Welded galvanized wire mesh is produced using high-quality low-carbon steel wire, which is automatically resistance welded and then electro-galvanized or hot-dip galvanized for corrosion protection to extend its service life. The entire production line is highly automated, with a stable, controllable, and standardized process, making it the most mainstream metal mesh production method in global construction, aquaculture, protection, and reinforcement projects. The entire production process includes 10 steps, which we will describe in detail below:
Raw material inspection: Q195 and Q235 low-carbon steel coils are preferred. The material composition, tensile strength, diameter tolerance, surface free of oxidation and cracks are strictly checked. Only raw materials with satisfactory quality proceed to the wire drawing process.
Wire drawing: The coiled steel wire enters a continuous wire drawing machine and is drawn step-by-step through multiple sets of dies to achieve the diameter required by the customer. The entire drawing process ensures high diameter accuracy, a smooth surface, and uniform strength. After drawing, the wire is cleaned, lubricated, and rust-proofed.
Wire straightening and cutting: The drawn steel wire is fed into an automatic straightening machine to correct bends and ensure straightness. It is then automatically cut to the required dimensions.
Automatic numerical control resistance welding: This is the core production process of Welded Galvanized Wire Mesh, which determines the strength and structural stability of the mesh. It can numerically control the aperture, wire diameter, width, and length, and all welding points are welded simultaneously to ensure that the welding points are firm, do not detach, and do not miss. After welding, an ungalvanized black wire welded mesh is formed, which can ensure uniform mesh, flat surface, and stable structure.
Leveling: After welding, the wire mesh enters a leveling machine to eliminate bends, waves, and deformations, ensuring a flat, warped, and dimensionally accurate surface.
Cleaning and Degreasing: Welded Galvanized Wire Mesh must be thoroughly cleaned before galvanizing; otherwise, the zinc layer will have poor adhesion and easily peel off. First, degrease with alkaline solution, then rinse with clean water. After acid pickling to remove rust, rinse again. A flux is used to enhance the adhesion of the zinc layer.
Zinc Plating: There are two main galvanizing processes: electro-galvanizing and hot-dip galvanizing. Electro-galvanizing has a zinc content of 8–20 g/m², resulting in a bright, silvery-white surface. It is mainly used indoors and in dry environments, offering advantages such as low cost and good appearance. Hot-dip galvanizing has a zinc content of 30–300 g/m², producing a thicker, silvery-gray surface with strong adhesion. It is mainly used outdoors and in corrosive environments. Of course, different production processes result in different types of Welded Galvanized Wire Mesh. Mesh prices also vary significantly; Post-treatment: This is what we commonly call passivation treatment, which improves the stability of the zinc layer, prevents white rust and oxidation, and allows the zinc layer to fully cure and the surface to become smooth through drying or natural air drying; Finished product inspection: After the Welded Galvanized Wire Mesh is produced, it must be inspected for hole diameter tolerance, wire diameter tolerance, zinc layer thickness, weld strength, mesh flatness, dimensional accuracy, etc. Only products that meet the requirements can leave the factory.