WHAT IS WIRE MESH?
Wire mesh, which is also referred to as wire cloth or wire fabric, is an extremely versatile product that has thousands of different applications throughout the world. What makes wire mesh such an adaptable product is that is can be produced in a countless number of specifications. Depending upon manufacturing capabilities, there are almost endless combinations of opening sizes and diameter wires that can be produced, either in a woven or welded construction.
Wire mesh is commonly used in industrial applications when separation or filtration is needed; it is also popular for use in commercial applications, like insect screening or animal fencing. More widespread applications for wire mesh include: various types of security mesh, like window, machine and stairwell panel guards, fireplace screen, bird screen, gutter guards, ventilation and RFI shielding. More recently, wire mesh has emerged into the architectural field and the art scene.
this material can be used for a variety of applications. Some of these applications include:
• Major league sports stadiums
• College and university facilities
• Power plants
• Postal facilities
• Military installations
• Chemical plants
Different kinds of wire mesh: Woven a nd We lded
Welded Wire Mesh
Welded wire mesh is constructed with two orthogonal wires that are joined together at their intersections using a resistance welding process to form a grid. The line wires of the grid are
guided through the welder using a pattern board. The machine drops cross wires into place and fuses them together to create the two distinctive planes that form welded wire mesh.
At Banker Wire we currently utilize six fully automated CNC grid welding machines and two CNC jig welders that allow us to produce to your exact specifications. Sheet sizes can be up to 132” wide and 240” long (dependent on mesh spacing). Wire spacing and diameter configurations are nearly endless, allowing us to be the top manufacturing partner for custom welded wire mesh.
Below in the next several sections of this page, you will find more detailed information on the basics of welded wire mesh and topics to take into consideration when ordering your specifications. Our knowledgeable staff is available to assist you with any questions you may have.
Also referred to as welded wire fabric, or simply “weldmesh”, welded wire mesh is a prefabricated grid of low carbon or stainless steel wires. These are welded together at each intersection, providing a highly durable and uniformly structured material suitable for a variety of applications.
Weldmesh Steel wires come in an assortment of thicknesses, and depending on the size of the wires themselves as well as the openings between them, the resulting mesh may be sold in either rolls or flat panels. The openings themselves may be square or (oblong) rectangular in form.
COMMON USES FOR WELDMESH
You’ll find welded wire mesh in a variety of industries, from agriculture and horticulture to transportation, mining, and construction. Here are just a few of the most common uses:
Thicker instances of welded wire mesh can make a good internal framework for reinforced concrete structures. This addition provides substantially increased tensile strength to a material that is otherwise quite vulnerable to cracking under the forces of vibration, twisting, and warping.
Those looking for a relatively cheap security solution that’s tougher than chain link and still allows visibility will often turn to welded wire mesh. Application sites range from lower-security prisons and military installations to private offices and residences. It may even be placed within factories and other industrial buildings as a guard material surrounding heavy machinery.
A perfect combination of strength, low cost, and ease of installation makes welded wire mesh a popular choice for grating roads – especially providing ventilation for subway systems – and for covering street-side drains.
Welded wire mesh is available in multiple colors and coatings, and can in fact make for a visually appealing framework for trellises, flowerbed enclosures, and birdcages – among others. Some find it a perfect fit for elevating plants above the ground, or for shelving in garden sheds, closets, and even retail stores.
woven wire mesh
Woven wire cloth, also known as woven wire mesh, is woven on looms, a process that is similar to the one used to weave clothing. The mesh can consist of various crimping patterns for the interlocking segments. This interlocking method, which entails the precise arrangement of the wires over and under one another prior to crimping them into place, creates a product that’s strong and reliable. The high-precision manufacturing process makes woven wire cloth more labor-intensive to produce therefore it is typically the more expensive than welded wire mesh.
WOVEN WIRE WEAVE STYLES STYLES
Plain Square Woven Wire
The most common wire weave, with the same diameter warp and shute wires, woven in a simple over and under pattern. This style produces screens with the same mesh count in both directions.
Twill Square Woven Wire
Each shute wire typically passes over two warp wires and under two producing square openings. Twill weave can be made from larger-diameter wires than would be possible in plain square weave, to obtain greater strength, density, or corrosion resistance.
Plain Dutch Woven Wire
This weave style is woven in a plain, over and under pattern. The plain dutch woven wire style is a very tight weave because a thinner, smaller diameter shute wire is used. Dutch weaves do not have a straight-through, clear opening like most plain weave styles. Instead, the weave style creates a tortuous path through which very fine filtration and particle retention can be achieved. Dutch weaves may be specified by a “mesh count” or an “absolute filter rating.”
Reverse Dutch Weave Wire
This weave style is the same weave as Plain Dutch, except the warp and shute wires are reversed. The larger shute wires are woven closer together than would usually be seen in a Plain Dutch weave.
Rectangular or “Off-Count” Weave Wire
This is a Plain weave wire cloth, woven in an over and under pattern with a different number of wires in the warp and shute direction, which yields a rectangular opening wire cloth. Rectangular openings are often used in sifting and sizing operations to increase product “through” capacity, with minor sacrifices in accuracy. To reduce material costs, off-count wire mesh may be substituted for square wire mesh in some applications that do not require a high level of accuracy. Some wire cloth vendors will substitute off-count wire cloth when certifications are not specified by the manufacturer. For example, a 90 x 100 mesh may be substituted for 100 x 100.
Stranded Weave Wire
Usually woven in the Plain Square style, each warp and shute “wire” is composed of a “bunch” or “group” of small-diameter wires, which are woven into a finished product.
Welded Wire Mesh Manufacturing Process
Welded Wire Mesh Manufacturing Process, include galvanize welded wire mesh and vinyl coated welded wire mesh production processing.
The raw material used for product material is of low carbon steel from various steel manufacturers, commonly known as wire rods. The raw material grades are SAE 1008, SAE 1010, and SAE 1012 which has a percentage of carbon in the range of 0.08 to 0.12. Stainless steel wire, iron wire, galvanized wire is the ideal raw materials.
Cold rolling is a metal working process in which metal is deformed by passing it through rollers at a temperature below Recrystallisation temperature. Cold rolling increases the yield strength and hardness of a metal by introducing defects into the metals crystal structure. These defects prevent further slip and can reduce the grain size of the metal.
Straightening & Cutting
Specialized machinery from Italy is utilised for straightening and cutting process. The cold rolled wire rods in the coil form is passed through preset die and cartridge units (special sets for different diameter wire rods) present in the straightening and cutting machine, where the wire rods are first straightened and then cut to set length (precision up to 2mm) automatically. The wire rods can be cut to any size ranging from 0.8 Metre to 12 Metre with a max tolerance of 2mm.
Welded wire steel fabric is manufactured with automatic welding machines, where wires are welded together in square or rectangular grids. The wires are welded by electric resistance in an automated state of the art machine which controls welding parameters precisely. All the settings for dimensions and welding are programmable. The weld is formed by a controlled combination of pressure, intensity and duration of electric current to develop fusion of the wires. Welded steel fabric utilizes welded intersections for bond and anchorage.
Bending & Cutting
Two separate machines from Schnell, Italy are available for cutting and bending operation. The cutting machine is utilised for cutting the finished meshes to desired dimension. It is a motorised unit, capable of cutting meshes at a speed of 2 to 3 cut per second. The bending machine available is used to bend the cut meshes to the required shape (as required by design). The machine is capable of bending sheet to any angle (Up to 180o). Depending upon the design requirements, the sheets requiring cutting and bending will be taken for this operation else the meshes will be directly taken for despatch from the third process.
After the Bending and Cutting process comes the final stage in manufacturing process, galvanizing or PVC coating.
Woven or Welded Wire Mesh
It is a metal strand or wire that is knitted together that creates a mesh structure. Despite the different materials, they aren’t too dissimilar from stockings and sweaters. There is a difference between woven mesh and knitted mesh. The main difference is that when you knit, you create interlocking loops that are able to move relative to each other. They are able to move without distorting the overall shape and structure of the mesh. When you weave something there is stronger connections between wires, which doesn’t allow for distorting. Ultimately, the main difference between the two is the knitted mesh is substantially more flexible, and this is because of an interlocking loop structure.
This doesn’t mean that knitted mesh is unbreakable because it is. If you distort the material past its yield point, then your material won’t return to its original shape.
Different types of mesh wires can be created and used, and that includes non-hardenable types, hardenable types, nominal chemical composition nickel alloys, and austenitic types. These are just some of the most popular alloy specifications, but different types of mesh wire can be made.
Knitted mesh wire is very strong and durable, but that is only one of the benefits of the material. There is a good deal of practical application when it comes to these materials. It is an extremely vestal product. It is used for air filtration, vibration dampening, EMI shielding, RFI shielding, mist elimination, and even gaskets and sealing.
Welded stainless steel mesh is a certain kind of mesh that is used primarily in the fencing industry. It can be purchased with and without galvanization, but buying without is cheaper.
Electro galvanized welded with mesh has a square opening. This particular type of wire mesh was made for infrastructural projects. This type of mesh is resistant to corrosion, and is used rather often in the construction industry. It comes in different forms: one is roll and one is a panel.
The creation of wire mesh has allowed for many industries to do amazing and important work. Companies that use these products need specialized knitted wire mesh that is made to do a particular job. If you need to find out more information about wire me, call a local company and talk to an engineer about your different options.
Woven or Welded Wire Mesh Which one is better?
There are two different ways to manufacture wire mesh. Either the wires are woven over and under, or welded permanently together. But which is best for your project? Woven or Welded wire mesh?
Each type of wire mesh has its own benefits, but each are more suited to specific applications.
1. Woven or Welded Wire Mesh: Flexibility
Woven wire mesh is created by weaving longitudinal and transverse wires together, to create tension. It involves minimal welding, resulting in a pliable mesh that can bend without breaking. Because of its flexibility, it’s an ideal mesh solution for applications where the mesh is likely to be affected by external forces, such as ventilation, animal fencing and insect screenings. Or for artistic and architectural uses, thanks to its ability to conform to contours. In comparison, welded wire mesh tends to be more rigid and inflexible.
2. Woven or Welded Wire Mesh: Strength
Both Woven and Welded wire mesh are strong and durable, but Welded wire mesh is superior in strength because of the resistance welding at each overlapping joint. As a result, larger uniform opening sizes can be achieved, making Welded Wire Mesh a good choice for applications with heavier demands, such as security screening and load-bearing industrial applications.
3. Woven or Welded Wire Mesh: Materials and wire sizes
Woven and Welded Wire Mesh are available in both 304 and 316 grade stainless steel, for applications where corrosion resistance is crucial. But woven wire mesh is also available in brass, making it a preferred choice for projects where aesthetic appearance is paramount. Woven wire mesh wire sizes can also be much finer, down to 0.06mm wire diameter and less, and ranging up to 3mm diameter and greater. Welded wire mesh wire is generally thicker, from 0.8mm up to 8mm. Custom wire mesh profiles can be manufactured for both types however, dependent upon material availability.