What is Wire Mesh?

Wire mesh is a common type of metal screen consisting of parallel rows and intersecting columns of wire. Although similar in appearance and their applications, perforated metal sheet and expanded metal sheet are not types of wire mesh. Wire mesh comes in an almost limitless amount of shapes and sizes, and a large variety of materials and metal alloys.

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How is Wire Mesh Made?

The intersecting wires are typically joined together by welding or weaving – two of the more common forms of wire mesh. The solid wire used is usually made by progressively drawing down a metal in a series of round dies until the desired diameter has been achieved.

There are two common types of mesh:

1. Welded Wire Mesh
2. Woven Wire Mesh

Welded Wire Mesh

Welded wire mesh has intersecting rows and columns of parallel wires that are welded together at the intersection. Once the wire has been drawn down to the desired size, it is fed into a machine which welds the multiple rows of wire together at their intersection.

As the mesh is fed through the machine, a parallel line of welds is created simultaneously where the perpendicular lines meet. The next intersection of wires is then fed through the machine to be welded, and this process continues, joining each row of wires together. This machine typically welds the wires using electrical resistance as the source of heat. Although other welding methods could be employed, this is the usually most economical. Once the mesh has reached the desired length, it is cut by a shear, resulting in a sheet of flat and rigid welded wire mesh.

Woven Wire Mesh

Woven wire mesh has an array of intersecting wires, similar to a woven cloth. Typically, the wires are woven over and under the perpendicular wires producing a stable sheet. This pattern is known as a “Plain Weave Mesh”. For applications that require a more flexible sheet, a “Twill Weave” can be used.

This involves wire that is woven over 2 perpendicular wires, then under the next set of 2 perpendicular wires, and so on. Woven wire mesh has no welds on them. Instead, they are fed into a machine similar to a loom which feeds a straight wire through chosen weave pattern. The wires are then bent to the reverse position, and the next straight wire is fed through the pattern. The machine continues this process until the desired dimensions are reached and the completed wire mesh sheet is then cut to the desired size.

Applications

Welded wire mesh and woven wire mesh are used in many different fields. Several uses include:

• Fences
• Sifters
• Grills
• Machine and equipment safety barricades
• Concrete reinforcement
• Shelves
• Cages

Welded wire mesh manufacturing process, include galvanize welded wire mesh and vinyl coated welded wire mesh production processing.

Wire rod

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

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 used for straightening and cutting process. The cold rolled wire rods in the coil form is passed through pre set 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 2 mm) automatically. The wire rods can be cut to any size ranging from 0.8 metre to 12 metre with a max tolerance of 2 mm.

Welding

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 used 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.

Finished mesh

After the bending and cutting process comes the final stage in manufacturing process, galvanizing or PVC coating.

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