Welded mesh is a bit of an umbrella term for metal-based panels that can be manufactured to a range of specifications. From light mesh to heavy-weight coated mesh, it&#;s important to understand the component aspects of the final product to ensure it will perform as required.
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Welded mesh is an increasingly popular choice for fencing panels where strength, durability and overall performance are valued. Suitable for a wide range of applications, from High security to low-level demarcation, this is an ideal solution for when full through-visibility is needed as part of a robust fencing structure.
Understanding welded mesh
Welded mesh is essentially a series of durable steel wires that are welded together at each intersection.
At Siddall & Hilton, we boast 5 cutting-edge machines that utilize coil-fed cross wires for electric resistance welding onto line wires. Out of these machines, 4 are specifically designed for line wire coils, while the ATT126 machine employs pre-straightened and cut-to-length line wires. This technique results in a flat and rigid panel with either a square or rectangular-shaped mesh with an excellent strength-to-weight ratio. Our machines perform resistance welding to join wires together. For machines using line wires from a coil, a guillotine is utilized to cut panels to the desired length. In contrast, the machine using cut lengths determines the panel length based on the number of line wires used in production.
The resulting structure is extremely robust and as a result, is highly effective as a perimeter solution. There are a number of common types of welded mesh available, including:
Wire gauge and thickness
An indicator of strength and durability; the thicker the wire, the smaller the gauge and the more expensive the product. However, the focus should be on the correct gauge for each specific project as selecting a wire that is too thin can result in a product that is not strong enough to withstand the intended application, while using a wire that is too thick can be unnecessarily expensive.
In fencing and fabrication, the choice of wire gauge depends on the specific requirements of the application. Heavy-duty security fencing, for instance, might use lower gauge wires for added strength and deterrence, while lighter applications or decorative fencing might use higher gauge wires.
It's essential to consider the intended purpose, load-bearing requirements, and environmental conditions when selecting the appropriate steel wire gauge for welded mesh panels in fencing and fabrication projects.
Material type and coatings/finishings
Whether selecting a commonly manufactured specification or something more bespoke, every mesh panel will be produced from good quality metal that will adhere to Internationally recognised standards, minimum level of material and tolerance requirements. The additional coating then begins to offer enhanced protection of the mesh, adding to the longevity and performance of each panel.
Self-colour &#; Simply put this is steel in its raw form. The wire used does not undergo any additional surface treatment or coating after being manufactured. it's important to note that self-colour steel wire is more susceptible to corrosion compared to coated variants. It can be used for concrete reinforcement and for fabrication into other steel structures. You may choose to hot dip to galvanise the panels and integrate them into fencing and gate systems.
Pre-Galvanised &#; Steel wire that has undergone the galvanising process Prior to welding. Pre-galvanised steel wire offers the benefit of slightly enhanced corrosion resistance, particularly when used in combination with polyester powder coating.
Hot dip galvanised &#; This is where we take a completed steel panel and immerse it into a bath of molten zinc, allowing the zinc to bond metallurgically with the steel surface. This zinc coating offers steel panels additional corrosion protection. Want to learn more about the hot Dip galvanising process read our article on 10 reasons you should hot dip galvanise.
Galfan &#; This type of protective coating is a combination of zinc and aluminium, which provides superior corrosion protection to traditional zinc alloy. Read our guide on Galfan coating for more information.
Powder coated - Also known as electrostatic spraying, this process is popular as it creates a thick and durable layer of protection for metal surfaces which is ideal for fencing solutions. In most cases, fencing panels receive triple resistance protection. A pre-galvanised wire is used and is then pre-treated with a phosphate solution (other chemical pre-treatments are available), this helps promote adhesion between the metal and the coating.
We exclusively utilise directly drawn mild steel wire, ensuring a maximum carbon content of 0.1%. When producing wire mesh panels, choosing the appropriate finishes and coatings is crucial. Factors such as the structure's purpose, exposure conditions, expected maintenance, lifespan, and budget all contribute to forming the optimal specification.
Application-specific considerations
The versatility and flexibility of wire mesh panels mean they are used across a wide range of applications.
In the agriculture sector, Profiled wire mesh is a strong, durable and economical option for a range of purposes. It is effective for animal enclosures as part of a post and wire fencing structure or to ensure animal safety in more structured spaces. It can also be used for crop protection and given its strength and durability, is popular for guarding machinery as part of a high-security system.
For high-security projects, such as prisons, military installations and critical infrastructure, the 358 range is the clear choice (358,35duo, 35 superior). These mesh fencing panels are a reliable and high-performing option. With finger and foot-proof anti-climb barriers and anti-cut design, these panels are designed to withstand immense pressure whilst being compatible with most electronic alarm and detection systems.
When it comes to demarcation, Safetop and profiled panels are a cost-conscious yet visually acceptable choice to help with public footflow. Whether being used to create safe walkways, separate areas of specific use or simply create no-go zones for the general public, wire mesh panels can play an important role in defining boundaries.
With its adaptable design and flexible security features, double panels such as 868 and 656 wire mesh panels are ideally suited to the sports and leisure industry. Aesthetically pleasing, low maintenance and available in a range of colours, this kind of fencing system offers excellent visibility whilst still providing a rigid, strong and secure perimeter solution.
Talk to us today about wire mesh solutions
When it comes to perimeter fencing, wire mesh is an excellent choice. It&#;s strong, low-maintenance and cost-effective, as well as being available in a range of sizes and materials. How it will be used is important in defining the characteristics a specific perimeter structure will need, as is the coating and wire gauge.
This guide is intended to help inform you about the different options available to help you make an informed decision as part of your buying process. If you&#;d like to explore how we can help you with your next welded mesh purchase, we&#;d love to talk to you.
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This article will give detailed information about welded wire mesh.
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Welded wire mesh consists of a series of wires welded together at the points where they intersect. The size of the mesh openings can vary based on the type of wire used and the intended function of the mesh. Regardless of the size or type of wire, welded wire mesh is extremely durable and cannot be deconstructed without the application of significant force.
The manufacturing process of welded wire mesh involves threading spools of wire through a welding machine. This machine is programmed to weld the numerous intersections of the wires uniformly, efficiently, and quickly, allowing for simultaneous welding at multiple points.
Welded wire mesh, also known as "weldmesh," is available in rolls or sheets. Thinner wires can be used to create larger open areas while still maintaining the mesh's strength and stability. Welded wire mesh is typically made from mild steel, galvanized steel, or stainless steel.
In construction, mild steel is often used for retaining walls or reinforcing structures. Galvanized mild steel is commonly used for fences, security screens, partitions, general storage solutions, machine guards, cages, and aviaries. The galvanized mesh can be made using pre-galvanized wire or hot-dipped wire, with hot-dipping preferred for its ability to conceal welds and provide a more polished appearance.
Stainless steel welded mesh is preferred in food or pharmaceutical production, where high hygiene standards are essential, or where the product needs to resist environmental conditions without rusting quickly.
Unlike woven mesh, where the opening is the clear space between wires, the opening for welded mesh is typically measured from the center of one wire to the center of the next. Therefore, when purchasing welded wire mesh, it's important to provide detailed information, including the material, center-to-center measurement (or clear opening), wire diameter, the required width and length, and the number of sheets or rolls needed.
Welded wire mesh is widely used due to its durability, strength, and versatility, maintaining its shape and form across various applications. Common uses include fencing, cages, shelving, and grates. Each application requires a specific type of welded wire mesh designed to meet the particular conditions.
Welded wire mesh is also known as welded wire fabric. It is constructed and configured similarly, consisting of a prefabricated grid where longitudinal wires are precisely spaced and welded to cross wires. The intersections of these wires are automatically welded using electric resistance welding.
Square welded wire mesh features intersecting wires that meet at right angles and are evenly spaced. This type of mesh is highly versatile and is commonly made from carbon steel or stainless steel.
Rectangular welded wire mesh is similar to square welded wire mesh, but with wires that intersect at right angles and are spaced further apart in one direction. This rectangular design enhances the mesh's strength.
PVC welded wire mesh is coated with a thin layer of PVC powder to provide corrosion resistance, adding color and protecting the underlying metal. In addition to its resistance to corrosion, PVC welded wire mesh is also resistant to aging, sunlight, and weather. It is used across various industries, including farming, construction, transportation, and mining, to protect structures and workers, house livestock and poultry, and serve as a decorative element.
Galvanized welded wire mesh is coated with a protective layer of zinc to prevent rust and corrosion. This coating can be applied using either an electro-galvanizing process or hot dipping. Hot dipping involves immersing the welded wire mesh in molten zinc, which adheres to the wire's surface and provides a robust shield against rust. Electro-galvanizing, on the other hand, uses electricity to bond zinc to the metal wires. Galvanizing can be done either before or after the wire mesh is welded.
Galvanized wire mesh has different aperture sizes and wire diameters, which is one of its advantages. It is applied to welded wire mesh for a range of applications.
Welded stainless steel wire mesh is created by joining stainless steel wires at their intersections, forming a strong and uniform barrier. Known for its durability and strength, this type of wire mesh offers a consistent appearance and is one of the most popular choices available. The resistance welding process, which fuses the wires without the use of filler metal, results in a robust and reliable product. Welded stainless steel wire mesh can be cut into smaller shapes such as disks, squares, or rectangles. Due to its resistance to reacting with fluids, it is often used in filters and is extensively applied across various industries, including transportation, agriculture, mining, horticulture, and leisure.
Welded wire fencing is available in rolls or panels and can be galvanized or non-galvanized, with non-galvanized options generally being more affordable. Installation is straightforward, particularly when replacing or adding to an existing deck. Custom rolls are made to order based on customer specifications, requiring minimal cutting and can be installed by one or two skilled individuals. Wire fence rolls are especially suited for large-scale projects that need extensive coverage and may involve work crews and expert installers.
To install welded wire fencing, you'll need posts, rings, pliers, and other essential tools. The panels are pre-fabricated in specific shapes and sizes, which allows for easy disassembly and reuse.
Welded wire fencing is made from thick gauge steel, which necessitates the use of torches for cutting, as conventional cutting methods are ineffective. Its robust steel construction, combined with posts set deep in the ground and secured with cement footings, makes welded wire fencing one of the most stable fencing options available. It is suitable for use in urban, suburban, rural, and industrial environments.
Heavy welded wire mesh is distinguished by its significantly larger wire diameter compared to other types of welded wire mesh. Made from the same materials as traditional welded wire mesh but with thicker, more robust wires, it offers enhanced strength and durability. This makes heavy welded wire mesh suitable for use in floor reinforcement, wall structures, and various construction applications.
The properties and characteristics of heavy welded wire mesh depend on the materials used in its production. Stainless steel and galvanized heavy wire mesh, for instance, are both resistant to corrosion and capable of withstanding extreme conditions.
The key difference between welded wire mesh and woven wire mesh is the welding process, which greatly enhances the strength of the mesh. This superior strength, durability, and endurance make welded wire mesh a popular choice for security applications and constructing enclosures.
The robust construction of welded wire mesh offers numerous advantages compared to similar products.
Welded wire mesh is also commonly used in construction for reinforcing concrete structures. In these applications, welded reinforcing mesh is placed within poured concrete forms, such as beneath a slab or within a foundation frame, to enhance the strength and durability of the concrete.
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Building Frames: A road-reinforcing mesh grid is a type of welded reinforcing mesh used to strengthen road surfaces or parking lots.
Mesh for masonry: It supports the roadway in coal mines as a supporting mesh.
The manufacturing process for welded wire mesh is consistent across various industries. It involves creating a prefabricated grid that is welded together using electric fusion welding. In this process, parallel longitudinal wires are precisely spaced and welded at their intersections with cross wires at measured intervals.
Welded wire mesh can be formed into many different shapes. It is made of high strength metals such as carbon steel, galvanized steel, and stainless steel. Special coatings may be added to make the metal surfaces more corrosive and chemical resistant.
In hot dip galvanization, the base metal is immersed in a pool of molten zinc. Before this process begins, the base metal undergoes thorough cleaning, both physically and chemically, to ensure that the zinc coating adheres properly and forms a strong bond. After cleaning, the base metal is treated with flux to remove any remaining oxides and ensure optimal coating quality.
A metallurgical bond is formed when the base metal is dipped into a bath of molten zinc. The zinc bonds with the base metal, and upon removal from the bath, the metal reacts with oxygen in the air to create a protective layer of zinc oxide.
Steps involved in hot dip galvanization:
Electrogalvanizing, or electrolytic galvanizing, is a cold process that involves applying a solution of zinc particles to the metal's surface. The chemicals in the solution react to form a zinc-steel alloy. After the solvent evaporates, a layer of zinc remains on the metal. In this process, zinc ions are electrically reduced and deposited onto the charged metal substrate.
Grain refiners can be employed to ensure a consistent zinc coating. In the continuous process for sheet metal, electro-galvanizing is often used. The most common setup involves lead-silver or other insoluble anodes with electrolytes containing zinc sulfates.
Galvanizing stainless steel Galvanizing can occur either before or after the metal is formed into wire mesh. Initially, the metal is drawn to the desired diameter and then galvanized. Alternatively, the zinc coating is applied to the individual metal wires before they are woven or welded into screens. If the coating is burned off during the welding process, it may need to be reapplied. For pre-woven steel products, the coating is either applied with a solvent or achieved by dipping the mesh into molten zinc during fabrication.
Compared to low-carbon steel, galvanized welded wire mesh provides superior corrosion resistance at a lower cost than stainless steel. This type of welded wire mesh is commonly used for constructing fences and other infrastructure. It is available in different formats, such as rolls and panels, to suit various industrial applications. The galvanization processes differ in terms of materials, thickness, and methods used.
Welded wire mesh is made from wire strands that are resistance welded at their intersections. In addition to galvanized steel, welded wire mesh can be produced using a variety of wire types, including carbon steel, stainless steel, aluminum, copper, and brass.
Carbon steel welded wire mesh is the most commonly used type of wire mesh. It consists of iron with a small amount of carbon, providing high tensile strength and resistance to abrasion from regular use. This type of mesh is used in filtration systems, infill panels, window guards, caging, and security enclosures. It comes in various wire diameters, thicknesses, and finishes, making it adaptable to a wide range of applications.
Stainless steel is renowned for its rust resistance, attributed to its 11.5% chromium content. It is widely used in the welded wire mesh industry for its durability, strength, and ability to withstand various conditions and environments. Stainless steel has a self-healing oxide layer that repairs itself when subjected to impact or stress, preventing the exposed area from corroding.
Welded aluminum wire mesh weighs about one-third as much as stainless steel welded wire mesh but offers similar properties. The primary advantage of aluminum is its resistance to corrosion, making it well-suited for harsh environments with extreme temperatures, heavy rainfall, and high winds.
In addition to its notable strength and durability, aluminum welded wire mesh is more affordable than heavier metals, making it suitable for a wider range of projects and applications. It can also be treated with various surface treatments to further improve its strength and resistance.
Brass, an alloy of zinc and copper, is ideal for use in environments with combustible and explosive materials due to its anti-sparking properties. Brass welded wire mesh is also valued for its attractive appearance, making it a popular choice for architectural and decorative applications. Common brass alloys used in welded wire mesh include C230, C260, and C270.
Welded copper wire mesh offers excellent electrical and thermal conductivity, along with good corrosion resistance. It is commonly used in architectural applications and marine environments.
Welded wire mesh panels, typically made from galvanized steel, are produced using electric welding machines in the same manner as other types of welded wire mesh. These panels are galvanized either before or after welding. The primary applications for welded wire mesh panels are security protection and fencing.
Galvanized steel mesh panels feature a smooth surface, are corrosion-resistant, and are more cost-effective than sheet materials. They are lightweight, easy to install, and convenient to use. Made from steel and stainless steel wire, these panels are galvanized through an electroplating process, which applies a zinc coating to protect the mesh from corrosion and rust.
In hot dip galvanizing, the panels are immersed in molten zinc to create a thick, protective coating, making them suitable for use in harsh, rugged conditions. On the other hand, the electro-galvanizing method is more efficient and cost-effective, providing a thinner zinc layer.
Galvanized mesh panels are commonly utilized in numerous applications because of their strength, resistance to corrosion, and appealing look. They are often used for:
Welded wire panels are commonly packaged with a layer of kraft paper and a plastic film to protect them from moisture during transport and storage. Additionally, wooden pallets are placed between the packages to secure the panels and prevent shifting during shipping, ensuring they arrive safely.
The cost of galvanized steel wire mesh can vary widely, typically ranging from $8 to $20. Several factors influence the price, including the size of the mesh, wire diameter, galvanization method, thickness of the zinc coating, packaging, shipping, and taxes.
Welded wire mesh is typically made from either stainless steel rebar or galvanized steel rods. Both materials offer excellent corrosion resistance and are suitable for use in damp conditions.
The wires adhere to IS:432-Pt II/ standards, which specify a characteristic strength of 480 N/mm² and a tensile strength of 570 N/mm².
Welded wire mesh is usually available in rectangular and square shapes. It can be produced in lengths up to mm, with widths also reaching up to mm. When delivered as flat sheets, the standard length is typically mm. Alternatively, it can be supplied in rolls with conventional lengths of 15 meters, 30 meters, or 45 meters.
Typically, the wires used in the production of welded wire mesh have diameters ranging from 2 to 12 mm. The fabric is classified according to IS:-, with long and cross-wire spacings varying from 25 to 400 millimeters.
Wire cutters make it easy to cut welded wire fabric to the desired size. The mesh is flexible, allowing it to be bent as needed. Once cut, it can be positioned for various applications, such as in stairways.
Lapping is usually not needed since wire fibers come in various sizes. However, if lapping is necessary, it is recommended to overlap by at least 6 inches.
Standard procedure requires leaving a gap of 1 to 3 inches between the wire fabric and the formwork.
To ensure even distribution of the mix and proper embedding of the fabric to reduce cracking, it is recommended to vibrate plastic concrete reinforced with welded wire mesh.
Welded wire fabric provides similar structural performance to HYSD bars or plain mild steel bars, thanks to the inherent strength of the welded wires which enhances its overall durability.
The bonding of concrete primarily occurs through the peripheral surface area. In welded wire fabric, stress is transferred between the concrete and steel through the rigid mechanical connections at the welds and cross-wires. Each rigid weld can withstand up to 210 N/mm², facilitating efficient and complete stress transmission between two welded joints within the critical section.
The primary features of welded wire fiber that help reduce cracks in concrete are the close spacing of the thinner wires and the strong mechanical anchorage at each intersection. The closely spaced wires effectively counteract strain-induced stresses caused by shrinkage and temperature fluctuations. This design ensures the slab's structural stability and minimizes cracking.
The most noticeable and advantageous benefits of using welded wire fabric are the immediate labor and time savings. Unlike traditional methods, there is no need to cut, mark, or space individual bars, and most importantly, binding wires are not manually tied, significantly reducing labor efforts.
Welded wire fabric is especially easy to handle because of its smaller wires. It provides an ideal and practical solution for various repair tasks, including replastering, thanks to its availability in long roll forms.
Recent advancements in welding technology, such as remote welders, have led to increased productivity and reduced downtime. Manufacturers that provide on-site repairs and modifications are highly valued for their ability to adapt to changing market demands. These services are increasingly in demand, with each type of technology used based on specific needs and requirements.
Galvanizing can be done before or after the wire mesh is created, whether it is woven or welded. After the mesh is formed, it is submerged in molten zinc. This process causes the zinc to adhere to the surface of the wire, forming a protective layer that guards against rust and corrosion. One of the key advantages of galvanized wire mesh is its variety of aperture sizes and wire diameters. This versatility allows it to be used in various applications, including safety guards, window grills, security cages, and building enclosures. Additionally, it is an excellent choice for general fencing needs.
Welded mesh is made from durable steel wire that is electronically welded at every point of contact, resulting in an incredibly strong and versatile material. This welding process ensures that each intersection of the steel mesh is securely bonded, making it suitable for a variety of demanding applications. It is commonly used to create safety guards and screens due to its strength and ease of manufacture.
Welded mesh finds applications across various industries, including horticulture, retail, transportation, and agriculture. It is versatile for both indoor and outdoor uses.
In residential settings, welded mesh is often used as an affordable fencing material, an impact screen for windows, or a safety cover for drains and open water.
The flat surface of welded mesh provides structural integrity and can support or protect other objects. Steel mesh, also known as welded wire mesh, is employed for numerous purposes, including
To accurately describe the types of treatments and styles of wire mesh, it's important to understand several key terms associated with welded wire mesh.
Calendering - This process involves flattening the knuckles of welded wire mesh to create a smooth surface.
Fill Wire - Also known as the shute wire, this is the wire that runs across the width of the mesh.
Hardware Cloth - Lightweight welded square wire mesh that is galvanized after welding.
Market Cloth - General use welded wire mesh suitable for a variety of applications.
Mesh Count - The number of openings per linear inch, measured from the center of one wire to the center of the next.
Oil Tempered Wire - Carbon steel wire that has been heat-treated to improve resistance to heat.
Opening - The distance between parallel wires in the mesh.
Selvage - The looped edges of welded wire mesh.
Space Cloth - A term describing welded wire mesh based on the size of the openings rather than the mesh count.
Warp Wire - The wire that runs parallel to the length of the mesh and is perpendicular to the fill wire.
Weave Pattern - The pattern created by the interwoven welded wires.
Wire Diameter - The thickness of the wire used to manufacture the welded wire mesh.
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