If you are looking for a product that will allow ventilation, drainage, or perhaps add a decorative touch, your three main choices are Expanded Sheet Metal, Perforated Sheet Metal, or Welded/Woven Wire Mesh. So which one do you choose and why?
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Expanded metal sheet is made by first creating multiple slits in the sheet, and then stretching the sheet. The stretching creates a unique diamond pattern opening with one of the strands protruding at a slight angle. These raised strands can be flattened later in the process if desired. As you can see this process creates no waste (thus keeping down production costs) and it can add structural strength to the product.
Perforated metal sheet is a product that is made from sheet steel that has been fed through a machine that punches out round holes (or other designs). These holes can be straight rows or staggered to increase the amount of the openings. Typically the perimeter of the sheet has a boundary where holes are not punched; this adds stability to the sheet. The removed metal from the holes can be recycled but it also increases the cost of the product. The larger the hole size (or increased amount of holes), the greater scrap volume, and therefore costs can be increased.
Welded wire mesh is a metal wire screen that is made from various alloys including steel, stainless steel, brass and copper. It is available in various sizes and shapes. Grids of parallel longitudinal wires are welded to cross wires at the required spacing, using electric fusion. The machines that are used to produce the mesh have precise dimensional control.
Also available in steel, stainless steel, brass and copper, woven wire mesh is made as a cloth with wire threads woven at right angles. Wires which run lengthwise are known as warp wires, whilst those running perpendicular are weft wires.There are two common styles of weave: plain weave and twill weave. It can be made from various alloys including stainless steel, brass and copper. Wire cloth can be woven to create a variety of opening sizes and wire diameters.
One of the benefits from the manufacturing of expanded metal is that the sheet retains its structural integrity because it has not undergone the stress of having shapes punched in it (like perforated sheet), and the mesh-like pattern will not unravel (like woven mesh can do). Expanded metal has been stretched rather than punched, reducing scrap metal waste; making it cost-effective. The main considerations when using expanded metal will be the chosen thickness and strand dimensions (weight and structural design requirements). Expanded metal can be almost transparent (depending on the opening); it has mechanical properties and is an excellent conductor.
Perforated metal sheet comes in a virtually endless variety of sizes, gauges, hole shapes and material types. Hole diameters range from a few thousandths of an inch to more than 3 inches, punched in material as thin as foil or as thick as 1-inch steel plate. From lightweight decorative elements to load-bearing structural components, perforated metal offers unique opportunities to combine strength, functionality and beauty.
The chance of improper bending of bars is reduced since bending machines bend the mat as a single unit. This provides the exact size of reinforcement where needed through variable bar size and spacing, thereby reduces steel waste. There can be a considerate savings because mesh is easy to handle and can be installed much faster. Typically you can purchase a welded mesh for less than a woven mesh.
Wire mesh is adaptable to almost any application. It is extremely durable and very easily cleaned.
Expanded metal sheet works well for steps, flooring in factories and on construction rigging, fences, wash stations, and security applications.
Perforated metal can be made into a multitude of products such as: screens, filters, baskets, trash cans, tubing, light fixtures, vents, audio speaker covers and patio furniture.
Widely used in agricultural applications, industrial, transportation, horticultural and food procuring sectors. It is also used in mines, gardening, machine protection and other decorations.
From sifting and screening machinery to conveyor and automotive belts, all the way to animal enclosures and architectural framework.
You can check out our video below to find out the difference between expanded metal, perforated metal and wire mesh:
Additionally, their integration of geometric patterns, makes both a popular aesthetic element added to various fixtures and structures.
Despite their similarities in function, these two metals are distinct; they require the use of different manufacturing methods, exhibit different characteristics, and have different best use cases. Understanding the differences between them is critical when selecting one or the other for an application.
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In the following blog post, we provide an overview of how perforated and expanded metal differ, outlining how they&#;re manufactured, key characteristics, and ideal applications.
For ventilation and drainage products, expanded metal is a strong and cost-effective option.
The key to expanded metal&#;s strength is in its manufacturing process. The first step is to perforate the sheet with a series of regular slits. Stretching the sheet after adding these openings creates the distinctive, repeating diamond pattern that distinguishes expanded metal from other material options. After the stretching process, some strands of metal may protrude slightly, but it&#;s possible to flatten these later on if necessary or desired.
There are two key advantages to this technique:
As indicated above, expanded metal retains its structural integrity better than perforated metal. In addition to this property, other key characteristics include low risk of unraveling (compared to woven mesh) and excellent conductivity.
When choosing to use expanded metal for an application, some of the key considerations include thickness and strand dimension, both of which depend on the structure&#;s requirements. It is available in a wide range of materials, mesh sizes (including near-transparent thickness), and pattern designs to suit different use cases.
Some of the most common applications for which expanded metal is ideal include:
Perforated metal is the preferred choice for use in certain applications such as filtration equipment.
Like expanded metal, perforated metal begins as a steel sheet. However, rather than slicing and stretching the sheet, a technician feeds the base material into a specialized machine that punches holes in a pre-defined pattern (typically either straight or staggered lines of holes). The machine usually leaves a thin section of metal around the perimeter unpunched to avoid compromising the material&#;s stability.
The perforation process does, by necessity, generate waste. While the excess metal can be recycled, doing so may increase the overall project cost. Manufacturing sheets with larger holes produces more material waste&#;resulting in higher production costs&#;so customers with such requirements should consider if expanded metal is a better fit for their budget.
Compared to expanded metal, perforated metal&#;s main advantage is its versatility. It is available in a broad selection of variations, with different material, hole gauge, hole size, and hole shape options.
As perforated metal is available in many different variants, it lends itself to use in a wide range of applications. Some examples include the following, although perforated metal applications are by no means limited to this list:
At Metalex, we recognize the value of both expanded metal and perforated metal. As such, we maintain a broad selection of perforated metal materials and expanded metal products for our customers. Whichever material you need, our expert sales and engineering team will ensure you get the right product for your application and requirements.
For additional information about our offerings or assistance choosing one for your next project, contact us or request a quote today.
Contact us to discuss your requirements of perforated gutter guard. Our experienced sales team can help you identify the options that best suit your needs.