One of the main types of manufactured products of the company's plant is a sleeve knitted mesh (SRP, SRG, SRGM) knitted from stainless wire AISI 321, 316 Ti, in accordance with the developed by us TU U 28.7-.001- and approved by the State Standard of Ukraine, the Center for Standardization metrology and certification. Our products are successfully used at the leading enterprises of the oil and gas and chemical industries.
The mesh is a component for mesh fenders in technological devices, flame arresters, filters, and is used as a packing.
The mesh designed for separating the entrained liquid from the steam (gas) flow in distillation, adsorption, stripping and other column apparatus, as well as separators, scrubbers, dust collectors, filters, dryers and many other devices.
Mesh SRP is produced by the method of smooth, knitted without a longitudinal seam (in the form of a sleeve). Unlike woven fabrics, woven mesh consists of a uniform and continuous series of loops that are intertwined on a tubular shape. The hinges in the mesh are extremely resistant to compression and tension loads. Each loop is free to move in three directions, thus providing a two-way stretch. The loop alone also acts as a small spring when subjected to stress or compression and immediately returns to its original shape when the stress is removed. Thus, this leads to unusual flexibility and resilience of the finished mesh.
In addition to SRP, our company produces SRG corrugated mesh, profiled on chevron rollers to provide even greater elasticity and bulk (as shown in the figure on the left). Corrugation height - 9 (+/-1) mm., distance between corrugations 17 (+/-2) mm.
Modernized corrugated mesh (SRGM) is produced in series with a width of 190 mm or more. up to 570 mm. and more. The use of SRGM meshes in the manufacture of fenders (drop eliminators) and filters made it possible to reduce labor costs in production, and due to the fact that the width of the mesh can be made corresponding to the size of the segment, a high quality of fender assembly is achieved.
The updated design made it possible to evenly distribute the working flow throughout the entire volume of the packing, which significantly improved the characteristics of the technological apparatus as a whole.
Mesh fenders manufactured according to OST 26-02- using a conventional sleeve mesh (SRP, SRG 95 +/- 5 mm wide.) entailed a lot of costs, both material and production. It was not always possible to achieve high quality indicators, and the degree of separation, after some time of operation, fluctuated in the range of 93-96%.
Due to the non-uniform laying of the mesh in volume, local blockage of the fender soon occurred, as a result of which the pressure drop in these zones increased excessively, and, as a result, flow breakthrough and premature shutdown of the technological process for repairs.
Mesh fenders made using SRGM mesh, thanks to a constructively new type and laying method, do not have the disadvantages present in drop eliminators with SRP and SRG mesh, and the operating time (depending on the environment) has increased by 1.4 - 1.8 times.
Mesh fenders made using SRGM mesh, thanks to a constructively new type and laying method, do not have the disadvantages present in drop eliminators with SRP and SRG mesh, and the operating time (depending on the environment) has increased by 1.4 - 1.8 times.
The main advantages of using a mesh are that it can be used where the filter material must be extremely stable after exposure to aggressive loads. Confident corrosion resistance, mechanical and thermal shock, elasticity, resistance to high vibration and high temperatures, resistance to destructive gases, dirty, oily and other extreme conditions - this is not a complete list of the advantages of woven mesh.
Various use of grids allows to make filters as flat and volumetric, as well as mesh fenders with a wide range of selection of the degree of separation and filtration.
When it comes to choosing wire mesh for your project or application, there has always been a long debate on woven vs. welded wire mesh. Each has a unique quality, pros, and cons. If you have encountered it, the question of inquiring about its properties is addressed to you. Both woven and welded wire mesh come in high-standard quality, and your selection will most definitely depend on the specific requirements of your project. Therefore, we will go through all the key differences between woven wire mesh vs. welded wire mesh so you can understand the fine details and make more informed decisions when it comes to your wire mesh selection.
What is Woven Wire Mesh?
Thin metal wires, warp and weft wires intersect in a crisscross with evenly spaced openings to produce woven wire mesh, also known as wire mesh or wire cloth. The warp wires run parallel to the mesh&#;s length, while the weft wires weave perpendicularly to them, forming the mesh. Woven wire mesh emphasizes flexibility and versatility. You can mold it to uneven surfaces more easily, or roll or cut it to fit an installation profile more easily. Additionally, the woven mesh is quite rigid due to its unique weave configurations.
What is the Production Process?
The production process of woven wire mesh starts with carefully choosing metal wire, drawn to the precise wire diameter needed based on the desired mesh properties like strength, thickness, and corrosion resistance. Common raw materials include mild steel, stainless steel, and aluminum. We may then coat the wire with zinc, PVC, or epoxy for additional protection. There are some other specialty raw materials: copper, nickel, and brass.
The weaving process for woven wire mesh takes place on specialized looms. It consists of a warp beam, heddle frames, reed, and rapier.
These looms feature a warp beam that holds numerous parallel wires. These wires will serve as the finished mesh&#;s foundation in a lengthwise direction.
Heddle frames act like puppeteers, controlling the warp wires. They can raise and lower specific groups of wires to create the desired weave pattern in the mesh.
During each weaving cycle, a rapier, which functions like a weaving needle, takes center stage. The rapier inserts perpendicular weft wires (the wires running across the mesh) between the raised and lowered warp wires.
The reed is another crucial component. This tool ensures the precise positioning of the weft wires during weaving. Each cycle of the loom involves the reed pushing the weft wire into place, creating a secure interlock with the warp wires.
The warp beam advances slightly after each cycle to accommodate the next weft wire, creating space.
The synchronized routine of warp beam movement, heddle frame control, rapier insertion, reed positioning, and interlocking continues until the mesh reaches the desired length.
Ultimately, we cut the woven mesh to size, finish it, and conduct quality checks before it reaches its destination. It is due to its manufacturing process, which facilitates easy rolling and cutting for installation and customization.
Weaving Patterns of Woven Wire Mesh
For woven wire mesh, there are different weaving patterns. Different types of weaving patterns include plain weave, which is the simplest and most common type. In this type, wires alternate between vertically and horizontally, creating square grid-like patterns. Twill weave patterns consist of wires interwoven diagonally, resulting in a stronger mesh, whereas Dutch weave is a more complex weave with diagonal patterns and several variations, including plain Dutch, twill Dutch, reverse plain Dutch, and reverse twill Dutch.
Applications of Woven Wire Mesh
Woven wire mesh has a wide range of uses due to its strength and flexibility, from sifting flour in bakeries to chemical processing. Its flexibility also makes it ideal for applications that require finer mesh with smaller openings, such as air and liquid filtration, powder sifting, and making insect screens for windows or porches. We use it in security and fencing to secure perimeters, just like woven wire fencing. This adaptable material finds use in construction and everyday life, reinforcing concrete structures, supporting plaster walls, and providing reliable food strainers in your kitchen. Moreover, woven wire mesh also serves specialized purposes like speaker grilles and medical filters.
What is Welded Wire Mesh?
The welding process of joining parallel longitudinal and transverse wires together at intersection points creates welded wire mesh, also known as welded wire fabric or welded mesh, which is a material with a grid-like pattern and consistent openings. The spot welding construction makes the structure exceptionally strong and resistant to deformation, making it ideal for high-impact applications like fences and security barriers. Additionally, welded wire mesh excels at holding its shape under pressure, making it suitable for demanding applications requiring a secure barrier or reinforcement in concrete structures.
What is the Production Process For Welded Wire Mesh?
The production process begins with transforming raw wire into welded wire mesh, which involves meticulous steps.
First, we choose the appropriate
welded wire mesh material
, such as mild steel for its cost-effectiveness or stainless steel for its enhanced resistance to corrosion, or we can add PVC coating, GI coating, or powdered coating for additional protection.
The next step is drawing to adjust the wire diameter to achieve the desired final mesh size, which directly affects the weight per unit area as thicker wires result in heavier mesh.
Then comes the welding process, in which specialized machines fuse the perpendicular and parallel wires at their intersections using controlled electric heat, creating a permanent, strong bond. This balance between wire spacing and wire diameter determines the final mesh size and weight.
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After welding, we cut the mesh to size, conduct quality checks, and apply finishing touches like deburring or protective coatings.
The desired welded wire mesh size is directly linked to wire diameter, and the interplay between welded wire mesh size and wire diameter, along with the material density, is crucial for welded mesh weight.
Weight &#; (Wire Diameter)^2 * Material Density / Mesh Size^2
Applications Of Welded Wire Mesh
Since welded wire mesh is versatile, durable, and strong, it has many practical applications in several industries, as listed below, among many other uses.
Concrete Slabs: Welded wire fabric is placed in concrete slabs, walls, etc., of roads in the construction industry to prevent cracks and distribute the load. The concrete construction industry uses welded wire fabric to prevent or reduce the formation of cracks.
Landscaping: For erosion control, soil stabilization, and retaining walls in landscaping, industries apply welded wire mesh. It acts as a barrier and holds soil in place, never allowing it to wash away, while also promoting plant growth. Cages of welded wire mesh, when filled with rocks, can also act as gabions and be further put to use in functional and retaining walls.
Agriculture: In the agriculture sector, welded mesh acts as a wire fencing material for fences and enclosures along the perimeter and at the centers, such as cages for lions, giraffes, and tigers.
Art and Craft: In the art industry, mainly PVC-coated welded mesh, which comes in different colors, makes artistic designs. Welded wire mesh material allows artists to use it to come up with different designs due to its flexibility, strength, and durability.
Material Availability Between Woven vs. Welded Wire Mesh
Are you curious about the best material for wire mesh? Generally, the principal material selection for both wire meshes is the same in terms of availability. Stainless steel is most represented in the field, both in terms of cost and common application. For example, stainless steel is a generally corrosion-resistant material that can be applied outdoors, in the food industry, and in other applications for enhanced hygiene. There is galvanized steel for welded mesh, which is zinc-coated and provides the best protection against corrosion. You can also apply a coating of PVC to either woven or welded mesh to provide additional resistance to oxidation, UV light, and certain chemicals.
Comparing the Costs of Woven and Welded Wire Mesh: A Detailed Analysis
There is a clear distinction between woven vs. welded wire mesh cost. Woven wire mesh is by far the cheapest. Automation plays a significant role in making woven mesh, resulting in reduced production costs and, consequently, lower material costs. However, the cost may vary depending on the material used and the woven mesh&#;s opening size. More material is required for finer woven mesh, which could result in a slight increase in cost.
Conversely, the cost of welded wire mesh is typically higher. The welding process adds complexity to the production process, resulting in higher costs. Again, wire diameter and overall mesh size have an impact on the final price, so larger welded mesh construction tends to get more expensive with thicker wires.
Woven vs. Welded Wire Mesh: Strength and Durability
In the battle for strength and durability, woven and welded wire mesh go toe-to-toe, but with distinctive advantages of their own. Woven wire mesh is flexible and adaptable, with an intricate weave pattern that allows it to bend and twist over uneven surfaces, which makes it perfect for curved applications.
In turn, rigid and strong welded wire mesh acquires its unrivaled stiffness and strength with welded connections at each wire intersection, which makes it the obvious choice for heavyweight use such as security barriers and fencing. Welded wire mesh also excels at maintaining its shape under pressure, making it suitable for reinforcing concrete structures.
Is opening size a crucial factor in woven and welded wire mesh?
The opening size between the wires is an important factor when choosing between woven and welded wire mesh. When smaller openings are required for a task, woven wire mesh is the best choice since the intricate weave structure can also allow fine filtering and sifting. However, larger opening sizes will automatically require welded mesh. In welded construction, the attachment of the wires is firm enough to prevent any wire shifting, and, by design, the size of the openings is retained.
On the other hand, welded meshes encounter problems when smaller opening sizes are required due to the need for thin wires to weld, but thin wires are meltable from welding heat. Conversely, while woven mesh excels in its flexibility within a cluster of opening sizes, it struggles with larger opening sizes due to the lack of welded construction between the wires of a large mesh. Because of this, the openings can shift, and the wires will not hold the shape of the opening as designed.
Woven vs. Welded Wire Mesh: Pros and Cons
Here are some woven vs. welded wire mesh pros and cons, so you can carefully consider the trade-offs and ensure the best project success.
Woven wire mesh:
Pros:
It is flexible and can easily take the shape of irregular surfaces. It is, therefore, suitable for application on curved surfaces.
Due to its flexibility, it is easier to roll, cut, and customize.
Ideal for applications that need fine filtering, sifting, and insect screens in a diverse selection of materials.
Cons:
Because there are no welded connections, it may lose shape with large openings.
It may not be as strong as welded mesh for high-impact applications.
Welded Wire Mesh:
Pros:
The welded connections provide welded mesh with excellent strength and resistance to deformation. This is preferable in high-impact applications with security barriers.
This material maintains its shape effectively under pressure, making it ideal for applications that require holding back through a secure barrier or with reinforcement in concrete structures.
You can incorporate larger openings into a mesh while maintaining the mesh&#;s structure without adding extra support.
Cons:
The material lacks flexibility, making it challenging to work with on curved surfaces or in complex custom designs. It may also pose a challenge for simple custom designs.
Wires with smaller opening sizes may need to be thinner, which increases the risk of melting during the welding process.
To help you choose the right mesh based on your specific needs and budget, we mention many major factors and with this comprehensive guide, you can determine whether a woven or welded construction type is right for your project.
Are you interested in learning more about Knitted Wire Mesh? Contact us today to secure an expert consultation!