Production of welded mesh on machine tools: Review + Video

Production of welded mesh on machine tools: Review + Video Making a chain-link mesh on automatic and semi-automatic machines

Several decades ago, a chain-link mesh was made manually. Today, thanks to the development of technology, the production process has become easier. Automatic and semi-automatic machines came to the aid of manufacturers.

General information

Semi-automatic machines

On semi-automatic machines, the wire is passed through a special bending machine, which bends it into wire spirals and connects them to each other using the coil method. Thus, a mesh of the required size is formed.

The cells can be of various sizes from 10x10 mm to 100x100 mm. The buyer can choose the required mesh size according to his needs. The most popular sizes are 35x35 mm and 50x50 mm.

Automatic machines

On automatic machines, the netting of the chain-link is made with minimal human involvement. The operator sets the spool with the required wire and sets the parameters (wire thickness, roll parameters, required mesh diameter).

The rest of the work is done automatically by the machine. The unwinder winds the wire from the roll onto the mechanism and forms a spiral from it. The guillotine device cuts off all unnecessary.

The finished cut wire is stretched under the weight of the load. Another piece of wire is attached to this spiral and wound.

Thus, cells of the required dimensions and a roll of the required length and width are formed. Then the equipment spins the finished mesh into a roll. The length of the net is usually no more than 10 meters, and the most popular height is 1.5 meters. On an individual order, the netting chain-link can be made up to 4 meters high and up to 18 meters long.

Transport

On both semi-automatic and automatic machines, the net is coiled into a roll. The only difference is that in the case of a semi-automatic machine, the ends of the roll do not bend, but for an automatic machine, they bend and join together. Before transportation, the wire is treated with machine oil to avoid additional wear and tear on the wire, which has already been subjected to friction and deformation. To avoid inconvenience during transportation, the edges of the rolls are wrapped in protective material (thick paper or polyethylene).

Welded mesh: production and use

Welded mesh is a type of rolled metal made of bars or wire welded perpendicularly to each other.

In this case, the guides are stacked at right angles, which makes it possible to form cells of both square and rectangular shapes. Simple manufacturing technology allows you to produce a mesh from bars or wires of any diameter.

Therefore, both light rolled metal and heavy reinforcement are used in production. Depending on the flexibility of the final product, rolled metal is supplied in rolls or sheets.The mesh sizes on the mesh can be any: from the smallest (from 3-6 mm) to rather long (about 200 mm).

It all depends on the subsequent appointment and preferences of the buyer.

Technical requirements for welded mesh

The strength of welded mesh mainly depends on the following factors: mesh size and diameter of rods. Small cells with large diameter rods provide maximum strength and rigidity. Accordingly, the more metal is used in the mesh, the stronger it is.

Low-carbon steel wire or reinforcement (usually types AI - AIII) is used to make the mesh.

Such raw materials lack elasticity and flexibility, which is very important for the future of rolled metal products. Welded metal meshes of roll or flat type are manufactured in compliance with GOST 23279-85, which classifies the final rolled metal as heavy or light, with transverse or offset rods along the width of the web. Heavy welded meshes are made of hot-rolled reinforcing steel bars, and light meshes are made of VR-1-type reinforcing wire.

Making a welded mesh

The bars are superimposed on each other cross to cross. Spot welding melts the steel and the rail joints are firmly sintered and fixed.

The guides are subjected to production tests for the fact that they have the same strength both horizontally and vertically. Even if equal strength is not a primary requirement for a specific finished rolled metal product, the difference should still not exceed fifty percent.

Welding quality is also subject to manufacturer's control. According to GOST, there is the following fairly simple way to check quality: a roll or sheet of mesh is dropped from a meter height, if no damage is found on it after that, then the welding is of high quality. Products that pass this simple test are sent for implementation.

Application of welded mesh

Welded mesh has a wide range of applications in various fields: construction, household or production. The visual permeability and correct geometry of the lattice allows it to be used for external fences. And the reliability and durability of the material make the welded mesh an excellent reinforcing frame for cement, concrete and block structures. It is much more convenient to use a ready-made mesh when reinforcing reinforced concrete structures than bar reinforcement, which still needs to be tied together. Welded mesh saves time and money for builders, and also guarantees a high-quality reinforcement function.

In addition, welded mesh is used when performing plastering work, erecting brick or block masonry, installing fences, laying sidewalks, and also as a means of strengthening the base of the road.

Depending on his needs, the buyer chooses the material of the mesh, the type of surface treatment, the size of the cells and the diameter of the bars.For a longer service life, even in open spaces, the welded mesh is covered with a protective layer, which significantly increases the service life.

Let's tell you more about the areas of application of welded mesh. Where is its application desirable and where is it required? Welded mesh is very popular and in demand in many areas for a reason.

The range of its application is very wide. It is used in construction and finishing works. Fences are made from it. And even used when laying road or sidewalk surfaces.

Welded mesh in construction

Its main application is to strengthen reinforced structures.

This is due to its use when casting foundations or reinforcing reinforced concrete structures. The so-called "armopoyas" is also made using welded mesh and concretes of varying severity. Welded mesh is used as an amplifier for thermal insulation and waterproofing structures. It is worth choosing the desired diameter of the rods and the size of the cells, as you can apply it anywhere.

Welded mesh for finishing works

Production of welded mesh on machine tools: Review + Video But this type of product is not used only in large-scale construction, but also in smaller works.

In finishing work, for example, the floor screed is made with a welded mesh. The self-leveling floor can spread and become unusable without a strong welded mesh frame. Many stages of maintenance or capital construction are associated with this material.

Welded mesh for road works

Another area of ​​application of welded mesh is road construction. The road surface (asphalt) is laid on a crushed stone cushion.

Crushed stone can be laid either directly on the ground or on the grid. It is known that in the first case, the quality of the road surface decreases, dips or cracks may form. Crushed stone, laid on the ground, simply falls into it. In order to prevent such problems, when laying the roadbed, the location of the crushed stone is fixed with a grid with the corresponding mesh diameter.

Welded mesh for fencing areas

The next area of ​​application of the mesh is the device of fencing.

The strength and reliability of this type of rolled metal makes it very popular in this area. If you choose the right type of mesh, then even under the most unfavorable conditions, it will last a very long time. Firstly, for the construction of outdoor fences, you need to use galvanized mesh. It is resistant to corrosion. Secondly, in coastal areas where the humidity is especially high and the air is very salty, you will need to choose a PVC-sheathed mesh.

In this case, the contact of metal and water will not take place and the threat of destruction of the mesh will disappear.

How to protect the welded mesh from corrosion?

This question is asked by anyone who plans to use the mesh outdoors under the onslaught of natural elements. So what security technologies are known? What are their differences and features? Let's consider the issue in detail.

Galvanized welded mesh

As you know, basically this rolled metal is made from steel wire or rods. Steel is a durable material.

A high-quality, durable frame is formed from it. It is appreciated in construction. But, steel is completely not protected from corrosion. Even the highest quality and strongest mesh will lose these excellent properties without additional protection. To rid the steel mesh of exposure to humid air and water, a galvanized technique is used.

Before making the mesh itself, the steel wire is galvanized.

There are four options for such processing:

  • 1) Electrically galvanized wire. Welding mesh from it. The zinc layer with this method is 10 g / m2.
  • 2) Welding the mesh first, and only then galvanizing (also electrically).

    The zinc layer is already 20 g / m2.

  • 3) Hot-dip galvanizing of the wire and further welding of the mesh. The zinc layer will already be 50 g / m2.
  • 4) Well, the last way is wire welding and hot-dip galvanizing of the finished mesh. The zinc layer is as thick as possible - 130 g / m2.

The galvanizing method is very important to consider when choosing a welded mesh. It all depends on the scope of its application. The larger the zinc layer, the longer it will last. In addition, galvanized mesh after assembly is clearly preferable to pre-welded mesh. Thus, the fourth treatment is the most corrosion resistant.

PVC protection of welded mesh

Polymer protection is less popular than galvanized, but clearly undeserved. The fact is that such processing is more technologically sophisticated and makes the mesh more expensive. Therefore, it is perhaps less popular. PVC protection is applied as a sheath to the wire, which is welded into a mesh. Usually PVC film is green.

Such protection completely protects the metal from moisture and wears out slowly by itself. This PVC film protects against the most aggressive environment (for example, sea air or tropical rain).

Which welded mesh protection to choose is your decision. Start from the operating conditions, the desired duration of use and other special factors of your own. The choice is yours, and you received the information.

How to choose a strong welded mesh?

The quality of welded mesh is regulated by government regulations in the field of manufacturing metal products for the construction industry.

There are two main GOSTs:

  • 1) GOST 23279-85 - makes requirements for reinforcing mesh for monolithic and frame construction.
  • 2) GOST 8478-81 - designed to regulate the requirements for meshes for reinforced concrete construction.

What is the difference between GOST and TU?

In addition to these GOSTs, there is a huge list of technical conditions (or TU). The manufacturer himself decides what to rely on in the manufacture of products, but must indicate this in the documentation for the product.

The main difference between products manufactured according to TU and GOST is that the requirements for finished products were not developed by scientific institutions and they did not undergo mandatory tests and checks. TUs are developed by enterprises independently. It is a personal matter for everyone to trust TR or not.

Which mesh is better?

There is a direct relationship between wire diameter and product strength and an inverse relationship between mesh size and strength. Thus, the larger the wire diameter and the smaller the mesh itself, the stronger the welded mesh will be.

Manufacturers are free to independently adjust the listed indicators. Some of them make nets from thin wire, which reduces the total volume of metal per square meter. The formation of large cells leads to the same result.

This is not surprising, because the cost of the mesh depends on the metal content in it, namely the cost of the wire itself. The thinner it is and the smaller it is, the cheaper the mesh.

Although visually on a roll, it can look quite solid. That is why prices from different manufacturers vary so much for a seemingly identical product.

To avoid cheating, when buying a roll, you can weigh the roll or ask to unwind it a little. So it will be possible to at least visually assess the quality of the products. The weight can be found in the technical documentation for the product and after weighing it can be compared with the real one.

Perhaps the real weight will unpleasantly surprise you and the cheap price will become clear. Manufacturers, in pursuit of profit, have learned to reduce the diameter of the wire, the length of the roll, to loosen the cells so that it would not be noticeable to the common consumer.

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