Welded Wire Mesh: Types, Uses, Features and Benefits
Introduction
This article will give detailed information about welded wire mesh.
The article will give details on topics regarding:
What is a welded wire mesh?
Types of welded wire mesh
Benefits and applications of using welded wire mesh
Galvanized wire mesh manufacturing methods
Galvanized steel mesh panel
Types of galvanized steel mesh panels
Applications and benefits of galvanized steel mesh panels
…and much more
Welded Wire Mesh by Banker Wire
Chapter 1: What is Welded Wire Mesh?
Welded wire mesh is a series of wires that are welded where the individual wires cross. The openings of the mesh varies depending on the type of wire used and the function of the mesh. Regardless of size and wire, welded wire mesh is permanent and impossible to deconstruct without using extreme force.
The manufacture of welded wire mesh includes threading spools of wire through a welding machine that is programmed to uniformly weld the many intersections of wire simultaneously, efficiently, and quickly.
Welded wire mesh, or "weldmesh," is produced in rolls or sheets. Thinner wires can be used to produce larger open areas while the mesh remains sturdy and stable. Mild, galvanized, and stainless steels are used to manufacture welded wire mesh.
In construction, mild steel is used for retaining or reinforcing purposes. Fences, security screens, partitions, general storage solutions, machine guards, cages, and aviaries are made of galvanized mild steel. Pre-galvanized wire or hot-dipped wire is used to create galvanized welded mesh. Hot-dipped is preferable for aesthetic reasons because it hides welds.
For usage in food or pharmaceutical production, when hygiene standards must be upheld, or where the end product must withstand environmental conditions without rapidly rusting, stainless steel welded mesh is chosen.
As opposed to the clear opening between wires, as is the case with a woven mesh, the opening for welded mesh is typically measured from the center of one wire to the center of the next wire. Therefore, when buying welded wire mesh, it is required to give as much information as possible about your inquiry, including the material, opening center to center (or clear opening), wire diameter, the needed width x length, and the number of sheets or rolls.
Chapter 2: Types of Welded Wire Mesh
The wide use of welded wire mesh is due to its durability, strength, and ability to be applied to multiple applications but still retain its initial form and shape. The many uses of welded wire mesh include fencing, cages, shelving, and grates, to name a few. For each of the different applications, there is a specific type and kind of welded wire mesh to fit the conditions.
Welded wire fabric is another name for welded wire mesh and is constructed, used, and configured in the same manner as welded wire mesh. It is a prefabricated grid that has longitudinal wires that are precision spaced and welded to cross wires. The intersections of the wires are welded automatically using electric resistance welding.
Square Welded Wire Mesh
With square welded wire mesh, the intersecting wires meet at right angles and are evenly spaced. It is one of the most versatile forms of welded wire mesh and is made from carbon steel and stainless steel.
Rectangular Welded Wire Mesh
Rectangular welded wire mesh is constructed like square welded wire mesh and has wires that intersect at right angles with its wires spaced further apart in one direction. The rectangular design gives the wire mesh greater strength.
PVC Welded Wire Mesh
PVC welded wire mesh is coated with a thin layer of PVC powder for corrosion resistance, which gives the mesh color and shields the underlying metal. Aside from its corrosion resistance, PVC welded wire mesh is age, sunlight, and weather resistant. It is used in farming, building, transportation, and mining to protect structures and workers, house livestock and poultry, and serve as a decorative accent.
Galvanized Welded Wire Mesh
Galvanized welded wire mesh is coated with a protective layer of zinc, which is applied using an electro process or a hot dipping technique. Galvanizing can occur before or after wire mesh is welded and may be delivered for manufacturing coated. Hot dipping of welded wire mesh involves submerging the welded wire mesh in molten zinc that adheres to the surface of the wire sealing and shielding it from rust and corrosion. Electro-galvanizing uses electricity to link zinc to the metal wires.
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
Welded stainless steel wire mesh is made by joining stainless steel at the intersections to make a uniform steel barrier. It gives its users durability and strength. The welded wire mesh made of stainless steel has a consistent appearance. It is among the most widely used types of wire mesh available. Resistance welding links the wires together rather than filler metal, producing a robust, reliable product. It can be reduced to smaller shapes like disks, squares, or rectangles. Stainless steel wire mesh filters are frequently utilized because they last longer and function better because they never react with fluids. It is extensively utilized in transportation, agriculture, mining, horticultural, leisure, and other service industries.
Welded Wire Fencing
Rolls or panels of welded wire fencing are used as fencing. Galvanized and non-galvanized forms are available with the price of non-galvanized being less. Installation is simple, especially when rebuilding a deck. Rolls are produced to order according to customer specifications, require little to no cutting, and can be installed by one to two trained individuals. Wire fence rolls are ideal for applications requiring work crews and expert installers and vast linear footage to cover.
Installation of welded wire fencing requires posts, rings, pliers, and other tools necessary to erect a fence. Panels are built in predetermined forms and sizes to fit the structure, which makes it simple to disassemble and reuse the fencing.
Welded wire fencing is made of thick gauge steel that needs torches to cut through since it cannot be cut using conventional methods. Its steel construction and posts set deep in the ground with cement footings makes welded wire fencing one of the most stable types of fence on the market. It is used in urban, suburban, rural, and industrial settings.
Heavy Welded Wire Mesh
The distinctive feature of heavy welded wire mesh is the diameter of the wires, which is much larger than all other types of welded wire mesh. Heavy welded wire mesh is made from the same materials as traditional welded wire mesh using larger more robust wires. Its strength and durability make it possible to use it as floor reinforcement, wall structure, and construction material.
The properties and characteristics of heavy welded wire mesh vary depending on the type of materials used to produce it. Stainless steel and galvanized heavy wire mesh are resistant to corrosion and are able to withstand extreme conditions.
Leading Manufacturers and Suppliers
Chapter 3: Benefits and Applications of Using Welded Wire Mesh
The major factor that differentiates welded wire mesh from woven wire mesh is the welding process that significantly increases the strength of the wire mesh. Its exceptional strength, endurance, and durability are the properties that make it so popular for use in security measures and the construction of enclosures.
Benefits of Using Welded Wire Mesh
The solid construction of welded wire mesh gives it a wide range of benefits over similar products.
Enhanced site productivity and efficiency with less reliance on on-site labor
Since bending machines bend the material as a single piece, the possibility of incorrect bar bending is decreased.
Adjusting bar size and spacing provides precisely the right reinforcement where needed.
Welding wire mesh may be positioned rather quickly. As a result, slab casting has a shorter cycle time.
It decreases building costs as a result of the increased construction pace.
Designers can achieve efficient stress transmission to concrete with substantially lower crack widths by using thinner bars at closer spacings, leading to better-finished surfaces.
Rolls rather than standard-length bars can be used to make welded wire mesh, reducing waste.
Less site storage space is needed for welded wire mesh.
Cutting and bending in the facility eliminates the requirement for a rebar yard on site.
Compared to bending rebar on the job site, manufacturing is fundamentally safer in the factory.
Quicker time to erect
Eliminates the location of reinforcement
Wire mesh adheres to concrete quite well and stays put when used.
Installation and unloading at the job site are simple.
Applications of Welded Wire Mesh
Other applications for welded wire mesh include construction. For the reinforcing of concrete structures, welded mesh is frequently utilized. In this instance, welded reinforcing mesh is inserted inside poured concrete forms (beneath the slab, the frame foundation slab is poured), increasing the strength of the formed concrete structures.
Building frames: A road-reinforcing mesh grid is welded reinforcing mesh used to reinforce road surfaces or parking lots.
Mesh for masonry: It supports the roadway in coal mines as a supporting mesh.
Chapter 4: Galvanized Wire Mesh Manufacturing Methods
The process for the manufacture of welded wire mesh is the same across all industries. A prefabricated linked grid is welded using electric fusion welding. Parallel longitudinal wires with precision spacing are welded at the intersection of 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.
Hot Dip Galvanization
With hot dip galvanization, the base metal is dipped in a molten zinc pool. Before beginning the process, the base metal is cleaned, physically and chemically, to ensure that the zinc coating will adhere to the base metal and form a high-quality bond. After the cleaning processes, the base metal is fluxed to remove lingering oxides that could have remained after cleaning.
A metallurgical bond is created by dipping the base metal into a heated zinc liquid bath where the zinc and the receiving metal bond. When the metal is removed from the bath, it reacts with oxygen in the air to create a zinc oxide protective layer.
Steps to hot dip galvanization:
Using a sodium hydroxide solution to clean debris off stainless steel, rust and other impurities are removed.
A cleaning chemical made of zinc ammonium chloride is sprayed on the surface to stop oxidation.
A vat of molten zinc is used to dip stainless steel in.
Until the steel achieves the same temperature as the hot zinc, it stays in the vat.
The stainless steel is quickly cooled in a separate tank after being removed.
Electro Galvanizing
Electro galvanizing, also known as electrolytic galvanizing, is a cold procedure that uses an organic solvent, made up of zinc particles that are applied to the surface of the metal. The chemicals react to create a zinc-steel alloy. Once the solvent evaporates, the zinc remains on the metal. During the process of electrolytic galvanizing, zinc ions are electrically reduced to zinc metal and positively placed on the charged metal substrate.
Grain refiners may be used to create a uniform zinc coating. On a roll of sheet metal, electro-galvanizing is normally applied constantly. Lead-silver or other insoluble anodes and electrolytes of zinc sulfates are used in the most typical zinc electrolyte-anode configuration.
Galvanizing stainless steel is an option before and after it is formed into wire mesh. First, the metal is pulled down to the desired diameter before galvanizing. Next, zinc is applied to the individual metal wires, which are weaved or welded into screens. The zinc coating may need to be reapplied if it was burned off during welding at the joints. Pre-woven steel goods are coated with a solvent or dipped into molten zinc when fabrication happens first.
Compared to low-carbon steel, galvanized welded wire mesh offers higher corrosion resistance without the cost of stainless steel. This particular brand of welded wire mesh is intended to construct fences and other infrastructure. For industrial usage, it is also offered in various formats, such as rolls and panels. Various galvanization procedures vary regarding the material utilized, the thickness, and the kinds of processes used.
Chapter 5: Welded Wire Mesh Materials
Welded wire mesh consists of wire strands that are resistance welded where they intersect when woven together. Aside from galvanized steel, there is a wide assortment of wire types that are used to produce welded wire mesh including carbon steel, stainless steel, aluminum, copper, and brass.
Carbon Steel
Carbon steel welded wire mesh is the most common form of wire mesh. It is made of iron with a small amount of carbon. Carbon steel has high tensile strength and is resistant to abrasion from normal wear and abuse. Welded carbon steel wire mesh is used for filtration systems, infill panels, window guards, caging, and security enclosures. It is available in different wire diameters, thicknesses, and finishes, which makes it flexible enough to fit various applications.
Stainless Steel
Stainless steel is well known for its resistance to rust due to its 11.5% chromium content. It is popular in the welded wire mesh industry due to its durability, sturdiness, and resilience to meet the needs of any conditions or environments. When stainless steel’s oxide layer is subjected to impact or force, it self heals such that the portion that has been stressed is not exposed.
Aluminum
Welded aluminum wire mesh is approximately one third the weight of stainless steel welded wire mesh and has the same properties as stainless steel. The main benefit of aluminum as welded wire mesh is its resistance to corrosion, which makes it ideal for use in hostile environments with freezing temperatures, heavy rain, and high winds.
Aside from its obvious positive strength and endurance properties, aluminum welded wire mesh is less expensive than the heavier metals, which makes it applicable to a wider array of projects and uses. It can be treated with a variety of surface treatments to enhance its strength and resistance.
Brass
Brass is an alloy of zinc and copper. Since it is anti-sparking, it is an ideal choice for use with combustible and explosive materials. Brass welded wire mesh has a very pleasing appearance that makes it useful as an architectural and decorative accent. Brass alloys used for welded wire mesh are C230, C260, and C270.
Copper
Welded copper wire mesh has exceptional electrical and thermal conductivity with corrosion resistance. It is used as an architectural accent and marine applications.
Chapter 6: Welded Wire Mesh Panels
Welded wire mesh panels, normally made from galvanized steel, are made using electric welding machines in the same way all other forms of welded wire mesh are produced. The welded wire mesh is galvanized before or after the panels have been welded. The main use for welded wire mesh panels is as security protection and fencing.
Galvanized steel mesh panels have a smooth surface, are corrosion resistant and are more affordable than sheet materials. It is lightweight, simple to install and convenient. Galvanized wire mesh panels are made from steel and stainless steel wire. They are galvanized by an electroplating process, which forms a layer of zinc coating to prevent the mesh from corroding or rusting.
With hot dip galvanizing, the panels are submerged in hot, molten zinc to form a thick zinc coating, which makes it possible to use the panels in tough rugged conditions. At the same time, the electro-galvanized method is more productive and less expensive.
Characteristics of Galvanized Steel Mesh Panels
Excellent durability - resistant to rust and corrosion
Smooth surface
Different gauges and mesh sizes are available.
Easy to install and store due to weight
Exceptional tenacity and flexibility
Applications of Galvanized Mesh Panels
Galvanized mesh panels are widely used in various applications, such as fencing for homes, gardens, sports fields, highways, and bridges, due to their high strength, corrosion resistance, and attractive appearance. Common applications include:
Animal enclosures and caging
Agriculture, gardening, and farm uses
Window gates or screens
Ornamental panels for the infill
Wall and slope retention using gabions
Industrial applications, such as filter systems
Packaging of Welded Wire Mesh Panels
A covering of kraft paper and a layer of plastic film are frequently used for packaging welded wire panels. It seeks to keep the panels dry while being transported and stored. In addition, wooden pallets are positioned between the packages to help secure the panels during shipping. Thus, the panels are safely received.
Price of Galvanized Mesh Panel
Numerous variables affect how much-galvanized steel wire mesh costs. The market offers prices for items ranging from $8 to $20. Size, wire diameter, galvanization technique, zinc coating thickness, packaging cost, shipping, tax, etc., are all factors that affect it.
Chapter 7: General Specification for Welded Wire Mesh
Material
Either stainless steel rebar or galvanized steel rods, which have great corrosion resistance and may be used in moist situations, produce the wires for welded fiber.
The wires comply with IS:432-Pt II/1982, which calls for a characteristic strength of 480 N/mm2 and tensile strength of 570 N/mm2.
Shape and Size
The welded wire fiber is typically found in rectangular and square shapes. The fabric can be produced in lengths up to 3000mm, although widths up to that size are possible. The normal length is 5500mm when delivered in flat sheet form ready to be laid. Otherwise, the fabric can be delivered in rolls at conventional lengths of 15 meters, 30 meters, or 45 meters.
Typically, wires with a diameter of 2 to 12 mm are produced for use in the production of fabric. IS:1566-1982 classifies it, and its long and cross-wire spacings range from 25 to 400 millimeters.
Cutting and Forming
Wire cutters make it simple to cut welded wire fabric. The mesh is bendable to the necessary size and placed down if it is to be used in a stairway.
Lapping and Clearance
Lapping is typically unnecessary because wire fibers are available in any size needed, but if it is required, a minimum of 6 inches of lapping is advised.
Standard procedure calls for 1 to 3 inches to be left between the wire fabric and formwork.
Vibrating
To ensure the mix is evenly dispersed and the fabric is adequately implanted to minimize cracking, vibrating plastic concrete reinforced with welded fiber mesh is advised.
Chapter 8: Welded Wire Fabric In Concrete Benefits and Uses
Benefits of Welded Wire Fabric in Concrete
Higher Design Strength
Welded wire fabric has the same structural behavior as HYSD bars or plain mild steel bars. The welded wires' inherent strength accounts for enhanced strength.
Better Bonding
The peripheral surface area mostly causes concrete bonding. Stress transfer from concrete to steel and vice versa in welded wire fabric is caused by the rigid mechanical connections between welds and cross-wires. Each rigid weld can resist up to 210 N/mm2 to achieve swift and full stress transmission inside two welded joints from the vital section.
Effective Crack Resistance
The two main characteristics of welded wire fiber contributing to the reduction of cracks in concrete are the close spacing of thinner wires and the strong mechanical anchorage at each intersection. The close spacing of the wires most effectively counters the strain-induced stresses brought on by shrinkage and temperature fluctuations. This feature of the welded wire fiber maintains the slab's structural stability.
Economical
The immediate and beneficial labor and time savings are the most evident and compelling benefits of using welded wire fabric. The bars are not chopped, marked, and spaced apart; most importantly, the binding wires are not laboriously tied.
Flexible in Handling and Placing
Welded wire fabric is particularly flexible to handle due to smaller wires. Welded wire fabric offers the best and most practical solution for all types of repair work by replastering due to its availability in considerable lengths in roll form.
Uses of Welded Wire Fabric in Concrete
Construction using structural flat slabs or slabs with beams
Large floor slabs create surfaces with fewer cracks, such as pavement, airport runways, and aprons.
Concrete features with curved or challenging shapes, such as arches, domes, lotus petals, etc., benefit greatly from the flexibility of welded wire cloth and its ready-to-use nature.
Fins or balcony drops are precast parts that are thin or challenging to reinforce. Other examples are:
Curved arch flat members
Hyperbolic paraboloid shells
Folded plate roof girders
Precast RCC and prestressed parts such as wall and slab panels are typically produced in large quantities.
As a bonding fabric when replastering or guniting is necessary for repairs and building rehabilitation
Unstressed shaping or form reinforcement is utilized in the box
I, T, or double T-section prestressed concrete girders
For ferrocement or ferroconcrete projects, the sole option for creating the reinforcing matrix for precast parts like water tanks, fins, shelves, etc., is welded wire fabric.
Applications of Welded Wire Mesh
There have been more recent developments and breakthroughs in welding technology. Remote welders enable increased output and reduced downtime. Manufacturers who offer on-site repairs and modifications are praised for their capacity to respond to the market's shifting demands. These services are in high demand. Each type can be employed according to the need and demand.
Galvanizing can occur before or after wire mesh is created, whether woven or welded. The mesh is submerged in molten zinc once welding or weaving is finished. Zinc adheres to the surface of the wire, completely sealing it off and shielding it from rust and corrosion. A galvanized wire mesh has several different aperture sizes and wire diameters, which is one of its key advantages. It is applied to wire meshes for a range of final product applications. It can be used for safety guards, window grills, security cages, and building enclosures. In addition, it is regarded as a fantastic choice for wants involving general fencing.
Weld mesh is made of tough steel wire electronically welded at every point of contact, creating an incredibly strong and adaptable material. It may be used for various demanding applications because each intersection of steel weld mesh is electronically welded. For example, it is used to make a variety of safety guards and screens since it is almost unbreakable and simple to manufacture.
It is frequently utilized in various sectors, including horticulture, retail, transportation, and agriculture, and has a wide range of indoor and outdoor applications.
Welded mesh has numerous residential uses, including as an affordable fencing material, an impact screen for windows, or a safety cover for drains and open water.
A welded mesh offers a flat surface that maintains a solid structure and can support or protect other objects. Uses for steel mesh, often known as welded wire mesh, include:
Safety covers
Fencing and cages
Stairways and balustrading
Catwalks
Large-scale construction projects
Anti-theft screens
Shelving
Fishing traps
Concrete reinforcement
Chapter 9: Welded Wire Mesh Terminology
When discussing welded wire mesh, there are a few terms that are associated with it that need to be understood in order to clearly describe the types of treatments and style of wire mesh to purchase.
Calendering - Calendering refers to flattening the knuckles of welded wire mesh to give it a smooth surface.
Fill Wire - The fill wire is the wire that runs across the width of the wire and is referred to as the shute wire.
Hardware Cloth - Welded square wire mesh that is lightweight and galvanized after welding.
Market Cloth - Market welded wire mesh is general use welded wire mesh.
Mesh Count - The mesh count is the number of openings per lineal inch measured from the center of wire to center of wire.
Oil Tempered Wire - Oil tempered wire is carbon steel that has been made heat resistant.
Opening - The opening is the distance between parallel wires.
Selvage - Selvage is the looped edges of welded wire mesh.
Space Cloth - Space cloth is a descriptor for welded wire mesh using the opening size and not the mesh count.
Warp Wire - The warp wire runs parallel to the length of the welded wire mesh and is perpendicular to the shute wire.
Weave Pattern - The weave pattern is the pattern that the intertwined welded wires make.
Wire Diameter - Wire diameter is the diameter of the wire being used to manufacture welded wire mesh.
Welded Wire Fence & Mesh vs. Woven Wire Fence & Mesh
Welded Wire Meshes and Fences
What are they?
As the name implies, they are made from wires that have been welded into a mesh.
In most cases, the same gauge of wire is used throughout the roll.
Welded joints are rigid and have little flexibility.
Many welded products with larger openings are used as fencing.
Mesh sizes can range from 1/2" x 1/2" up to 6" x 6".
Meshes with smaller openings are usually made with lighter gauge wires.
These are mostly used as screening.
Some specifications of welded meshes are vinyl coated.
What are their uses?
Welded fencing is ideal to use on flat terrain where little flexibility is necessary.
Some examples of uses:
- Swimming pool fences
- Cages for animals
- Garden fences
- Dog kennels
- Partition dividers
Woven Wire Meshes and Fences
What are they?
Fences made by weaving the wires into a mesh.
Different gauge wires are sometimes used in the same roll.
Woven joints are flexible yet very strong.
There are a wide variety of mesh size openings available.
Hexagonal netting (chicken wire), field and farm fence, deer and wildlife fence, chain link and ornamental fence are some examples.
What are their uses?
Woven wire fences are ideal to use in situations where the ground is uneven.
The inherent flexibility allows the fence to adjust more easily to grade changes.
Some examples of uses:
- Garden fences
- Horse paddocks
- Boundary fence
- Orchard fence
- Farm fence
Basics of Wire Mesh
Introduction
This Article takes an In-depth look at Wire Mesh
You will learn more about topics such as:
Basics of Wire Mesh
Wire Used to Make Wire Mesh
Uses for Wire Mesh
The Benefits of Wire Mesh
Basics of Wire Mesh
Wire mesh is fabricated by the intertwining, weaving, or welding of wires of various thicknesses to create proportionally equal parallel rows and intersecting columns. Also known as wire fabric, wire cloth, or hardware mesh, the production of wire mesh involves the weaving of wire on industrial looms, leaving square or rectangular gaps between the wires. Welded wire mesh or fabric is manufactured using an electric welder that joins parallel longitudinal wires where the wires intersect.
There are a limitless number of shapes, sizes, and configurations of wire mesh made from an assortment of highly durable and resilient materials whose major function is to separate, screen, structure, and shield various applications and processes. The types of wire include galvanized steel, stainless steel, aluminum, steel, and copper alloy wire. The type of application, necessary tensile strength, durability, longevity, and required flexibility are some of the factors used to determine the desired type and style of wire.
How Wire Mesh is Made
The processes used to produce wire mesh are weaving and welding, with wire weaving being similar to the weaving of cloth on a loom, while welding is used to join the wires where they intersect. Both processes are completed using pre-programmed machines.
Wire Weaving
Near the end of the 17th century, woven wire cloth for the mining and pulp industries came into high demand, leading to the development of wire weaving looms. Over the centuries, the use for wire mesh has advanced beyond mines and pulp mills to architecture, plastic extrusion, aggregate screening, and filtration processing. The rise in demand has led to the modern industrial wire weaving industry.
Weaving Loom — Weaving looms weave mesh rolls with widths of 48”, 60”, 72”, 98”, or wider. The loom has a warp beam, heddle frames, a reed, a rapier for transporting weft wire, and a take-up mechanism.
Manufacturers use looms to weave meshes of standard and custom patterns. The completed mesh rolls are cut to varying lengths depending on the needs of customer specifications. Wires woven horizontally or lengthwise are warp wires, while wires woven vertically or crosswise are referred to as weft wires or shute wires, terms commonly used in textile manufacturing.
Warp Beam — The warp beam is a cylindrical drum wrapped with the warp wires. The warp beam's tension must be meticulously controlled to avoid elongation of the woven mesh. The number of warp wires varies depending on the mesh width and must be kept the same length.
Heddle Frames — The heddle frames separate the wires that are fed by the warp beam. Most looms have two heddle frames, with one used to lift half of the warp wires while the other pulls the warp wires down. The heddle frames change position as the weft wires move across the warp wires.
Rapier Band — The weft wires are carried across the full width of the cloth by the rapier at each cycle of the heddle frame. It feeds a single weft wire between the sets of warp wires.
Reed — The reed keeps the warp wires from the warp beam in place and accurately spaced and separated. Once the weft wire moves across the warp wires, the reed beats the weft wires tightly in place in the wire cloth.
Take-Up — The take-up mechanism is a set of rollers that takes the fabric away from the loom with a pickup roller and two other rollers that work together to wind the cloth to the cloth roller. The fabric is wound in single layers with a smooth flat surface created by it being passed through the set of rollers.
Once the loom has been assembled and the warp beam loaded, the weaving process is completed automatically. As the loom begins, the warp beam unwinds in slow, even increments. In unison with the warp beam feeding the warp wire, the take-up mechanism winds the woven completed cloth in the same increments as the warp beam. The synchronized motion helps the loom maintain tension on the warp wires, which is a critical necessity for the production of high-quality cloth.
Welded Wire Mesh
Wire mesh is welded using a semi-automatic process that welds the intersections of the woven wires. Welding machines are programmed to weld the intersections at the horizontal and vertical aligned wires. Several welding techniques are used to join the connections, including resistance welding, tungsten inert gas (TIG) welding, plasma welding, and soldering.
Weld Mesh Machine — The process of wire mesh welding begins with feeding wires into a weld mesh machine, which is much like the heddle frames and reeds of wire weaving.
Wire Spools — Separate spools of wire are fed through a straightener. Pre-cut wires that match the dimensions of the wire mesh are placed separately from the wires fed from the spools. Since the wires are coming off spools, whether pre-cut or fed from them, they are mechanically straightened to lay flat on the welding surface.
Mechanical Placement — The pre-cut wires are laid flat across the wires being fed from the spools. The wires are perpendicular to each other at right angles in mesh welding.
Welding — Once the wires are positioned, the programmed welding process begins and applies a uniform weld at each cross-section.
Process Completion — The collection of the final wire mesh from the welding process can be in rolls, like wire weaving, or sheets that are trimmed to size and placed in piles of wire mesh panels.
Welded mesh is heavier, sturdier, and stronger than woven wire mesh and can only be used with thicker wires that are capable of withstanding the welding process. Since the wire is welded, it is more rigid and durable, which makes it ideal for fencing, cages, and concrete mesh sheets.
Types of Wire Mesh
The different kinds of wire mesh are classified by how they were made, their qualities, function, and weave patterns. Each of the various types is designed to meet the strength, weight, and finish requirements of a project or application. The determining factors regarding the type of wire mesh that will be used are its finish, type of metal, and type of pattern, with finish and metal being the major determining factors.
Welded Wire Mesh
Welded wire mesh has square-shaped wire patterns. The welding process forms a strong mesh, which makes it perfect for security fencing, storage and racking in warehouses, storage lockers, animal holding areas in veterinary clinics and animal shelters, room divisions, and traps for pests.
Welded wire mesh is:
Durable and capable of withstanding changes in weather
Held securely and firmly in place without creep or shifting
Customizable to fit any dimensional needs or specifications
When welded wire mesh is made from stainless steel, it has stainless steel’s durability and corrosion resistance.
Galvanized Wire Mesh
Galvanized wire mesh is made from plain or carbon steel wire that is galvanized, a process that involves applying a zinc coating. The zinc layer acts as a shield that protects the wire mesh against rust and corrosion. Galvanized wire mesh can be welded or woven using galvanized wire or plain steel wire that is galvanized after being woven or welded. Of the two processes, galvanizing the wire mesh after it is processed initially costs more but produces a higher-quality wire mesh.
Galvanized wire mesh is ideal for fencing for agriculture and gardening, greenhouse, architecture, building and construction, security, window guards, and infill panels. Due to its cost, it is one of the more widely used of the different types of wire mesh.
Vinyl-Coated Wire Mesh
The application of a vinyl coating to welded or woven wire mesh creates a strong barrier for very flexible wire mesh. Vinyl-coated wire mesh is stable over a wide range of temperatures, is not degraded by exposure to the sun, and is resistant to scrapes, abrasions, and impact.
The vinyl coating of wire mesh gives the impression that the mesh is made of plastic and is sometimes referred to as plastic mesh. Aside from giving wire mesh an appealing appearance, vinyl-coated wire mesh is long-lasting, durable, and rust- and corrosion-resistant. It seals the wires from water and other intrusive elements.
Welded Steel Bar Gratings
Welded steel bar gratings are produced by forge welding at extremely high temperatures. In this process, perpendicular bars are drawn across a parallel series of rectangular bars, connecting the bars together. The process creates a fused, long-lasting connection that can withstand the most demanding and hazardous conditions. The steel for welded steel bar gratings is carbon steel or stainless steel and is exceptionally durable, strong, and rigid.
Designed to carry heavy workloads for many years, welded steel bar grating is used for landing mats, bridge decking, ventilation grills, ramps, sidewalks, and industrial flooring. Panels are produced in two to three-foot widths in two-foot lengths in a wide range of bar sizes, from 1” to 6” depths and 0.25” up to 0.50” thicknesses.
Stainless Steel Wire Mesh
Stainless steel wire mesh has all of the positive properties of stainless steel and provides high-quality protection and performance. Steel is widely used to produce wire mesh but rusts easily when exposed to the air. Stainless steel, which has the same compounds as steel, has chromium added that is rust-resistant and protects stainless steel from oxidation.
In wire mesh manufacturing, stainless steel is known for its reliability, sturdiness, and durability. The rust resistance of stainless steel makes it adaptable to any outdoor application. It consistently delivers strength and longevity, making it the most popular wire mesh form.
As with all forms of wire mesh, stainless steel can be welded or woven. The grades of stainless steel used to produce wire mesh are 304, 304L, 316, 316L, 321, 347, or 430 in wire diameters ranging from 0.0085 inch (0.216 mm) up to 0.307 inch (7.8 mm). The openings of wire mesh change in accordance with the type of wire mesh. Openings that are less than 0.25 inch (6.35 mm) are classified as wire cloth. Critical factors for wire mesh are the percent of the open area and the weight of the mesh.
Grade 316 stainless steel is a premium alloy that is used for marine applications. It has exceptional corrosion resistance and is not affected by acids, salt water, or seawater, and comes in fine, medium, or coarse sizes. Stainless steel grade 304 is not as corrosion resistant as grade 316 but is exceptionally workable and less expensive than grade 316.
Wire Mesh Patterns
The pattern of wire mesh determines its capacity and how it can be used. There are an endless number of standard weave patterns and customized ones designed to fit a specific application. One distinction between the various patterns is whether the wire is crimped or not crimped, with crimping mechanically changing the contour of the weft or warp wires.
Crimped Wire Mesh
Crimped wire mesh is a square or rectangular weave that is woven using a crimping mesh machine. The processes used to produce crimped wire mesh involve compressing the wire such that the weft wire wraps over the warp wire and the warp wire wraps over the weft wire. The crimping process produces a bending effect on the wires such that they wrap over each other.
Pre-Crimp — Pre-crimped weaves are crimped with small folds or ridges that are added before the wire is woven to increase the strength and rigidity of the wire mesh. The process prevents the weft and warp wires from moving and keeps them secure.
Lock Crimp — Lock crimp is another pre-crimp process that uses the grooves from the crimping process to lock the weave together at the intersections of the weft and warp wires. As with pre-crimping, the final weave is sturdier and immovable.
Inter-Crimp — With inter-crimp, the warp and weft wires are crimped with additional crimps added between the intersections. It is a process used with fine wire with large openings to ensure the weft and warp wires are accurately and properly locked to provide additional rigidity.
Non-Crimped Wire
Non-crimped wire refers to plain wire mesh where the wire mesh is formed by a simple over-under weave of the warp and weft wires. The final product has a simple appearance with a smooth, even surface. Traditionally, non-crimped wire or plain wire has a higher mesh count.
Plain weave wire mesh is the most common of the wire mesh products. Wire mesh that has a 3 x 3 or finer wave has a plain weave pattern. It is commonly used for screening, such as screen doors and window screens.
Double Weave Wire Mesh
Double weave wire mesh is a variation of the pre-crimped weave pattern. In the weaving process, the warp wires pass over and under two weft wires to form a wire mesh pattern capable of withstanding stressful and demanding uses. The double weave wire mesh pattern produces a wire mesh with extra durability for supporting vibrating screens in mining operations and crushers, fences for farming, and screens for barbecue pits.
Flat Top Weave Wire Mesh
Flat top weave has non-crimped warp wires and crimped weft wires that create a sturdy, lockable wire mesh with a flat surface. It has a long abrasive life since no wires project from the top of the mesh to wear. Flat top weave wire mesh has little flow resistance, making it popular for architectural and structural applications requiring a smooth surface. A common application for flat top weaves is for vibrating screens.
Twill Weave Wire Mesh
The twill weave pattern is ideal for weaving heavier and larger diameter wires. The pattern is formed by weaving warp wires over and under two weft wires or where a weft wire passes over and under two warp wires. The warp wire is inverted at the intersections to create a highly stable, rigid, and strong wire mesh. As the pattern develops, it becomes staggered, giving an appearance of parallel diagonal lines.
Twill weave wire mesh can support heavier loads and perform fine filtering. It is a basic component of the production of filters, colanders for aliments, chemical production, shielding, and mosquito nets. For filtering processes, it is made of stainless steel grades 304 and 316 due to their resistance to acids and wear.
Dutch Weave Wire Mesh
Dutch weave is different from plain weave wire mesh and twill weave wire mesh. In dutch weave wire mesh, the weft wires have a different diameter than the warp wires, with the warp wires being coarser to supply greater tensile strength. Weft wires are finer with smaller diameters to enhance filtering performance. The increased strength and finer openings make dutch weave wire mesh popular as a filtering cloth.
The dutch weaving process can be plain or twill, each of which has individual characteristics to fit the needs of different applications.
Plain Dutch Weave Wire Mesh — Plain dutch weave combines the dutch weave process with plain wire weave. Using two different diameter wires, the coarse warp wire passes over and under the weft wire while the weft wire passes over and under the warp wire. The main advantages of plain dutch weave wire mesh are mechanical stability, finer wire openings, and exceptionally high tensile strength.
Twill Dutch Weave Wire Mesh — Twill dutch weave is a combination of regular twill weave and dutch weave. The weft wire alternately passes over and under two warp wires creating a fine mesh in the direction of the warp wire, with the warp wires forming a coarser mesh in the same weave. Twill dutch weave is superior to normal twill weave due to the finer openings and the ability to support heavier loads for filtering applications.
The advantages of twill dutch weave wire mesh are its better filtering potential, tensile strength, the ability to filter exceptionally fine materials, and its stability.
Reverse Dutch Woven Wire Mesh — Reverse dutch woven wire mesh is the same as plain dutch woven wire mesh. The difference between the two weaves is how the weft and warp are woven, with the warp and weft wires being reversed. Thin warp wires are placed close together and woven with thicker weft wires, which creates higher strength in the warp wires. The reverse dutch weave is used in applications that need wire mesh with acoustic properties, mechanical strength, and throughput filtration.
Off Count Wire Mesh
Off count wire mesh refers to wire mesh that does not have the same mesh count in both directions creating a rectangular rather than square mesh pattern. It is used in sifting and sizing operations to increase productivity and also where slight inaccuracies are not an issue.
Stranded Weave Wire Mesh
Stranded weave wire mesh uses small-diameter weft and warp wire bunches that are woven in a plain square pattern. The use of multiple wires creates a twill style pattern that is extremely tight and strong. The tightness and density of the weave are useful in microfiltration cloth.
Mesh Count
The term mesh count refers to one of the most important principles of the wire mesh manufacturing industry. It is in regard to the number of openings per linear inch in wire mesh. The mesh count is determined by counting the number of openings in one linear inch from the center wire of a wire mesh. It is expressed as a single digit, such as no. 4 for a 4 by 4 mesh or no. 20 for a 20 by 20 mesh. The number is an indication of the number of openings in one linear inch.
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