This article takes an in depth look at hardware cloth.
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Hardware cloth is a type of woven mesh created by interlacing wire of different sizes to form a versatile metal fabric. It is commonly used for applications such as animal cages, fencing, strainers, and filtering screens. Variations in hardware cloth are defined by factors such as the wire type and gauge, the finish applied, and the method used to join the wire fibers at their intersections.
In hardware cloth, a higher gauge number indicates a thinner wire. Common wire gauges for hardware cloth include 16, 19, 23, 24, and 27, with gauge 16 being the thickest and largest.
Hardware cloth is formed by parallel rows of wire intersecting with columns of wire. Though it may be presumed to be similar to perforated metal or expanded metal sheets, its production is far different. Hardware cloth is produced using a wire fabricating process and can be made from any size wire with smaller wire gauges being preferable.
A key distinction between types of hardware cloth lies in how the wires are joined at their intersections. There are two primary methods: welding and weaving. In the welding method, intersecting wires are fused together using a welding machine that rapidly joins the intersections. In contrast, woven hardware cloth is made using a traditional fabric weaving technique, where wires are interlaced in an over-and-under pattern.
Any type of metal wire can be used to produce hardware cloth. In most cases, manufacturers prefer stainless, carbon, or galvanized steel. For many years, hardware cloth was made exclusively of stainless or galvanized steel since they have exceptional durability and resistance to corrosion. In recent years, hardware cloth has been produced using various types of plastic coats, which has expanded the selection of metals.
Stainless steel hardware cloth is manufactured using various grades such as 304, 304L, 316, and 306L, and is produced with either plain or twill weaves.
Carbon steel is an excellent material for hardware cloth due to its ductility, which allows it to form tight and secure connections. Variations in carbon content modify the properties of carbon steel, making it suitable for different applications. There are four types of carbon steel used for hardware cloth, each distinguished by its specific carbon content.
Low carbon steel contains 0.05% to 0.25% carbon and up to 0.4% manganese. Also known as mild steel, it is highly malleable and is carburized to enhance surface hardness.
Medium carbon steel has a carbon content of 0.29% to 0.54% and manganese ranging from 0.6% to 1.65%. It is known for its strength and ductility, providing excellent wear resistance.
High carbon steel is exceptionally strong and durable, with a carbon content of 0.55% to 0.95% and manganese ranging from 0.3% to 0.9%.
Very high carbon steel has a carbon content of 0.96% to 2.1%, making it extremely strong but also more brittle.
Historically, galvanized steel was the most commonly used material for hardware cloth and remains a popular choice today. However, advancements in metallurgy have introduced various other options for hardware cloth production. The zinc coating on galvanized hardware cloth provides corrosion resistance and extends its lifespan.
While stainless steel, carbon steel, and galvanized steel are commonly used for hardware cloth, virtually any metal that can be formed into wire can be used to create hardware cloth.
The image below features brass hardware cloth, known for its excellent wear resistance, composed of 80% copper and 20% zinc.
Welding hardware cloth starts with aligning the parallel columns and rows so that they intersect. During the drawing process, the wires are shaped to fit the desired opening size before welding. The welding machine then simultaneously performs a series of welds at each intersection of the rows and columns. As the wire is continuously fed into the machine, each row is welded in succession as it passes through the welding apparatus.
Woven hardware cloth is produced through various techniques, some of which are proprietary to specific manufacturers. While there are multiple methods for weaving hardware cloth, the fundamental process involves intertwining wires using an over-and-under pattern similar to traditional fabric weaving. Despite this basic description, the actual weaving process can be quite complex due to the different approaches employed.
Plain weave, also referred to as square weave, is commonly used for manufacturing hardware cloth. In this method, the warp wires (which run parallel to the length of the cloth) alternate crossing over and under the weft wires (which run perpendicular to the cloth). Both warp and weft wires are typically of the same diameter and gauge.
In a twilled weave, each weft wire alternates passing above and below every successive pair of warp wires. This technique is employed for heavier gauge wires, such as 16 or 19, which are too robust for plain weave methods.
The Dutch weave uses two different wire sizes, with the warp wire being larger than the weft wire. This weave is characterized by its dense and tightly packed structure, resulting in hardware cloth with very fine openings. Variations of the Dutch weave include reverse, twilled, and reverse twilled, each imparting distinct properties and characteristics to the final product.
The five heddle weave is created by passing the fill wire alternately over and under five warp wires. This technique results in parallel diagonal lines on the final product. The five heddle weave is designed to accommodate heavier wires, enabling it to support greater loads effectively.
The four weaves described above are among the most commonly used for producing hardware cloth. In addition to these, there are numerous variations, including oblong, multi-layer, cable, spiral, and various combinations of these methods.
Wire knitting creates hardware cloth with interlocking loops that form a honeycomb-like structure. This method results in a product that is durable, flexible, sustainable, and compressible, with the ability to stretch in two directions. The machinery used for knitting wire is similar to that used for making sweaters and scarves. The hardware cloth can be made from either flat or round wires, with round wires being the most common and easier to handle.
Crimped wire cloth is made from both ferrous and non-ferrous metals. Several methods are used to produce crimped hardware cloth, including flat top, lock, double, and intermediate crimping techniques. This type of hardware cloth features square or rectangular openings and is constructed using wires of varying gauges.
Flat top crimped, or pressed crimped, hardware cloth features knuckles on the underside, resulting in a smooth surface. In this method, both the warp and weft wires are crimped prior to weaving.
Lock crimping employs pre-crimped wires, where the bumps or knuckles secure the crimp in place, resulting in a very rigid cloth. The locking is achieved by pressing on either side of the raised wire, firmly holding the wires in position.
Double crimped hardware cloth features a weave where both the warp and weft wires are secured with straight wires. The wires are crimped and sprung to create a tight, durable weave. This pattern involves the warp wires passing alternately over and under the fill wires, as illustrated in the image below.
Intermediate crimped hardware cloth comes in two types: single and double. In single intermediate crimping, the weft wire is pre-crimped while the warp wire is woven directly. In the double crimped method, both the weft and warp wires are pre-crimped before being woven together.
Hardware cloth is a versatile wire product that can be customized in various sizes and configurations to suit different applications. It is frequently used for making screens and as a component in filtration and separation systems.
Different sizes, styles, wire types, construction methods, and mesh patterns of hardware cloth are tailored to meet specific needs, with specialized versions available for unique or uncommon uses. The type of metal used plays a crucial role in determining the functionality and suitability of the hardware cloth for various applications.
Hardware cloth is commonly used in architecture to enhance the appearance of structures. Its distinctive texture and structure can provide a modern, finished look to new buildings and update the appearance of existing ones.
In addition to its aesthetic uses, hardware cloth serves practical purposes such as filtering and blocking sunlight. It helps control indoor climate by providing shade, reducing temperature, and retaining heat, which can contribute to lower heating costs.
The petrochemical industry demands equipment that is rugged, durable, and long-lasting. Hardware cloth used in this sector is critical for applications such as filtration and separation of gases and liquids, including mist eliminators and demisters.
For these purposes, hardware cloth is made from various materials, including stainless steel, nickel alloys, galvanized steel, carbon steel, and aluminum. To further enhance the performance and longevity of the hardware cloth, some metals are aluminized, which extends their service life.
In the food processing industry, hardware cloth is typically made from lighter metals such as stainless steel, brass, copper, and aluminum. It is commonly used for sifting flour and other milling processes due to its large open mesh. Given its contact with food, hardware cloth for this industry must comply with Food and Drug Administration (FDA) regulations. Plain weave is often employed in its production to facilitate easy cleaning and to inhibit bacterial growth.
While concrete hardens and sets into a rigid form, it often requires additional support to maintain its shape. Traditionally, rebar has been used for this purpose due to its strength and durability. However, hardware cloth is increasingly being used as an alternative in some applications. Its adaptability, ductility, and ease of shaping make it a viable option for reinforcing concrete. Hardware cloth is utilized to help concrete retain its form and to provide support for repairing holes in floors and walls.
For many years, chicken wire has been used to enclose plants, animals, and secure equipment. Although chicken wire is a useful material, it can be easily broken or cut. To address these limitations, gardeners, farmers, and DIY enthusiasts are increasingly turning to hardware cloth. Its greater density and strength make hardware cloth a more robust option for protection, as it is resistant to tearing and maintains its shape more effectively.
Hardware cloth can be categorized based on its manufacturing method (welded or woven), the type of wire used, and how the wires intersect. These distinctions help identify different forms of hardware cloth. Additionally, its applications are a key factor in defining its specific type, as hardware cloth is tailored for particular uses.
Hardware cloth is versatile and used in various fields, from gardening projects to industrial applications. Its flexibility and adaptability contribute to its widespread popularity and usefulness.
Architectural hardware cloth serves both aesthetic and functional purposes in building design and engineering. It offers a range of design options for architects while also blocking exterior elements and protecting the interior environment. This type of hardware cloth is designed to provide a variety of architectural choices.
Bolting hardware cloth is known for its strength and flexibility. Made from thin, smooth, and resilient wires woven in a square pattern, it is ideal for screening and bolting applications. Typically constructed from stainless steel, it resists rust and corrosion, making it a popular choice for sifting and screening materials.
Filtering hardware cloth is engineered for durability and strength, featuring robust warp wires to handle the demands of filtering and screening. Its design is suitable for separating slurries and liquids. With various weaves such as plain Dutch, twilled Dutch, and reverse Dutch, this cloth offers enhanced porosity and ease of cleaning. It is often preferred over synthetic or fiber filters for its superior filtering capabilities.
Galvanized hardware cloth is produced using a hot-dip galvanization process that applies a zinc coating. This coating provides a protective layer, making it ideal for outdoor use. Made from light gauge wire, galvanized hardware cloth is commonly used for fencing, construction, and pest control. It is waterproof, durable, rust-resistant, long-lasting, and lightweight. Despite its light weight, galvanized hardware cloth offers excellent strength, stability, and endurance.
Market grade hardware cloth is woven wire available in common diameters and wire combinations. It is produced from a variety of metals and is typically found in hardware and home improvement stores with various openings per linear inch. Made from heavier wires, such as 16 and 19 gauge, market grade hardware cloth is designed for heavy-duty applications.
Mill grade hardware cloth is a lighter-weight version of market grade cloth. It is made from metals such as stainless steel, aluminum, brass, and copper. With thinner wire diameters, such as 23 or 27 gauge, mill grade hardware cloth has fewer openings and is ideal for sifting and milling flour, as well as processing light materials.
Refinery grade hardware cloth is specially designed for industrial use in the petroleum, natural gas, and refinery industries. It is either woven or welded to meet rigorous standards for reliability and endurance. Applications include pipe fittings and catalyst support grids. Key characteristics include rigidity and continuous slot construction to prevent pulling and clogging.
Space hardware cloth derives its name from the spacing between the wire strands, which is designed during its construction. It is produced through weaving and welding processes. Commonly used as screen material for gravel, sand, and aggregates, space hardware cloth facilitates accurate sizing, washing, classification, and separation of materials.
Any metal that can be formed into wire is capable of forming into hardware cloth. The three most common metals are stainless, carbon, and galvanized steels, which have been used for years to make wire cloth, wire mesh, and chicken wire. With the development of modern production methods and techniques, it has been possible to use other metals to produce hardware cloth.
The choice of metal for hardware cloth largely depends on its intended application. Stainless steel, carbon steel, and galvanized steel have long been favored for their strength, durability, and malleability. However, these desirable characteristics can also be found in other metals, which may be selected based on specific requirements and conditions of use.
Since the development of an efficient method for refining aluminum, it has become the most widely used metal on the market. It is the lightest of the available metals with a density 35% lower than steel. The exceptional ductility of aluminum makes it ideal for the manufacture of hardware cloth.
Aluminum hardware cloth is typically chosen for applications where a lightweight metal is required. It is rarely used in its pure form; instead, it is usually alloyed with other stronger metals to enhance its durability while benefiting from its corrosion resistance.
Much like aluminum, nickel is normally alloyed to enhance its properties and take advantage of the properties of its alloys. Nickel is resistant to oxidation and corrosion and maintains its strength in high temperature applications as well as resistance to the effects of acidic and chemical conditions. Nickel alloys are used to produce filters, separators, and strainers for petrochemical, pharmaceutical, and chemical processing.
Bronze is an alloy that consists mainly of copper and has the same characteristics and properties as copper including copper‘s malleability, durability, and ductility. Hardware cloth produced using bronze has a 90% copper content and a 10% zinc content. Bronze wire hardware cloth is used in conditions where there is atmospheric corrosion such as marine applications. As with nickel, bronze is commonly used as material for filters and separators. Due to its appearance, bronze is also used in architectural applications.
Brass is also an alloy of copper with a 65% copper content and a 35% zinc content. It is a very soft metal that can be easily shaped and formed but is not very durable. The high zinc content gives brass added resistance to abrasions and higher tensile strength. As with bronze, the appearance of brass makes it appealing to architects as a finishing touch for construction projects. The industrial uses of brass include filters and separators.
Titanium, a silver-white metal, is renowned for its corrosion resistance, exceptional strength, biocompatibility, and excellent shape memory. Hardware cloth made from titanium is used in applications such as seawater filtration, water purification, and chemical drug filters. With a density that is 60% of that of steel, titanium offers an outstanding strength-to-weight ratio.
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