How To Build a Gabion Grilling Station
Get step-by-step instructions to emulate the one-of-a-kind grill station from DIY Network Ultimate Retreat 2017 at your home by varying the wire cage style and rock choices.
Getting Started
Gabion literally means “big cage” in Italian. The combination of wire cages filled with rock have been used for centuries in earth work, flood walls, and other barriers. Because DIY Network's Ultimate Retreat 2017 was perched high on exposed red rock, we decided playing off that topography was a perfect way to integrate a grilling area.
What You'll Need
Materials: 1 pallet of stone, (8) 8” CMU blocks, (8) bags type-S mortar, (2) 4' pieces of #4 rebar, (3) sheets of 4x4 welded wire mesh, (1) box rebar ties, (2) 10' 1x6 T&G cedar, (1) charcoal grill, and 6 CF crusher run stone
Tools: Masonry saw, angle grinder, rebar wire tie, mortar tray, shovel, hand tamp, hammer drill, and rubber mallet
Time: 8 hrs
Cost: $500
Step One
Start by making a plan. This will help you greatly in purchasing the right amount of materials and working out the sizing requirements. Because of the type of wire mesh we used, it was also helpful to work the sizing in 4” increments to coincide with the grid.
Step Two
Source your materials. In our case, we found a great deal on local Green Mountain granite at our stone supply. There are many variations on gabion yard projects so feel free to use other types of wire and stone. Since our stone was rectilinear, we did not need cross ties. If you used round rocks, like river rock, you would need to add wire cross braces to hold the sides in. The 4” welded wire mesh was purchased a local concrete supplier along with some of the other tools and materials.
Step Three
Next, clear and flatten the area of the grilling station. You will want the stone and wire to sit on subgrade, so dig out any top soil.
Step Four
In our case, we were building on a hill so vertical rebar is added to prevent shifting and over turn. We drilled in (2) 1/2” holes for #4 rebar.
Step Five
Layout the rebar locations to coincide with the 8” block cores.
Step Six
Stone weighs a lot so make sure you have a good stable subbase. Install 4” of crusher run gravel in the area of removed topsoil.
Step Seven
Hand tamp it into place to ensure it is fully compacted. For larger areas, you can also rent a gas powered plate compactor.
Step Eight
Set the first courses of 8” CMU down over the rebar and check the spacing to your drawing.
Step Nine
Tamp the blocks in place with a mallet.
Step Ten
Check for level across the blocks.
Step Eleven
Next, trim the wire sheets to form the sides of the cages with an angle grinder. We designed our grilling station to work to the 4” increments of the wire and made it a U shape to tie the base together and give a place to set charcoal and accessories.
Step Twelve
Stand the sides in place.
Step Thirteen
Tie the corners together with rebar ties 4” on center.
Step Fourteen
Continue assembling the cages.
Step Fifteen
Fill the cores of the CMU block solid with block fill or Type S mortar. Be sure to pack it in tight around the rebar. Then start prepping for the stone infill and adjust the wire one last time.
Step Sixteen
Start infilling the rock. Choose pieces that fit in each area similar to a puzzle. For larger rock, like ours, it will be necessary to trim the end pieces with a masonry cut off saw.
Step Seventeen
Tamp pieces into place to make sure the rock is well consolidated. For round rocks, this is less necessary as they will self settle.
Step Eighteen
We bought a charcoal grill and base but only assembled the side brackets. These brackets normally hold the side surfaces so we mounted them upside down to give a good support on the rock fill. Measure the distance between these.
Step Nineteen
Trim out the wire where the side bracket will sit.
Step Twenty
Finish the rock around the grill.
Top It With a Custom Counter
To counterbalance the strong stone and metal base, we made a cedar wood cap which softens the look and gives a good food prep surface. Yard projects don't have to be super expensive. For only $500 and a day's work, we created this custom gabion grilling station and you could too.
