previously described.

The use of RAID can reduce

much of the work which is
undertaken on the site of the
force-protection operation.
Whereas a section of four to
eight soldiers is normally
 5mm

Notes
Basic construction guidelines
2.36

HESCO Construction Guide for Engineers

3
Design of
Concertainer
structures
 Design of Concertainer structures
General
It is possible to design and
construct walls that give
complete protection from
weapons and threats such as
small arms fire, cannon rounds,
RPG, mortars and shrapnel and
fragmentation from larger types
of shells or bombs. It is not,
though, possible to build a
structure to totally protect
against the effects of blast from
larger explosive devices.
HESCO Construction Guide for Engineers
However, the construction of a
competent defence wall may
substantially reduce the blast
effects. For instance, the walls
of a building immediately behind
a Concertainer unit wall may be
subjected to a blast pressure
significantly lower than it would
have been otherwise.
One of the main aims in
constructing defence walls is to
put distance between the target
and the potential site of charge
initiation. The creation of
“stand-off” is by far the best
means of defence and in its
best form will negate the need
for any walls at all. This ideal
situation will unfortunately rarely
be the case, so some other
3.01
means of creating stand-off will
be required. This can be in the
form of Concertainer unit walls,
ditches, fences, portable
barriers and earth bunds.
Concertainer units provide a
proven, rapidly erected means
of creating barriers to enforce
stand-off.
Another main aim of constructing
defence walls is to provide
close-in ballistic protection for
personnel and assets. In the
simplest terms for ballistic
protection, the wall must extend
to interrupt the line-of-sight
from the firing position of the
potential attacker to all areas of
the target.
To provide some blast
protection, the wall must be
sufficiently high, long and
separated from the target to
attempt to deflect the blast
wave over and around it, whilst
also protecting against
penetration from fragments and
shrapnel. It is generally accepted
that a blast wall should be as
high as possible but a minimum
of 3 metres (9'10").
Design of Concertainer structures
The blast wave will re-form at
some distance on the other
side of the defence wall but it
will, of course, have reduced in
intensity due to the extra
distance it has had to travel.
Concertainer unit structures
provide protection against the
effects of weapons by
optimising the mass and
characteristics of the fill
material. Field guides to force
protection normally provide
guidance for the design of
structures in terms of the
thickness of various materials
required against defined threats.
This will generally suffice for
operational structures.
For many applications a single
course of the appropriate size
of HESCO Concertainer is the
most effective solution in
providing a protective structure.
For higher walls, stacking of
units is generally the solution.
A wide variety of stacking
configurations is possible,
particularly as the heights
increase. Experience has led to
3.02
a number of configurations that
have been proven through use,
as well as some guidelines as to
configurations that should be
avoided. This section of the
Construction Guide will provide a
number of proven configurations
as well as guidelines for the
design of larger walls.
Whilst it is possible to build
structures of virtually any height,
experience has led to the
HESCO Construction Guide for Engineers
conclusion that walls higher
than 4.92m (16') require special
care in their design and use of
specialised equipment, which
may not be readily available.
For very large or complex
structures, competent
engineering advice should be
sought as this guide does not
contain sufficient information
for such walls.
 Design of Concertainer structures
Design procedure
The basic design parameters
required in the design of a
wall are:
- the threat expected and what
aspects you want the wall to
mitigate against
- topography
- fill material available
- size, shape, layout and value
of the target to be protected
HESCO Construction Guide for Engineers
- type of Concertainer unit
available (this may be dictated
by those already in theatre)
- available space to build on
3.03
Expected threat
This will be a key determinant
in establishing the minimum
thickness and/or height
required for the wall. This may
range from limited small arms
fire through mortar bombs right
up to very large VBIED. The use
of vehicles to break through the
defence wall should also not be
overlooked. With regard to
attack, the desired mitigating
effects which you wish the wall
to achieve should also not be
overlooked. For instance, do
you want the wall to:
- disrupt the blast wave?
- interrupt primary
fragmentation from the
weapon?
- catch secondary
fragmentation?
- not break up and create
significant secondary
fragmentation?
- mitigate risk?
- eliminate risk?
Design of Concertainer structures
Topography
The lay of the land (topography)
may have a direct impact on
the wall design. In simplistic
terms, if your base or asset that
you must protect is on the top
of a hill then theoretically the
wall need not be as high to
enable it to interrupt both line of
sight and direct line of fire.
Conversely, if the camp is on flat,
level ground or is, indeed, in a
depression, then walls will have
to be much higher to achieve the
same effect.
3.04
Fill material
The fill material available will
influence the thickness of
the wall.
Use of locally available fill is the
usual method for defences built
in the field. In this case an ideal
fill material may not be
immediately available. This may
require an increase in width of
the wall to achieve the same
protective qualities.
HESCO Construction Guide for Engineers
Good fill material must be used
when building structures with
an expected longer service life.
Safety
Care should be taken with
structure design when
using a poor fill material.
Use of poor fill may lead to
instability of the structure.
 Design of Concertainer structures
Target to be protected
The target will dictate the plan
of the structure and the
required height in a number
of ways.
- The layout of the targets.
This may be complex such
as attempting to provide
protection to existing
buildings, or may be much
more straightforward in the
case of an ammunition
HESCO Construction Guide for Engineers
3.05
Footprint available to build on
The height to which the wall can
be built will sometimes be dictated
by how much space you have
available for the wall’s base width.
A wall, for instance, that has a
base width of 2m (6'6") should
not be more than 4m (13') high.
Safety
The height of a wall should

not exceed two times the

compound. base width. For instance,
a wall with a base width
- The size of the target. Length, of 1.5m cannot be taller
depth and height. than 3m.

- The position of the target in

relation to the attacker or
potential site of initiation of a
device. In some cases where
the target is well back from
the possible site of initiation
then multiple walls may be
required to provide the best
protection.
Design of Concertainer structures
Selection of wall configuration
The following pages show
typical structure configurations
designed to protect against
clearly defined threats. It should
be noted that every situation is
unique, therefore the examples
shown are intended only as
a guide.
Concertainer units are grouped
with units of a similar width.
An example of the end of the
structure is given against each
of the specified threats. In many
cases a more substantial
structure is required where the
fill material is deemed to be
poor: clay, snow etc.
The heights of the suggested
structures are for illustration
purposes only. However, the
heights for air delivered bombs
and VBIED walls should be
regarded as the minimum
required. This is due to the
likelihood of a large charge size.
3.06
Heights of all other defensive
structures must be decided
upon by taking into account the
target to be protected,
topography and likely location
of the attacker. For example, a
soldier who requires protection
but must still be able to fire
over his Mil 1 unit protective
structure will only require the
structure to be one unit high;
whereas if you require complete
protection then it must be at
HESCO Construction Guide for Engineers
least two units high.
When constructing higher
structures the height should not
exceed two times the base width.
A Mil 7 unit cannot be stacked
directly on top of another Mil 7
unit. To gain extra height when
using Mil 7, either a pyramid
formation of Mil 7 can be used,
or smaller units should be
used on top of the base Mil 7.
This rule also applies to Mil 1,
Mil 1.9, Mil 6, Mil 10 and
EPW 1 units.
 Design of Concertainer structures
The tables on the following pages
show the structures required to
provide protection against
specific threats. Each table has
been derived from extensive
testing and trials by DERA (UK
MOD) and other leading testing
agencies worldwide.
The inclusion of these tables in
this document does not
suggest that these structures
give guaranteed protection from
HESCO Construction Guide for Engineers
the threats specified.
Further guidance on the use of
these tables can be sought
from HESCO Bastion Ltd.
Safety
A Mil 7 unit cannot be
stacked directly on top of
another Mil 7 unit. To gain
extra height when using
Mil 7 either a pyramid
formation of Mil 7 can be
used or smaller units
should be used on top of
the base Mil 7. This rule
also applies to Mil 1,
Mil 1.9, Mil 6, Mil 10 and
EPW 1 units.
3.07
Note:
RPG7
A 1m thick wall filled with
good quality rock fill will
provide protection from a
RPG 7 warhead. However,
walls filled with all other fill
materials will require a wall of
at least 1.2m to provide
protection.
Artillery
A 1m thick wall filled with
very good/good fill will
provide protection from the
effects of a close-in detonation
of a 155mm artillery round,
but the wall will burst if
subjected to a direct hit.
Air delivered bombs
Users must be aware that
fragments from air delivered
weapons may pass through
the very top layer of the wall
when filled with poor fill
material.
Design of Concertainer structures 3.08

Mil 1 H 1.37m (4'6") W 1.06m (3'6")

EPW 1 H 2.1m (7') W 1.06m (3'6")
Mil 1.9 Load Bearing H 2.74m (9') W 1.06m (3'6")
Threat Very Good Fill/Good Fill Poor Fill
Small arms
Single shot

Burst

HESCO Construction Guide for Engineers

Cannon
HE Volley

AP Volley

RPG7

Grenade
 Design of Concertainer structures 3.09

Mil 1 (continued)
Threat Very Good Fill/Good Fill Poor Fill
Mortars
(up to 120mm)
For mortars larger
than 120mm use
Artillery table

Artillery
Up to 155mm in
contact
HESCO Construction Guide for Engineers

Air delivered
bombs
Designs will give
a high level of
protection against
bombs of up to
2000lbs

Configuration not applicable for EPW 1 and Mil 1.9 Load Bearing unit

VBIED*

*Vehicle Borne
Improvised
Explosive
Devices

Configuration not applicable for EPW 1 and Mil 1.9 Load Bearing unit
Design of Concertainer structures 3.10

Mil 2 H 0.61m (2') W 0.61m (2')

Mil 5 H 0.61m (2') W 0.61m (2')
Mil 6 H 1.68m (5'6") W 0.61m (2')
Threat Very Good Fill/Good Fill Poor Fill

Small arms
Single shot

Burst

HESCO Construction Guide for Engineers

Cannon
HE Volley

AP Volley

RPG7

Grenade
 Design of Concertainer structures 3.11

Mil 2 and Mil 5 (continued)

Threat Very Good Fill/Good Fill Poor Fill
Mortars
(up to 120mm)
For mortars larger
than 120mm use
Artillery table

Artillery
Up to 155mm in
contact
HESCO Construction Guide for Engineers

Air delivered
bombs
Designs will give
a high level of
protection against
bombs of up to
2000lbs.

Configuration not applicable for Mil 6 unit

VBIED*

*Vehicle Borne
Improvised
Explosive
Devices

Configuration not applicable for Mil 6 unit

Design of Concertainer structures 3.12

Mil 3 H 1.0m (3'3") W 1.0m (3'3")

Threat Very Good Fill/Good Fill Poor Fill

Small arms
Single shot

Burst

HESCO Construction Guide for Engineers

Cannon
HE Volley

AP Volley

RPG7

Grenade
 Design of Concertainer structures 3.13

Mil 3 (continued)
Threat Very Good Fill/Good Fill Poor Fill
Mortars
(up to 120mm)
For mortars larger
than 120mm use
Artillery table

Artillery
Up to 155mm in
contact
HESCO Construction Guide for Engineers

Air delivered
bombs
Designs will give
a high level of
protection against
bombs of up to
2000lbs.

VBIED*

*Vehicle Borne
Improvised
Explosive
Devices
Design of Concertainer structures 3.14

Mil 4 H 1.0m (3'3") W 1.5m (5')

Threat Very Good Fill/Good Fill Poor Fill

Small arms
Single shot

Burst

HESCO Construction Guide for Engineers

Cannon
HE Volley

AP Volley

RPG7

Grenade
 Design of Concertainer structures 3.15

Mil 4 (continued)
Threat Very Good Fill/Good Fill Poor Fill
Mortars
(up to 120mm)
For mortars larger
than 120mm use
Artillery table

Artillery
Up to 155mm in
contact
HESCO Construction Guide for Engineers

Air delivered
bombs
Designs will give
a high level of
protection against
bombs of up to
2000lbs.

VBIED*

*Vehicle Borne
Improvised
Explosive
Devices
Design of Concertainer structures 3.16

Mil 7 H 2.21m (7'3") W 2.13m (7')

Threat Very Good Fill/Good Fill Poor Fill

Small arms
Single shot

Burst

HESCO Construction Guide for Engineers

Cannon
HE Volley

AP Volley

RPG7

Grenade
 Design of Concertainer structures 3.17

Mil 7 (continued)
Threat Very Good Fill/Good Fill Poor Fill
Mortars
(up to 120mm)
For mortars larger
than 120mm use
Artillery table

Artillery and
Mortars
(over 82mm)
HESCO Construction Guide for Engineers

Air delivered
bombs
Designs will give
a high level of
protection against
bombs of up to
2000lbs.

VBIED*

*Vehicle Borne
Improvised
Explosive
Devices
Design of Concertainer structures 3.18

Mil 8 H 1.37m (4'6") W 1.22m (4')

Threat Very Good Fill/Good Fill Poor Fill

Small arms
Single shot

Burst

HESCO Construction Guide for Engineers

Cannon
HE Volley

AP Volley

RPG7

Grenade
 Design of Concertainer structures 3.19

Mil 8 (continued)
Threat Very Good Fill/Good Fill Poor Fill
Mortars
(up to 120mm)
For mortars larger
than 120mm use
Artillery table

Artillery
Up to 155mm in
contact
HESCO Construction Guide for Engineers

Air delivered
bombs
Designs will give
a high level of
protection against
bombs of up to
2000lbs.

VBIED*

*Vehicle Borne
Improvised
Explosive
Devices
Design of Concertainer structures 3.20

Mil 9 H 1.0m (3'3") W 0.76m (2'6")

Threat Very Good Fill/Good Fill Poor Fill

Small arms
Single shot

Burst

HESCO Construction Guide for Engineers

Cannon
HE Volley

AP Volley

RPG7

Grenade
 Design of Concertainer structures 3.21

Mil 9 (continued)
Threat Very Good Fill/Good Fill Poor Fill
Mortars
(up to 120mm)
For mortars larger
than 120mm use
Artillery table

Artillery
Up to 155mm in
contact
HESCO Construction Guide for Engineers

Air delivered
bombs
Designs will give
a high level of
protection against
bombs of up to
2000lbs.

VBIED*

*Vehicle Borne
Improvised
Explosive
Devices
Design of Concertainer structures 3.22

Mil 10 H 2.21m (7'3") W 1.52m (5')

Threat Very Good Fill/Good Fill Poor Fill

Small arms
Single shot

Burst

HESCO Construction Guide for Engineers

Cannon
HE Volley

AP Volley

RPG7

Grenade
 Design of Concertainer structures 3.23

Mil 10 (continued)
Threat Very Good Fill/Good Fill Poor Fill
Mortars
(up to 120mm)
For mortars larger
than 120mm use
Artillery table

Artillery
Up to 155mm in
contact
HESCO Construction Guide for Engineers

Air delivered
bombs
Designs will give
a high level of
protection against
bombs of up to
2000lbs.

VBIED*

*Vehicle Borne
Improvised
Explosive
Devices
Design of Concertainer structures
Selection of the pyramid
configuration
Once the three parameters and
the design table are analysed,
the length of the wall, its height
and its minimum thickness will
be known. Once the height and
minimum width of the structure
is decided upon, a configuration
can be designed.
3.24
4.57m (15') wall with a base
width of 2.13m (7'), and a
minimum thickness of 0.76m
(2'6"). This provides excellent
resistance to ballistic and
fragmentation penetration.

For high walls the most

structurally sound design will be

HESCO Construction Guide for Engineers

based on a pyramid configuration.
The uppermost tier must be the
minimum thickness required to
defeat the specified threat.
Upper tiers should not be
higher than the lower tiers and Mil 7, 8 and 9.
ideally should be shouldered in Aircraft revetment kit.
by 300 – 600mm (1' – 2').

Typical pyramid structures Warning

A pyramid of one Mil 1 stacked
on a base of two Mil 1 has
become very common,
particularly for perimeter
protection. This again provides
good resistance to ballistic and
fragmentation penetration.
Designed specifically for aircraft
revetments, a pyramid of Mil 9,
on a Mil 8, on a Mil 7 creates a
The height of the wall must
not exceed two times the
base width. A Mil 1 unit
should not be stacked
directly on top of another.
This wall may become
unstable and collapse
causing serious injury or
loss of life.
 Design of Concertainer structures 3.25

Mil7/Mil 1 perimeter wall Mil 7 wall post attack

HESCO Construction Guide for Engineers

Entry control point Mil 7, 8 and 9 aircraft revetment

Design of Concertainer structures 3.26

When using larger units in a

single course, a substantial
wall can be created very
quickly. This provides excellent
resistance to ballistic and
fragmentation penetration.

HESCO Construction Guide for Engineers

It also provides a substantial
physical barrier.
 Design of Concertainer structures
Vehicle barriers
Concertainer units can be used
in a number of configurations to
form very effective vehicle
control barricades. These walls
range from single cells used
merely to slow and channel
traffic to walls designed and built
to completely exclude vehicles
from entry to certain areas.
Concertainer units have been
tested by various agencies as a
HESCO Construction Guide for Engineers
vehicle barricade. The use that
the barricade is to be put to will
dictate its design.
A common structure built for a
short term vehicle check point
is a 2-cell Mil 1 wall. This is
used to form a serpentine or
chicane and is used only to
channel and slow the vehicles.
It is most commonly used
along with additional 2-cell
sections.
A single 2-cell Mil 1 structure
has been shown to stop a
cargo-carrying goods vehicle
travelling in excess of 35mph
(56kph) in around 10 metres
(32'7") (Figure 1). Where you
wish to stop the vehicle in a
3.27
shorter distance, a more
substantial wall should be built.
A wall of 2 cells backed up by
2 cells has been shown to stop
the same vehicle in a little
over 5m (16'5").
The complete exclusion of a
vehicle from an area such as a
camp, airfield, port or essential
services processing area may
require a much more substantial
wall. This will typically be a
single storey wall of double
thickness or a wall in a 2:1
configuration built from Mil 1
units or 2:2 Mil 3 structure.
Similar configurations to these
have been tested in the US.
The tests were conducted to
K12 standards, which is one of
the highest classifications that
can be awarded in the US for
vehicle barriers. The Mil 1 and
Mil 3 unit have been awarded
K12 Certification.
These configurations will prevent
a cargo-carrying goods vehicle
travelling in excess of 45mph
(72.4kph) from bursting through
into the protected or controlled
area (Figures 2 and 3).
Design of Concertainer structures 3.28
Larger walls have been built and Further details on vehicle
tested to prevent much larger barriers can be provided on
vehicles entering areas. Vehicles request.
as large as 65,000lb (29.48
tonnes) travelling at 50mph
(80kph) have been stopped.

HESCO Construction Guide for Engineers

Figure 1

Figure 2 Figure 3
 Design of Concertainer structures 3.29
Notes
5mm
HESCO Construction Guide for Engineers
4
Fill selection and
characteristics
 Fill selection and characteristics
Selection of fill material
The protective properties of
defence walls built from
Concertainer units are
substantially defined by the
characteristics of the infill
material. Generally, the ideal fill
is a sand/gravel mix. Offering a
high degree of protection with
little incidence of secondary
fragmentation, a sand/gravel
mix is easily handled. Fine
material such as silt and clay
HESCO Construction Guide for Engineers
4.01
Clumps can also damage the
unit during the filling process,
as can large stones and rocks.
Large rocks or stones should
be avoided as they may
become secondary fragmentation
in the event of a large blast.
The table on the following
pages provides a brief outline
on potential fill materials.

makes filling more difficult, as

they do not flow easily from the
buckets of the loading shovels
and, in fact, may tend to clump
causing voids in the structure.
Fill selection and characteristics 4.02
Characteristics of fill material
Fill Material Construction/Structural Stability
Concrete Generally excellent. Foundation
Structural Concrete required for long-term stability.
Lean Concrete
Ground Impregnated
Aggregates
Crushed Rock Generally very good with suitable
Type 1 – Scalping foundation. Stability can be
affected by moisture variations
within the fill material.
Gravel, Sand Generally very good with suitable
foundation. Stability can be
affected by moisture variations
within the fill material.
Clay Generally only suitable for short-term
construction. The moisture content of
the material may significantly influence
performance (increased moisture =
decreased performance).
Organic Matter Generally unsuitable and should only be
Peat used when alternative material
Top Soil unavailable.
Other Materials Only suitable for short-term applications
Ice Concrete (ice bound unless in a permanently cold
Aggregate) environment.
Snow
Fill selection and characteristics
Blast Protection
Generally good unless blast
results in catastrophic failure of
the structure resulting in
dangerous secondary effects.
Generally good. Care should be
taken to avoid inclusion of large
rocks which may form damaging
secondary projectiles.
Generally good. Minimal
contribution to secondary
projectile threat.
Generally not as good as the
materials above.
Generally not as good as the
materials above.
Variable depending on the
nature and quality of material.
4.03
Ballistic Protection
Generally likely to provide the
highest level of protection of
all the materials in this table.
Generally good. Unlikely to
supersede concrete materials,
but generally better than clays.
Similar to crushed rock.
Generally significantly inferior to
materials above. The moisture content
of the material may significantly
affect performance (increased
moisture = decreased performance).
Generally inferior to the materials
above.
Variable depending on the
nature/quality of fill.
Fill selection and characteristics
Selection of fill material
(continued)
The selection of a poor fill
material may be the only
realistic option given operational
or economic considerations;
in this event, trade-offs in
protective capability or service
life will have to be considered.
For example, the use of poor
fill may require a wall of greater
thickness to achieve the desired
level of protection.
As important to the above are
changes to the moisture
content of the fill material or
foundation material after
construction. This may
adversely affect the protection
offered by the wall or its stability
and long-term durability.
These effects may be prevented
by careful selection of fill material,
good compaction and protection
against the ingress of water.
The geotextile used in HESCO
Concertainer is designed to be
permeable to water. This allows
for drainage of the fill material,
should water enter.
4.04
In addition to wet fill having a
lower protection factor, if heavily
saturated the resultant
hydrostatic pressures can cause
large and potentially damaging
lateral forces to be generated. It
is recommended for structures
above 3m (9'10") high that fill
material be selected to contain
a maximum of 10% fines
(material passing a #200 or
75mµ sieve).
HESCO Construction Guide for Engineers
Capping the exposed fill or
otherwise protecting against
saturation is therefore highly
recommended for large
structures, particularly those
that will be in service for an
extended period.
Note: Fine grained soils are
those which have more than
35% by weight of a particle
size smaller than 0.06mm.
These are a problem and
should always be avoided.
 Fill selection and characteristics
Soil and rock in more detail
This guide talks generally about
soil and rock in a number of
areas, particularly with regard to
its protective capabilities. This
small section goes on to
elaborate a little on the
information already provided.
This will enable the HESCO user
to have a better understanding of
the foundation and fill material.
The term soil is used for
HESCO Construction Guide for Engineers
different material types: topsoil,
soil and rock. These can be
broadly defined as follows:
i) Topsoil
Topsoil is the material which is
a mixture of plant material and
weathered mineral debris. It is
generally in a layer between
150 – 300mm (6-12") thick and
is not capable of supporting
engineering structures.
ii) Soil
Soil is the generic term for
loose geological deposits which
are the result of the breakdown
of rock. It can be excavated
without having to rip or blast
the deposits. It will not normally
be found in layers thicker than
4.05
10m. In most cases once
treated (e.g. compacted) it will
be capable of supporting light
engineering structures, such as
Concertainer walls.
iii) Rock
Rocks are a mixture of minerals
which are generally high
strength. They derive this
strength from grains of material
which are cemented together or
from a mixture of interlocking
crystals. Bed rock and crushed
rock are very good at supporting
engineering structures.
The person responsible for the
construction of HESCO
structures has an interest in
these materials, since he must
make decisions based on the
material he is dealing with.
Topsoil
Does this material need to be
removed prior to construction?
What depth is it? Therefore,
how much good soil must he
import to reinforce the
foundation?
Fill selection and characteristics
Soil
Can the local soil be used to
form the foundations and can it
also be used as the fill material
for the HESCO cells? What type
of soil is it? Does the standard
thickness of the HESCO wall
have to be increased due to the
local soil being of a particularly
poor quality? Is the soil going to
become unstable when subjected
to variations in moisture content?
Rock
Given the demands in a tactical
theatre for construction materials,
it is unlikely that there will be
sufficient stocks of crushed rock
readily available for use in the
construction of HESCO walls.
Therefore, the person
responsible for planning the
task must make an assessment
as to which material to use,
based on the logistic effort
required. Large rocks can be
used in the construction of the
foundations but are not suitable
for filling Concertainer units,
unless it is first to be crushed to
a size not exceeding 50mm.
4.06
Soil classification
The materials which form soils
are divided into groups. Each
group contains only soil which
is likely to perform or react in a
similar manner to the other soils
in the same group. This makes
it much easier for the engineer
to predict what the soil group
will do when incorporated into
an engineering structure. This
guide will very briefly explain
how to classify soils. The
HESCO Construction Guide for Engineers
guidance should not be used if
designing other types of long-
term or permanent structures.
Soils are first of all divided into
two groups: coarse-grained and
fine-grained soils. Coarse-
grained soils are those with
particles above 0.06mm in size,
forming at least 65% by weight
of all the material present in the
sample. This material is then
further sub divided into gravels
(particle size 2 – 60mm) and
sands (particle size 0.06 –
2mm). The material type is
normally decided upon by
laboratory testing. This entails
drying samples and then
passing them through a series
of sieves. Soils which have a
 Fill selection and characteristics
similar weight of material
retained on each sieve are said
to be “well graded”; those that
have the majority of the material
retained on either one, two or
three sieves are termed either
“single size”, “poorly graded” or
“gap graded”. The single size
would have all the particles
retained on only one sieve.
A well-graded material is by far
the best for the construction of
HESCO Construction Guide for Engineers
long term structures, since this
has the most efficient means of
achieving mechanical interlock.
The single size, poorly or gap
graded material may still be
useful when working with
Concertainer units, and could be
used in the construction of the
foundations or as a fill material.
The particle size of 0.06mm is
about the smallest size that can
normally be seen by the human
eye. Particles below this size
are either clay or silt, neither of
which is conducive to good
construction. It is highly
recommended that materials
with a fines content of more
than 10% should be avoided
when building long term HESCO
4.07
structures. This material is
extremely sensitive to changes
in moisture content. A change in
moisture content can lead to a
dramatic change in the materials
ability to stand up. A foundation
from this material, which may
have been thought to be sound,
can easily collapse with an
increase in moisture content,
and Concertainer units filled
with this type of material have
been known to fail dramatically.
The following details a procedure
that can be used to determine
the quantity of fines in a sample
of material being considered
for use.
i) Take a sample
- Take a representative sample
of the material that you are
proposing to use.
- Estimate the volume.
ii) Separate the gravel
- Remove all particles larger
than 2mm from the sample.
- Make an estimate of the
volume that you have removed
in percentage terms against
the complete sample, eg 15%.
Fill selection and characteristics
iii) Sedimentation test
- Break up a sample of the soil
without gravel and place it in
a glass container to a depth
of around 25mm.
- Add water to a depth of
130mm and shake it well.
- Allow the sample to settle for
30 seconds and then
measure the depth of the
settled material.
- The proportion that has
settled is sand (0.06mm) and
that which is still in suspension
is fines (clay or silt).
If at this point you believe that
the proposed material has more
than 10% fines then you should
regard it as not suitable for use
as a fill material for a long-term
structure. Nor should it be used
for foundation work.
Ground Bearing Capacity
(GBC) and California Bearing
Ratio (CBR)
A rock or soil which is subjected
to a bearing load within its
capabilities should not show signs
of indentation or collapse after its
initial settlement period. During
4.08
construction this initial settlement
is taken up by compaction.
Each soil or rock has a different
capability with regards to GBC
and CBR. The GBC of an
igneous rock is very high and is
likely to be in the region of
1960KN, with weak clay only
being able to withstand around
40KN.
The moisture content at the
HESCO Construction Guide for Engineers
time of sampling will have a
huge influence on the results
gained on the weaker soil types,
such as sand containing more
than 10% fines. The wetter the
soil is, the lower the reading.
However, do not rely on a high
reading from a dry, weak soil
type as this soil will almost
certainly become wet at
sometime during the life of the
structure, and it will then lose
strength. This may lead to a
collapse of the structure.
The GBC of soils with little or
no stones can be estimated by
means of a cone penetrometer;
this equipment is available
within various engineer units in
 Fill selection and characteristics 4.09
the military and is used by
some civilian organisations.
It will provide a CBR reading
which can then be roughly
translated into a GBC.

The following table very roughly

transfers CBR into GBC; it
should not be used for
technical engineering designs.
The table also attempts to
provide guidance as to what
CBR and GBC is likely to be
HESCO Construction Guide for Engineers

required to support a given

structure.

Required CBR ratings for Concertainer Structures

CBR (%) Approx Typical Concertainer Structure

GBC (t/m2)
1 1.9 Single storey Mil 3

2 3.5 Single storey Mil 1

4 6 1:1 Mil 8 or single storey Mil 7

5 7.5 3:2:1 Mil 1 or Mil 7 Aircraft Revetment Kit

7 10 20ft or 40ft Bunker Kit

11 14 Single EOPS
Fill selection and characteristics 4.10
Notes
5mm

HESCO Construction Guide for Engineers

5
Preconfigured
structures
 Preconfigured structures 5.01
General Concertainer units and the
In addition to the standard required additional components
Concertainer units, HESCO tailored to create protective
Bastion Ltd provides several structures quickly and efficiently.
specialised products designed
to meet a number of
requirements identified by
operational users. A variety of
off-the-shelf sets has been
configured which include
HESCO Construction Guide for Engineers

HESCO Accommodation Bunker (HAB)

Preconfigured structures
Guard post/Sangar
The components of this set
provide a small emplacement
with 0.61m (2') thick walls and
0.45m (1'6") of overhead cover.
Embrasure (firing/observation
port) forms are included in the
set, as are roof joists and
waterproof roofing material.
Guard Post Kit
5.02
The interior space is 1.22m (4')
by 1.8m (6'), with 1.98m (6'6")
of headroom. The complete set
is delivered on a single pallet
weighing 375kg (826lb).
Detailed instructions for the
assembly of the guard post are
supplied with the set.
HESCO Construction Guide for Engineers
 Preconfigured structures
Personnel and material bunkers
Bunker sets have been
developed to utilise 40ft and
20ft ISO containers. Walls are
constructed using reinforced Mil 1
sections of preconfigured
lengths providing a wall
thickness of 1.09m. The roof
design provides 0.61m (2') of
overhead cover. Material
bunkers provide access from
one end of the bunker, while
personnel bunkers provide
HESCO Construction Guide for Engineers
access from both ends.
For personnel bunkers using a
standard sea container, it is
20' Bunker Kit
5.03
highly recommended that an
escape hatch be provided by
cutting a hole in the other end
from the container doors.
Sea containers are not provided
with the sets. Detailed instructions
for the assembly of the bunker
are included with the kit.
The Concertainer units used for
the lower layers of the walls are
specially designed for this
application and therefore have
a higher bearing capacity than
a standard unit.
Preconfigured structures
Containerised bunker kit
A containerised kit has been
developed which offers an
effective means of transporting
all the components required to
construct a bunker. The
specially modified ISO container
has a fully opening side,
facilitating rapid deployment of
all components. The container
also comes complete with a
prefabricated personnel door
and a rear escape hatch, both
5.04
Note: Although ISO containers
are not absolutely necessary
when building bunkers, they
do provide enhanced
protection, by acting as a
spall liner. If properly
ventilated, they provide
excellent environmental
protection to the occupants.

HESCO Construction Guide for Engineers

of which can be opened from
the inside.

A single container can carry the

component parts for an
additional two bunkers (this
does not include the sea
containers for the additional
two bunkers).
HESCO Construction Guide for Engineers Preconfigured structures 5.05

Containerised Bunker Kit

Preconfigured structures
HESCO Accommodation
Bunker (HAB)
HAB has been developed by
HESCO Bastion Ltd as a result
of the ever increasing threat to
deployed personnel from
indirect fire weapons.
The bunker is designed to provide
safe living accommodation for
up to eight persons, giving each
person a space of around 2m
(6'6") square. There is up to
2.16m (7') of headroom inside
the bunker.
HAB will provide protection
from weapons systems up to
and including large mortar
rounds. It has side walls formed
from Mil 6 Concertainer units
and a specifically engineered
roof structure to combat the
effects of indirect fire weapons.
It is provided in kit form and is
delivered in wooden crates.
These crates hold all the
components for the bunker and,
indeed, form part of the structure
themselves. Everything required
is provided in the kit apart from
the fill material.
5.06
A comprehensive tool kit is also
provided to ensure that those
constructing the bunker have
such tools as string lines, tape
measures and spirit levels.
Two bunkers can be built in two
days by one section of soldiers
assisted by a loading shovel.
The bunker can be fitted out for
air conditioning, heating and
other services by using the
factory formed aperture placed
HESCO Construction Guide for Engineers
at one end.
A HAB has a footprint of 12.4m
(40'8") long and 6.2m (20'4")
wide and an overall height of
around 3.5m.
If a larger accommodation unit
is required then HAB can be
joined end to end to form a
longer unit.
Hab is also used for Forward
Aid Posts, dining facilities,
command posts and welfare
facilities.
HESCO Construction Guide for Engineers Preconfigured structures 5.07

HESCO Accomodation Bunker (HAB)

HAB interior
Preconfigured structures
Extended Overhead
Protection System (EOPS)
HESCO Bastion Ltd have
developed a system designated
as the “EOPS”. This system
provides side and overhead
protection for extended widths.
One cabin that can be protected
typically measures in excess of
7m (22'11") wide. EOPS will give
protection from munitions
detonating in contact with the
roof with explosive payloads in
excess of 20kg (it will not provide
protection against munitions
fitted with a delay fuse).
The EOPS typically takes two
and a half days to construct
and is formed from a number of
component parts. The parts that
are supplied by HESCO Bastion
Ltd are the Concertainer units
and the specially manufactured
weight bearing locating cups
which transfer the roof load
onto the container structure.
It is expected that the users will
procure the remainder of the
components consisting of steel
sheet piles, sheet steel etc from
5.08
the local market; they can
though be purchased from
HESCO Bastion Ltd, if required.
The system can also be
adapted to provide overhead
protection for more than one
cabin under a common roof.
This system of having a number
of containers under one
common roof is ideal where a
large linked structure is required
such as a field hospital, large
HESCO Construction Guide for Engineers
command post or dining facility.
Further guidance and advice on
the construction of EOPS can
be obtained from HESCO
Bastion Ltd on application.
Note: The container system
being used must comply with
ISO standards with regard to
load bearing.
HESCO Construction Guide for Engineers Preconfigured structures 5.09

Extended Overhead Protection System (EOPS)

EOPS locating cup

Preconfigured structures
HESCO Lightweight Bunker
Roof (HLBR)
HLBR has been developed by
HESCO Bastion Ltd to provide
a lightweight protective roof
solution in those areas under
threat from IDF weapons.
The HLBR is designed to be
built on existing walls, be they
HESCO, concrete, brick or block
work. The minimum requirements
of the walls are that they must
not be more than 3.3m (10'10")
apart, must have a minimum
bearing area of 0.2m (8") and
must be capable of supporting
the weight of the completed
roof – approximately 25 tonnes
(55,000lb). The HLBR is
designed to provide protection
from large mortar rounds and
has been tested accordingly.
5.10
Each roof is 5m (16'4") long when
built and can be easily extended
by the addition of further kits.
The roof kit is supplied in one
wooden crate and can be
assembled by four men in less
than five hours. Like the HAB,
the roof kit is supplied with a
comprehensive tool kit.
Other preconfigured
structures
In addition to those sets
HESCO Construction Guide for Engineers
developed and configured by
HESCO Bastion, several
preconfigured sets have been
developed by, for example,
Engineer Research and
Development Centre for the
US Army. These kits are generally
similar to those developed by
HESCO Bastion Ltd.
HESCO Construction Guide for Engineers

5mm Notes
Preconfigured structures
5.11
6
Improvised
structures
 Improvised structures
The regular shape of
Concertainer units and the
ability to easily join units using
the provided joining pins
enable the rapid construction
of many different structures.
When designing, care must be
exercised in creating a structure
that is sound. For operational
survivability, the adherence to
good construction practices,
HESCO Construction Guide for Engineers
Improvised guard post
6.01
described earlier, and the
application of appropriate
guidelines, such as those
included in current military
doctrine and training publications,
will result in effective and safe
structures. The US Army field
manual FM 5-103 Survivability
gives design guidelines, for
example.
Improvised structures 6.02

Technical information
appertaining to roof structure
design etc can be provided by
HESCO Bastion Ltd on
application.

HESCO Construction Guide for Engineers

Security position

Improvised bunker
HESCO Construction Guide for Engineers

5mm Notes
Improvised structures
6.03
7
Maintenance
and repair
 Maintenance and repair 7.01

Repair procedure (1)

Repairs to Concertainer
structures may be required as
a result of attack or accidental (2)
mechanical damage. There are
a number of repair techniques
available, with the technique
adopted depending on the
nature and extent of the damage.
In the majority of cases once (4)
repairs have been carried out
the wall will once again be as
(5) (6) (3)
competent as it was before the
HESCO Construction Guide for Engineers

damage occurred.

In general, material required for

repair consists of:

- welded mesh panels (1)

- coils (2)
Repairs may range from minor
- pins (3) repair of torn geotextile to
the repair or replacement of
- geotextile (4)
complete sections of wall.
- hog rings (5) The modular design of the
Concertainer units allows all
- multi-tool (6)
of these repairs to be
completed in an economical
Alternately repair material can and efficient manner.
be gained by cannibalising
parts from unused units.
Maintenance and repair 7.02

Minor repair
It is very rare for a complete unit
or cell to require replacement,
but more common for an
exterior panel to have suffered
some damage. This can be
repaired by the application of
a repair panel or a small section
of panel if cannibalising
materials from unused units.
Typical damage caused by
Measure the size of repair patch a rocket.
required (Figure 1) and decide

HESCO Construction Guide for Engineers

whether to apply a patch over
the damaged area, or apply a
complete panel.
For a small patch
- Secure the left side to the
existing wall by means of a
coil coiled through the patch
and the existing cell panel
(Figure 3).

- Cut an oversize patch from - Place the cut geotextile

the repair panel or behind the welded mesh
cannibalised unit. patch ensuring the 150mm (6")
overlap is folded within the
- Cut two coils to the patch’s
welded mesh patch (Figure 4).
depth (Figure 2).
- Close the welded mesh patch
- Cut a geotextile patch. Leave
over the area of repair, then
a generous overlap – 150mm
wind in the right-hand coil
(6") all round is generally
(Figure 5).
sufficient (Figure 2).
- Refill or top up the fill in the
- Place the welded mesh patch
unit, as necessary.
over the damaged area.
 Maintenance procedure 7.03

Figure 1 Figure 2
HESCO Construction Guide for Engineers

Figure 3 Figure 4

Figure 5
Maintenance and repair 7.04

For a complete panel

Obtain a full size panel to the
correct size, two coils, two
joining pins and a piece of
geotextile 150mm (6") larger on
all sides (Figure 6).

- Fit coils to both sides of the

repair panel (Figure 6).

- Interlink the coil on one side

with the coil of the existing unit
Figure 6
and fit a joining pin (Figure 7).

HESCO Construction Guide for Engineers

- Place the geotextile patch on
inside of the repair panel and
fold in the 150mm (6") overlap
(Figure 8).

- Close the repair panel tight.

Interlink the coil on the
opposite side and fit a pin
(Figure 9).

- Refill the unit to complete the

repair (Figure 10).

Note: It may be necessary to

fit additional coils to increase Figure 7
the length of the repair panel
to enable the coils to be
overlapped and a joining pin
to be fitted.
 Maintenance and repair 7.05

Figure 8 Figure 9
HESCO Construction Guide for Engineers

Figure 10
Maintenance and repair
Complete replacement
The complete replacement of
cells will only normally be
required when a substantial
amount of damage has been
incurred.
- Cut away damaged panels
(Figure 11).
- Remove all loose fill
(Figure 12).
Figure 11
7.06
- Place new cells (Figure 13).
- Insert joining pins and fit hog
rings to secure the new units
(Figure 14).
- Place fill and compact in the
normal manner (Figure 15).
Note: Additional coils may
be required (see note on
page 7.04).
HESCO Construction Guide for Engineers
 Maintenance and repair 7.07

Figure 12 Figure 13
HESCO Construction Guide for Engineers

Figure 15

Figure 14
Maintenance and repair 7.08

Reinforcement
In this technique, new cells are
established alongside the
damaged section (Figure 16).
Where damage has been
incurred in the upper layers of a
multi-layer structure, it may be
necessary to build a buttress
(Figure 17). This is a quick and
efficient repair method but relies
on the availability of ground to
increase the size of the
structure’s footprint.

HESCO Construction Guide for Engineers

Figure 16

Figure 17
 Maintenance and repair
Capping
For structures which are
expected to have a long service
life, are in wind-affected areas
or are adjacent to aircraft
operating surfaces, it is
important that loss of fill
material is prevented. This can
be achieved by a number of
means:
- Fill material should be shaped
and sufficiently compacted to
HESCO Construction Guide for Engineers
allow moisture to run off.
- The structure can be covered
by tarpaulins or other
waterproof membranes.
- A lean mix concrete or
cement bound material can
be used as the final layer.
- Where fine sand has been
used as the bulk fill and is
susceptible to being blown
out by the wind, then a slightly
coarser aggregate can be
used to cap the cells.
7.09
Protection against ultraviolet
radiation
The geotextile used in HESCO
Concertainer is susceptible to
the effects of UV radiation after
a period of prolonged exposure.
The manufacturer of the
geotextile has carried out a raft
of development work. This has
resulted in a geotextile that has
a design life of five years, with
no planned maintenance
required for the first two years.
One of the problems with trying
to predict the effects of UV is
that it varies considerably from
region to region and can, in fact,
differ within the same region.
There are, of course, a number
of other issues which affect the
severity of any degradation that
may occur:
- fill material used in the cells
- orientation of the units to
the sun
- the level of fill within the unit
Maintenance and repair
General advice
Our advice to all users of HESCO
Concertainer units is that if you
believe the material is to be in
service for more than two years
then you should apply a
protective layer. This is the
same principle as applying
termite treatment to a timber
home in the USA.
Protection can be applied at the
two year point, this alleviates
the problem of trying to predict
how long the base or mission
will last when carrying out the
initial build.
7.10
How to protect
There a number of ways to
protect the geotextile from the
effects of UV radiation
generated by the sun:
- the application of a protective
coating, such as UV CAM,
cement slurry or paint
- covering the structure with a
sacrificial layer of material
- the planting of foliage to
HESCO Construction Guide for Engineers
provide shade
- the use of specialist HESCO
units which do not have an
exposed geotextile face
Application of protective
coatings
The application of a protective
coating, such as UV CAM,
cement slurry or, indeed, paint
(water-based emulsion), is likely
to extend the life span of the
geotextile to 10 years or more.
With maintenance, the life is
likely to be much longer.
A sprayer such as a stucco gun
(texture gun) connected to a
7.5 cu ft/m compressor is ideal
 Maintenance and repair 7.11

for the application of UV Cam,

cement slurry or paint. UV Cam,
cement slurry or paint can also
be applied by brush or roller.

UV CAM is supplied in 25 litre

drums. One litre will cover 5m2
(5.98yd2). It can be sourced
direct from HESCO Bastion Ltd.

Cement slurry is simply a

mixture of cement powder and
water. It is mixed to a strength
HESCO Construction Guide for Engineers

of approximately 1:1 but this

can be adjusted to suit
whatever application method is
being used. Sand can also be
added if desired. The unit to be
coated is often wetted prior to
the application of the slurry; this
prevents the slurry from drying
out too quickly.
 5mm

Notes
Maintenance and repair
7.12

HESCO Construction Guide for Engineers

8
Product
technical
information
 Product technical information 8.01

General
The design of the Concertainer
unit is available in a variety of
differing sizes. The range of
sizes provides the force
protection engineer with
flexibility, allowing him to more
easily tailor the wall to provide
the optimum solution for a wide
range of protective requirements.

The following pages provide

basic product specifications to
HESCO Construction Guide for Engineers

be read in conjunction with the

tables at the end of this section.
Product technical information 8.02

Mil 1

Height Width Length Unit Code Stock Number

1.37m 1.06m 10m Mil1B* 5680-99-835-7866
(4'6") (3'6") (32') Mil1G* 5680-99-001-9396
*B=Beige G=Green

HESCO Construction Guide for Engineers

9 cells (1x5, 1x4)

A geotextile-lined unit for general use as an earth-filled gabion. The unit

is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal.

 Product technical information

EPW 1

Height Width Length Unit Code Stock Number

2.1m 1.06m 33m EPW1B Pending
(7') (3'6") (108') EPW1G Pending
HESCO Construction Guide for Engineers

A geotextile-lined unit for general use as an earth-filled gabion. The unit

is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
30 cells (6x5) and flood-protection barriers. The EPW 1 is designed specifically for
rapid erection, reducing exposure of the construction force to hostile fire.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal.

Product technical information 8.03 Product technical information 8.04

Mil 1.9 Load Bearing Unit Mil 2

Height Width Length Unit Code Stock Number Height Width Length Unit Code Stock Number
2.74m 1.06m 3.18m Mil1.9B Pending 0.61m 0.61m 1.22m Mil2B 5680-99-968-1764
(9') (3'6") (10'6") Mil1.9G Pending (2') (2') (4') Mil2G 5680-99-001-9397

HESCO Construction Guide for Engineers

3 cells (1x3) 2 cells (1x2)

A geotextile-lined unit designed specifically for load-bearing applications.

The unit is suitable for filling with earth, sand, gravel, crushed rock
and other granular materials. The unit fulfils a wide range of uses,
including the construction of protective walls and barriers, soil-retaining
and load-bearing structures. The Mil 1.9 Load Bearing Unit is designed to
support a load of 4,000lb per linear foot (5 tonnes per metre). It is therefore
ideal for use in the construction of structures involving overhead loads.
A geotextile-lined unit for general use as an earth-filled gabion. The unit
is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2. All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal. All dimensions nominal.

Product technical information 8.04

Mil 2

Height Width Length Unit Code Stock Number

0.61m 0.61m 1.22m Mil2B 5680-99-968-1764
(2') (2') (4') Mil2G 5680-99-001-9397

HESCO Construction Guide for Engineers

2 cells (1x2)

A geotextile-lined unit for general use as an earth-filled gabion. The unit

is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal.

 Product technical information 8.05

Mil 3

Height Width Length Unit Code Stock Number

1.0m 1.0m 10m Mil3B 5680-99-001-9392
(3'3") (3'3") (32') Mil3G 5680-99-001-9398
HESCO Construction Guide for Engineers

10 cells (2x5)

A geotextile-lined unit for general use as an earth-filled gabion. The unit

is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal.

Product technical information 8.06

Mil 4

Height Width Length Unit Code Stock Number

1.0m 1.5m 10m Mil4B 5680-99-001-9393
(3'3") (5') (32') Mil4G 5680-99-001-9399

HESCO Construction Guide for Engineers

10 cells (2x5)

A geotextile-lined unit for general use as an earth-filled gabion. The unit

is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal.

 Product technical information 8.07

Mil 5

Height Width Length Unit Code Stock Number

0.61m 0.61m 3.05m Mil5B 5680-99-001-9394
(2') (2') (10') Mil5G 5680-99-001-9400
HESCO Construction Guide for Engineers

5 cells (1x5)

A geotextile-lined unit for general use as an earth-filled gabion. The unit

is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal.

Product technical information 8.08

Mil 6

Height Width Length Unit Code Stock Number

1.68m 0.61m 3.05m Mil6B Pending
(5'6") (2') (10') Mil6G Pending

HESCO Construction Guide for Engineers

5 cells (1x5)

A geotextile-lined unit for general use as an earth-filled gabion. The unit

is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers. An ideal unit for protective structures around
tented or other soft-skinned accommodation.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal.

 Product technical information

Mil 7

Height Width Length Unit Code Stock Number

2.21m 2.13m 27.74m Mil7B 5680-99-169-0183
(7'3") (7') (90') Mil7G 5680-99-126-3716
HESCO Construction Guide for Engineers

13 cells (1x5, 2x4)

A geotextile-lined unit for general use as an earth-filled gabion. The unit

is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal.

 Product technical information 8.09 Product technical information 8.10

Mil 8 Mil 9

Height Width Length Unit Code Stock Number Height Width Length Unit Code Stock Number
1.37m 1.22m 10m Mil 8B 5680-99-335-4902 1.0m 0.76m 9.14m Mil 9B 5680-99-563-5949
(4'6") (4') (32') Mil 8G 5680-99-517-3281 (3'3") (2'6") (30') Mil 9G 5680-99-052-0506

HESCO Construction Guide for Engineers

12 cells (2x6)
9 cells (1x5, 1x4)

A geotextile-lined unit for general use as an earth-filled gabion. The unit
is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.
A geotextile-lined unit for general use as an earth-filled gabion. The unit
is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2. All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal. All dimensions nominal.

Product technical information 8.10

Mil 9

Height Width Length Unit Code Stock Number

1.0m 0.76m 9.14m Mil 9B 5680-99-563-5949
(3'3") (2'6") (30') Mil 9G 5680-99-052-0506

HESCO Construction Guide for Engineers

12 cells (2x6)

A geotextile-lined unit for general use as an earth-filled gabion. The unit

is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal.

 Product technical information

Mil 10

Height Width Length Unit Code Stock Number

2.21m 1.52m 30.5m Mil 10B 5680-99-391-0852
(7'3") (5') (95') Mil 10G 5680-99-770-0326
HESCO Construction Guide for Engineers

20 cells (4x5)

A geotextile-lined unit for general use as an earth-filled gabion. The unit

is suitable for filling with earth, sand, gravel, crushed rock and other
granular materials. The unit fulfils a wide range of uses, including the
construction of protective walls and barriers, soil-retaining structures
and flood-protection barriers.

All wires conform to BS 1052. Alu-Zinc coatings are to BS / EN 10244 - 2.

All dimensions nominal.

Product technical information 8.11 Product technical information 8.12

Training units The table below gives technical

HESCO Mil 1, and Mil 3 units data for the geotextile used in
are ideal for training purposes. all HESCO Concertainer
products.
These standard units have
pinned joints on each of the Geotextile technical data
side walls. This allows the filled Property Test Method Typical Value MARV
units to be split by extracting Physical
successive pins, allowing the fill Mass/Unit Area ASTM D5261 220 g/m2 203 g/m2
material to fall away. Thickness ASTM D5199 1.45 mm 1.04 mm
Mechanical
The pins are then replaced, Grab Tensile Strength (md)1 ASTM D4632 756 N 580 N
Grab Tensile Strength (cd)2 ASTM D4632 890 N 710 N
reassembling the units for

HESCO Construction Guide for Engineers

Grab Elongation (md) ASTM D4632 65% 50%
re-use. It is recommended that Grab Elongation (cd) ASTM D4632 70% 50%
a single sized sand gravel is Wide Width Tensile
Strength (md) ASTM D4595 13 kN/m 8 kN/m
used as a fill material. Wide Width Tensile
Strength (cd) ASTM D4595 16 kN/m 12 kN/m
Wide Width Elongation (md) ASTM D4595 50% 35%
Wide Width Elongation (cd) ASTM D4595 50% 35%
Static (CBR) Puncture ASTM D6241 2447 N 2000 N
Hydraulic
Apparent Opening Size (AOS)3 ASTM D4751 0.15 mm 0.21 mm
Permittivity ASTM D4491 2.00 sec-1 1.30 sec-1
Permeability ASTM D4491 0.40 cm/sec 0.24 cm/sec
Water Flow Rate ASTM D4491 6111 l/min/m2 4075 l/min/m2
1
md = machine direction. 2 cd = cross direction.
3
For AOS, smaller numbers are more desirable. The MARV in this case indicates Maximum Average Roll Value.

The values given above are indicative and correspond to average results obtained in our suppliers' laboratories
and in testing institutes. The right is reserved to make changes without notice at any time.
Product technical information 8.12

The table below gives technical

data for the geotextile used in
all HESCO Concertainer
products.

Geotextile technical data

Property Test Method Typical Value MARV

Physical
Mass/Unit Area ASTM D5261 220 g/m2 203 g/m2
Thickness ASTM D5199 1.45 mm 1.04 mm
Mechanical
Grab Tensile Strength (md)1 ASTM D4632 756 N 580 N
Grab Tensile Strength (cd)2 ASTM D4632 890 N 710 N

HESCO Construction Guide for Engineers

Grab Elongation (md) ASTM D4632 65% 50%
Grab Elongation (cd) ASTM D4632 70% 50%
Wide Width Tensile
Strength (md) ASTM D4595 13 kN/m 8 kN/m
Wide Width Tensile
Strength (cd) ASTM D4595 16 kN/m 12 kN/m
Wide Width Elongation (md) ASTM D4595 50% 35%
Wide Width Elongation (cd) ASTM D4595 50% 35%
Static (CBR) Puncture ASTM D6241 2447 N 2000 N
Hydraulic
Apparent Opening Size (AOS)3 ASTM D4751 0.15 mm 0.21 mm
Permittivity ASTM D4491 2.00 sec-1 1.30 sec-1
Permeability ASTM D4491 0.40 cm/sec 0.24 cm/sec
Water Flow Rate ASTM D4491 6111 l/min/m2 4075 l/min/m2
1
md = machine direction. 2 cd = cross direction.
3
For AOS, smaller numbers are more desirable. The MARV in this case indicates Maximum Average Roll Value.

The values given above are indicative and correspond to average results obtained in our suppliers' laboratories
and in testing institutes. The right is reserved to make changes without notice at any time.
 Product technical information 8.13

The table below gives technical Note: All wires conform to

data for the welded mesh used BS 1052. Alu-Zinc coatings
in all HESCO Concertainer are to BS/EN 10244-2.
products.

Welded mesh technical data

Property 3" x 3" x 4mm wire 3" x 3" x 5mm wire

Steel 0.10% Carbon Max 0.10% Carbon Max

Properties Mild Steel Mild Steel
(6.50mm base rod) (5.50mm base rod)

Coating Weight Zinc / Aluminium Zinc / Aluminium

(g/m2) 145 min 145 min

Wire Tensile 540 – 770 540 – 770

HESCO Construction Guide for Engineers

(N/mm2)

Mesh Tensile 70% of Wire tensile 70% of Wire tensile

(N/mm2)

Tolerance
Wire (un-coated) 3.89 / 3.91mm 4.9 / 4.92mm
Wire (coated) 3.92 / 4.00mm 4.92 / 5.00mm
Panel +/- 3mm on length +/- 3mm on length
+/- 3mm on width +/- 3mm on width
+/- 2mm on mesh spacing +/- 2mm on mesh spacing

Panel 39” x 39” +/- 3mm max 87” x 42” +/- 6mm max
Squareness 54” x 21” +/- 3mm max 87” x 60” +/- 6mm max
54” x 42” +/- 5mm max 87” x 30” +/- 6mm max
24” x 24” +/- 3mm max 87” x 84” +/- 8mm max
66” x 24” +/- 3mm max

Panel Flatness 39” x 39” +/- 12mm max 25mm max

54” x 21” +/- 12mm max
54” x 42” +/- 16mm max
24” x 24” +/- 12mm max
66” x 24” +/- 12mm max

Elongation Approx 5% Approx 5%

The values given above are indicative and correspond to average results obtained in our suppliers' laboratories
and in testing institutes. The right is reserved to make changes without notice at any time.
 5mm

Notes
Product technical information
8.14

HESCO Construction Guide for Engineers

9
Trial
information
 Trial information
General
Concertainer units have
undergone a huge array of
testing worldwide. This testing
has been conducted by world-
leading test authorities in the
field of blast mitigation,
containment of blast effects
and force protection.
Weapon systems tested against
HESCO units include:
HESCO Construction Guide for Engineers
- small arms (5.56 – 14.5mm AP)
- cannon (20 – 40mm including
HE, AP and long rod)
- shaped charges (RPG 7 and
RPG 18)
- grenades
- mortars (81, 82 and 120mm)
- artillery (122, 152 and 155mm)
- air delivered bombs
(US Mk 82)
- conventional plastic and
home made explosive bare
charges, including vehicle
borne improvised explosive
devices
- fuel air explosives
9.01
Aim
The aim of this section is to
summarise some of the testing
carried out on Concertainer units,
from the early 1990s to date.
Limitations
The majority of test information
is owned by Military Authorities
and in the case of the British
MOD is still subject to the
Official Secrets Act. Therefore,
some critical data has been
omitted to allow a wider
circulation of this document.
Further information may be
obtained on application.
Testing
The Concertainer unit was first
introduced to the British military
in 1991; it was then subjected
to testing against a wide range
of small arms munitions. These
tests were conducted by the
Defence Research Agency (DRA)
Fortifications section, (UK MOD
research agency) and by the
British Army Infantry Trials
Team. DRA Fortifications is now
part of QinetiQ.
Trial information
Weapons used were:
- shotgun
- 7.62mm, single shot and
general-purpose machine gun
- 0.5" Amour piercing AP,
Soviet 12.7 and 14.5 mm AP
- Rarden 30mm long rod
penetrator cannon
The above tests were against
Concertainer Mil 2 units filled
with a good quality fill material.
None of the rounds achieved
complete penetration of the
Concertainer units. The Mil 2
unit at 600mm (2') thick is the
smallest unit manufactured
by HESCO.
9.02
Concertainer Mil 1 Units were
also tested against .50"
machine gun fired in bursts of
3 – 5 rounds. The cells were
sand filled and no rounds
penetrated.
The Mil 1 unit was also tested
against:
- 81mm mortar
- 155mm HE artillery shell
HESCO Construction Guide for Engineers
- simulated 120mm HESH
round in direct contact
In 1993 HESCO, in conjunction
with the UK MOD, developed a
collective protection system
(COLPRO). This was designed
to provide protection from
close-in detonation of 155mm
artillery shells fitted with super-
quick fuses. The COLPRO
system is made up of a 20ft
ISO container protected by
Concertainer Mil 1 units. Steel
sheet piles, Concertainer Mil 2
units, and 600mm (2') of soil fill
provide overhead protection.
This test proved that the
COLPRO system would prevent
serious casualties even when
 Trial information
the structure was subjected to
a detonation in contact. This
system has subsequently been
used extensively around the
world to provide mortar, bomb
and artillery type shelters. Shells
fitted with a delay fuse will cause
casualties with a direct hit.
1995 saw the US military at
Fort Leonard Wood test
Concertainer units against
155mm artillery shells close into
HESCO Construction Guide for Engineers
the target of a Concertainer Mil 3.
Damage was judged “superficial”.
1997 saw a substantial amount
of testing take place in the US,
UK and Germany.
The UK tested the system
against RPG7. Gravel-filled
Concertainer Mil 1 units will
prevent penetration of RPG7
rounds, but may allow the tail
fin to pass through. At least
1.8m of poor fill material is
required to defeat RPG7.
Concertainer units were tested
in the US at Wright Laboratories,
Tyndall. This testing was against
235lbs of ANFO, this resulted in
9.03
minor damage. The second test
was an Mk 82 bomb, at fairly
short stand-off; this resulted in
superficial damage. The wall
was not breached. The third
and last test was over seven
tonnes of C4 explosive to
simulate a large VBIED.
Concertainer units were one
of three wall systems tested.
Concertainer units fared the
best of the three, generating
no significant secondary
fragmentation. They also far
outshone the other systems
when a cost benefit analysis
was carried out.
The German MOD tested
Concertainer units along with
other gabion systems in 1997.
Weapons systems used were
similar to previous testing. The
results achieved were also
similar to those achieved
elsewhere. The system was also
attacked, in a trial, by anti-tank
grenades and 82mm mortar in
contact. The resulting damage
was judged as “not significant”.
Trial information
The Dutch Trials Agency, TNO
has also conducted trials using
Concertainer units. These
originated with the Dutch
testing the COLPRO system,
achieving similar results as the
UK. The Dutch have also trialled
Concertainer units for
ammunition storage separation
walls. The test consisted of
5011kg of explosives contained
within artillery shells in a 20ft
ISO container. Live detonators
were stored within Container
units adjacent to the donor
charge. The explosive charge
was initiated, which resulted in
severe damage to the adjacent
container units but no
sympathetic detonation of the
acceptor charge occurred. This
has resulted in the Quantity-
Distances being reduced.
Concertainer units were tested
in June 2004 as a vehicle
barrier. The Transport Research
Laboratory conducted this testing
at the request of the UK security
services. Two tests were carried
out, the first with two cells of
Concertainer Mil 1 units filled
9.04
with gravel. A medium sized
truck travelling in excess of
40mph was crashed into the
barrier. The vehicle was
stopped within approximately
11m (36'). The 2nd was against
four cells with gravel. The same
type of vehicle at the same
speed was used. On this
occasion it was stopped within
6m (19'8") and was extensively
damaged. HESCO had long
held the belief that the system
HESCO Construction Guide for Engineers
would be effective against
vehicles but had never had it
tested. These tests confirmed
our confidence in the system for
this application.
A similar test has been
conducted in the USA by Air
Force, Force Protection Battle
Labs – on this occasion, a
similar-sized vehicle, travelling
at approx 50mph. The barrier
was 10m (32') in length with a
double thickness wall of
Concertainer Mil 1 units on the
base and a single Mil 1 unit on
top. This resulted in the vehicle
being stopped in a very short
distance.
 Trial information
Further testing of the ability
of Concertainer units to stop
vehicles was carried out in
December 2004 by the Texas
Transportation Institute. This
testing was carried out to K12
standards. This was the US
standard for crash barrier
testing. The units tested were
the smaller flood-mitigation units.
This has resulted in HESCO
being awarded K12 Certification
for a variety of its units.
HESCO Construction Guide for Engineers
December 2005 saw further
testing of Concertainer units as
a vehicle barrier, this time
against a 65,000lb truck
travelling at 50mph. This has
resulted in HESCO being
awarded H50 certification.
Testing of Concertainer units
has been carried out by firing
107mm rockets and 120mm
mortars into a Concertainer
wall. Mortar rounds have also
been statically detonated in
contact with the HESCO walls.
The Extended Overhead
Protection System (EOPS) has
been tested against contact
9.05
cased charges of C4. All the
charges were placed on the
roof and ranged from 2kg to
30kg. Only the largest charge
caused any damage to the
structure. Pressures measured
inside the protected area were
well below the level which is
perceived to be the threshold
for eardrum damage.
The HESCO Accommodation
Bunker (HAB) has been tested
against indirect fire weapons.
The bunker provides protection
from fragmentation and blast
effects from small, medium and
large mortars. Similar testing
has been conducted on the
HLBR.
Trial information 9.06

Conclusion
The above is a quick summary
of some of the main testing
which has taken place over the
last 15 years, to which we have
been privy. It can be seen from
the above that the system has
been comprehensively tested
and continues to be so.

This level and variety of testing

demonstrates the pedigree of
the system and the number of

HESCO Construction Guide for Engineers

different protective uses it can
be put to.
HESCO Construction Guide for Engineers

5mm Notes
Trial information
9.07
10
Packing and
shipping
 Packing and shipping
Optimum packing for
transportation
While many packaging options
are available, experience has
led to the following optimum
shipping configurations, based
on stacking of units on timber
skids or pallets. Generally these
pallets are then loaded into
shipping containers, loaded on
trailers or airlift pallets, as
appropriate. Units may be
loaded in bulk into containers,
HESCO Construction Guide for Engineers
which would provide for a
greater capacity. However,
loading and unloading would be
more difficult, so the practice is
therefore not recommended.
10.01
Many HESCO units when
packaged accordingly are
capable of being air delivered
by dropping by parachute. The
HAB is also capable of being air
delivered.
The delivery of a number of
types of unit in RAID configuration
provides a reduction in the
logistics burden of supporting
force-protection operations.
Packing and shipping 10.02

Flat-packed individual units dimensions and weights

Unit Height Width Length Weight

Mil 1 0.25m 1.07m 1.37m 148.5kg

(10") (42") (54") (327lb)
EPW 1 0.75m 1.07m 2.1m 840kg
(30") (42") (82") (1851lb)
Mil 1.9 0.10m 2.18m 2.74m 198kg
Load (4") (85") (107") (437lb)
Bearing
Mil 2 0.05m 0.61m 0.61m 10kg
(2") (24") (24") (22lb)

HESCO Construction Guide for Engineers

Mil 3 0.2m 1.0m 1.0m 105kg
(8") (39") (39") (231lb)
Mil 4 0.2m 2.49m 1.0m 160kg
(8") (98") (39") (352lb)
Mil 5 0.11m 0.61m 0.61m 23kg
(4.5") (24") (24") (51lb)
Mil 6 0.22m 0.61m 1.68m 46kg
(8.5") (24") (66") (101lb)
Mil 7 0.72m 2.23m 2.23m 950kg
(28") (91") (91") (2090lb)
Mil 8 0.25m 1.22m 1.37m 155kg
(10") (48") (54") (341lb)
Mil 9 0.3m 0.76m 1.0m 99kg
(12") (30") (39") (218lb)
Mil 10 0.79m 1.66m 2.25m 1050kg
(31") (65") (88") (2310lb)
 Packing and shipping 10.03

Palletised unit dimensions and weights

Units Per Pallet

Pallet Length

13.5m Trailer

40' Container

20' Container
Pallet Weight
Pallet Height

Pallet Width

Pallets per

Pallets per

Pallets per
Unit

Mil 1 7 2.03m 1.14m 1.40m 1060kg 18 16 8

(80") (45") (55") (2332lb)
EPW 1 1 0.84m 2.1m 2.3m 890kg 20 15 6
(33") (83") (90") (1962lb)
Mil 1.9 6 0.80m 2.18m 2.74m 1220kg 12 8 4
Load (32") (85") (107") (2688lb)
HESCO Construction Guide for Engineers

Bearing
Mil 2 120 0.84m 1.90m 2.0m 1220kg 18 12 6
(33") (75") (78") (2684lb)
Mil 3 8 1.78m 1.17m 1.17m 860kg 22 20 10
(70") (46") (46") (1892lb)
Mil 4 8 1.70m 1.04m 2.67m 1313kg 10 8 4
(67") (41") (105") (2889lb)
Mil 5 50 0.84m 1.9m 2.00m 1160kg 18 12 6
(33") (75") (78") (2552lb)
Mil 6 27 0.76m 1.9m 2m 1255kg 18 12 6
(30") (75") (78") (2761lb)
Mil 7 1 0.6m 2.20m 2.30m 980kg 20 15 6
(24") (86") (90") (2156lb)
Mil 8 4 1.5m 1.06m 1.27m 640kg 18 18 8
(59") (42") (50") (1408lb)
Mil 9 7 1.7m 1.1m 1.1m 714kg 20 20 10
(67") (43") (43") (1571lb)
Mil 10 1 0.79m 1.62m 2.35m 1079kg 20 14 6
(31") (64") (92") (2374lb)

Note: Pallet weight includes the units, the pallet and the packaging.
 5mm

Notes
Packing and shipping
10.04

HESCO Construction Guide for Engineers

11
Conversion
tables
 Conversion tables 11.01

The following pages provide

tables of conversions for
common measurement systems,
in both directions.

Caution:
Every care has been taken
to ensure that the conversion
factors are accurate.
However, the conversion
factors contained within this
document are included as a
courtesy and should not be
HESCO Construction Guide for Engineers

relied upon for use in complex

engineering problems.
Conversion tables 11.02

Dimension To Convert Into Multiply by

Length Inches mm 25.4

feet m 0.3048
yards m 0.9144
miles km 1.609
Area square inches cm2 6.452
square feet m2 0.093
square yards m2 0.8361
acres hectares 0.405
square miles km 2
2.590

HESCO Construction Guide for Engineers

Volume cubic feet m3 0.0283
cubic yard m3 0.765
imperial gallons litres 4.5461
US gallons litres 3.7851
Mass ounces g 28.35
pounds (lb) kg 0.4536
hundred weight kg 50.8
ton kg 1.016

Note: Hundred weight are UK long. Ton is UK long.

 Conversion tables 11.03

Dimension To Convert Into Multiply by

Length mm Inches 0.039

m feet 3.28
m yards 1.09
km miles 0.621
Area mm2 square inches 0.0016
m2 square feet 10.764
m2 square yards 1.196
m2 hectares 0.0001
hectares acres 2.47
HESCO Construction Guide for Engineers

km2 square miles 0.386

Volume cm3 cubic inches 0.061
m3 cubic feet 35.31
m3 cubic yard 1.307
cm 3
fluid ounces 0.035
litres m3 0.001
litres imperial gallons 0.2198
litres US gallons 0.264
Mass g ounces 0.035
kg pounds (lb) 2.204
kg hundred weight 0.020
Tonnes ton 0.984

Note: Hundred weight are UK long. Ton is UK long.

Conversion tables 11.04

Dimension To Convert Into Multiply by

Density ton/yard t/m3 1.329

Speed Miles/hour m/s 0.4470
Miles/hour km/hour 1.61
knots m/s 0.5148
Force lb.force (lb.f) N 4.444
Poundal (pdl) N 0.1383
ton force kN 9.964
Pressure lb/ft2 N/m2 47.88
Psi (lb/in )2
kN/m2 6.895

HESCO Construction Guide for Engineers

Ton/ft2 kN/m2 107.2
Ton/in2 N/mm2 15.44
Bar N/mm 2
0.1
atmosphere bar 1.013
PSI (lb/in2) kPa 6.895

Note: Ton is UK long. Standard atmosphere used.

 Conversion tables 11.05

Dimension To Convert Into Multiply by

Density t/m3 ton/yard 0.752

Speed m/s Miles/hour 2.237
km/hour Miles/hour 0.621
m/s knots 1.945
Force N lb.force (lb.f) 0.225
N Poundal (pdl) 7.233
kN ton force 0.1
Pressure N/m2 lb/f2 0.021
kN/m2 Psi (lb/in2) 0.145
HESCO Construction Guide for Engineers

kN/m 2
Ton/ft2 0.009
N/mm2 Ton/in2 0.065
N/mm2 Bar 10
bar atmosphere 0.987
kPa PSI (lb/in )2
0.145

Note: Ton is UK long. Standard atmosphere used.

 5mm

Notes
Conversion tables
11.06

HESCO Construction Guide for Engineers

12
Contacts
 Contacts 12.01

Contact information

Company address
HESCO Bastion Limited
Knowsthorpe Way
Cross Green Industrial Estate
Leeds LS9 0SW
United Kingdom

www.hesco.com

Sales enquiries
For product sales and shipping
HESCO Construction Guide for Engineers

enquiries, please contact:

Email: sales@hesco.com
Tel: +44 113 248 6633
Fax: +44 113 248 3501

Technical enquiries
For specific technical enquiries,
or enquiries about product
training, please contact:
Email: technical@hesco.com
Tel: +44 207 350 5454
Fax: +44 207 350 5455

Marketing enquiries
For marketing materials or to
order more copies of this
document, please contact:
Email: marketing@hesco.com
Tel: +44 207 350 5454
Fax: +44 207 350 5455

Contacts photograph courtesy of US DoD

 5mm

Notes
Contacts
12.02

HESCO Construction Guide for Engineers

HESCO Bastion Ltd
41 Knowsthorpe Way
Cross Green Industrial Estate
Leeds LS9 0SW
United Kingdom

Tel: +44 113 248 6633

Fax: +44 113 248 3501
Email: info@hesco.com
Web: www.hesco.com

Disclaimer
The information contained in this publication
is provided by HESCO Bastion Ltd ('HESCO')
or is derived from sources that HESCO
reasonably believes to be reliable and
accurate or are otherwise expressions of
independent third party opinion. Whilst
HESCO has made reasonable efforts to
ensure the accuracy, completeness and
relevance of such information, any reliance on
it, in whole or in part, is entirely at the risk of
the party using it and it will not rely on such
information in substitution for making all
proper and necessary enquiries from HESCO
or other relevant third parties. The selection,
configuration and installation of any of
HESCO’s products on site is not HESCO’s
responsibility and, HESCO, its directors,
employees, agents, distributors, suppliers or
contractors shall not be liable for any failure
of any of HESCO’s products caused by
improper installation.
At the sole and absolute discretion of
HESCO, the contents of this publication are
subject to change at any time without notice.
Patents
RAID is covered by patent nos. 2445356 (UK)
and 7905685, 7896583, 7789592, 7708501,
7883297, 7891913 (US); and is subject to
application no. 0808420.4 (UK). EPW is
covered by patent nos. 1951963, 2432611 (UK);
and is subject to application no. 12/090,648
(US). HLBR is subject to application nos.
0820411.7 (UK) and 12/937,888 (US).
HAB 1 is covered by patent nos. 2145064,
1992768 (UK) and 7856761 (US); and is
subject to application nos. 0803661.8 (UK)
and 12/595,436 (US) and other international
equivalents.
Trade Marks
HESCO, Concertainer, Mil, RAID and HAB
are registered® trade marks of HESCO
Bastion Ltd.
Quality Standards
HESCO Bastion Ltd manufactures to quality
standards ISO 9001 (1987), BS 5750 Part 1
(1987) and EN 29001 (1987) certificate no.
910654.

HESCO further reserves the right to amend

specifications without notice.

Copyright Notice
Certain material featured in this document is
subject to copyright protection. Any lawful
reproduction of such material is subject to
obtaining prior written permission from
HESCO Bastion Ltd. Any requests for such
permission should be made in writing.

Copyright © HESCO Bastion Ltd 12.07.11