May. 26, 2025
The Mesh Company are broadening our range ever further in . One material that we are delighted to now offer is expanded metal mesh (EXP). We will be launching new options across the year, and we have written this handy guide to hopefully answer any question that you may have.
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Expanded metal is also known as expanded sheet metal, or just expanded metal. It a type of sheet metal that has been cut and stretched to create a diamond-shaped pattern. This process increases the surface area of the metal, making it more durable and versatile. Expanded metal mesh is commonly used for architectural and industrial applications, such as building facades, security fencing, and machinery guards. It is available in a wide range of materials, including steel, aluminium, and stainless steel, and can be customized to meet specific structural, aesthetic, or functional requirements.
Perforated metal sheet may also be of interest as it is a similar product type. It is totally flat however, which may suit some applications better.
Yes. Expanded metal ceiling tile can be used in a variety of applications, including commercial and industrial buildings, as well as in residential settings. They are suitable for high traffic areas, such as airports, shopping centres, and other public spaces. These tiles are easy to install and can be suspended from a ceiling grid system. They are also lightweight, which makes them easy to handle and install. Additionally, Expanded metal replacement ceiling tiles are fireproof, soundproof and heat insulation. They also offer high ventilation and light transmission, making them an energy-efficient solution for lighting and HVAC systems.
Expanded metal mesh can be used as a reinforcing material for rendering, also known as a “scratch coat”, which is the first layer applied to a surface before the final render is applied. The expanded metal mesh is typically embedded in the wet rendering material and provides additional strength and stability to the surface, preventing cracking and other issues. It also helps to bridge any cracks or holes that may exist in the surface, providing a smooth and even surface for the final render.
It is used in the external insulation and finish systems (EIFS) in the construction industry as a reinforcement for the insulation layer. It is applied to the insulation layer which is then covered with a finish coat, this helps to increase the strength and durability of the insulation, preventing cracking and other issues.
Additionally, expanded metal mesh is also used in the construction of stucco walls, which is a traditional form of wall finish made of cement, sand, and water. The expanded metal mesh is embedded in the wet stucco mixture and helps to reinforce the wall and prevent cracking.
It can be cut using a variety of tools, such as tin snips, bolt cutters, or power saws. Tin snips are a manual tool that work well for cutting small pieces of expanded metal, while bolt cutters can handle larger pieces. Power saws, such as a metal-cutting band saw or a plasma cutter, can also be used to cut expanded metal, but they require a high level of skill and experience to operate safely.
It all depends on the thickness of the product. There are cutting guides on every product page depending on the material itself. We also offer a free cutting service if you require a bespoke size.
Yes, it is possible to weld expanded metal, but it can be more difficult than welding solid sheet metal due to the open structure of the material.
When welding expanded metal, it is important to use the correct type of welding process and filler metal. The most common welding process used for expanded metal is Gas Tungsten Arc Welding (GTAW), also known as Tungsten Inert Gas (TIG) welding, which is a precise and clean process that allows for control of the welding heat.
Another option is Gas Metal Arc Welding (GMAW) also known as Metal Inert Gas (MIG) welding, which is a faster process that also produces a clean weld.
To ensure a strong weld, it is also important to use a filler metal that is compatible with the expanded metal and the base metal. The base metal should be cleaned thoroughly before welding to remove any dirt, grease, or oil to ensure a good weld.
In general, welding expanded metal is a challenging task that requires skill and experience. It is always recommended to consult with a professional welder and make sure to follow safety guidelines when welding.
Yes, you can paint expanded metal. However, the open structure of the material can make it more difficult to paint than solid sheet metal. Also, some metals do not take paint. Plain steel is the best for painting.
Before painting expanded metal, it is important to clean it thoroughly to remove any dirt, grease, or oil. This will ensure that the paint adheres properly to the surface. A wire brush or sandpaper can be used to remove any loose rust or debris.
It’s a good idea to use a high-quality, rust-inhibiting primer before applying the final paint coat. This will help to prevent rust and protect the metal from the elements.
When applying the paint, it’s important to use a brush or roller with synthetic bristles or foam, as natural-bristle brushes can leave brush marks on the surface of the expanded metal.
It’s also important to use paint that is suitable for metal surfaces and to apply it in thin, even coats. Avoid applying too much paint in one area, as this can cause drips and runs.
It’s highly recommended to use a paint with a good quality and with the ability to withstand the elements, like a epoxy paint, or a polyurethane paint.
It’s also important to follow safety guidelines when painting, as some paints may contain harmful chemicals.
Yes, it is possible to bend expanded metal, but it can be more difficult than bending solid sheet metal due to the open structure of the material.
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The process of bending expanded metal typically involves using a brake press or a press brake. This is a machine that uses a punch and die to bend the metal to a specific angle. The punch pushes the metal against the die, which shapes the metal as it is bent.
It’s important to note that the open structure of the expanded metal can make it more prone to tearing or cracking. To avoid this, the metal should be bent gradually and at a slow speed, and the punch and die should be adjusted to the appropriate size and shape for the metal being bent.
Also, it’s important to use a lubricant to reduce friction and heat during the bending process to avoid cracking.
It’s highly recommended that the metal should be bent at the manufacturer or by a professional metal bender with experience working with expanded metal. As the process can be complex and requires specialized equipment, and knowledge of the metal properties to avoid any damage.
Bending expanded metal can be challenging and it’s important to follow safety guidelines when working with metal and equipment.
What is expanded metal? Expanded metal is an industry term that refers to metal that is cut by an industrial die and expanded (stretched), creating a diamond pattern. There are many industrial applications for this kind of material, which provides strength, flexibility, and various surface finishes, while being processed into coil and sheared sheets.
Manufacturers that produce air filters rely on expanded metal to give their filters strength with open area for ventilation. This makes expanded metal a key component in manufacturing air filters, including:
With so many types and variations of expanded metal intended for so many applications, how can manufacturers be sure they’re getting the right pattern and material for their air filter products? At Zauderer Associates, we’ve spent over four decades fielding questions from manufacturers just like you in pursuit of the right expanded metal for air filtration products.
Let’s take a look at the most frequently asked questions and the information you’ll need to consider when sourcing expanded metal.
Determining the correct expanded metal pattern requires understanding the strength requirements, type of metal needed, and how much airflow is necessary. For example, the thicker the strand width, the stronger the expanded metal will be. The thickness of the expanded metal is usually determined by the column strength required in a specific application. Lastly, the larger the opening (open area), then the greater the airflow that is created.
Below is terminology that is helpful in determining the correct type of pattern for your project:
Once you have determined what pattern of expanded metal that you need for airflow and strength, then you will need to determine if you want coil or cut to size parts:
There are many standard sheet sizes available at distributors but if you want to purchase your expanded metal coil or sheets to your exact specification, you will need to buy from a manufacturer of expanded metal. Zauderer Associates sells customized patterns of expanded metal in coil and sheet to meet your specific requirements for airflow, environment, and strength.
Since air filters are finished products that require expanded metal in different thicknesses, materials and gauge sizes, due to their specific function, it’s important for filter producers to find an expanded metal manufacturer that can custom produce expanded metal at different sizes and thicknesses from .016” to 0.055” thick, depending on the material chosen.
Some filter producers will buy standard sheet sizes and cut them down themselves, but this creates a less efficient process and generates significant scrap. Look for a producer who can meet your exact expanded metal specifications for sheet sizes with widths from 2” all the way up to 48”.
Since expanded metal is made from one intact sheet of material, it is much stronger than other types of mesh like chicken wire, which is assembled from individual wires. When used in construction applications, expanded metal is favored because it can be customized with different angles and hole sizes to maximize strength.
For industrial air filtration manufacturing purposes, the key is to find an expanded metal product that is strong without compromising flexibility where required. Expanded metal manufacturers who specialize in serving air filtration producers can provide metal that is flattened or unflattened (louver effect) and in coil or cut to size sheets, depending on the needs of the customer.
When you’re looking to buy, not just any expanded metal, but the right expanded metal for air filtration products, it’s important to partner with a specialist who understands the specific considerations for manufacturing of this kind.
Since , Zauderer Associates, Inc. has helped manufacturers simplify the purchasing process for the critical components they need to deliver a top quality finished product. We have represented the same expanded metal producer for over 40 years, and we leverage our expertise to make it easier for manufacturers to purchase the customized expanded metal products they need.
With strategically located representatives throughout the United States, we’re positioned to take the guesswork out of the buying process with straight answers to questions like these, rapid sample submissions, and fast turnaround times for expanded metal that meets your exacting specifications.
Still have questions? Need to fill an order quickly to keep your production moving? Contact Zauderer Associates, Inc. today.
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