Why weld strength matters more than just wire gauge

In the world of 358 mesh fencing, not all panels are created equal. Many companies market panels by quoting wire thickness such as 3.9 mm, 4.0 mm, etc. But that metric alone doesn’t tell the full story.

We recently carried out a series of destruction tests on three 358 panels to compare real-world performance. The results show why relying on wire thickness alone can leave your perimeter exposed. We chose 358 as it is often seen as a High Security Fencing system and therefore a safe panel for many projects such as schools, transport and logistics, and commercial projects.

The Test Setup & Results

Panel	Origin	Wire Diameter (mm)	Failure Load	% of Wire Tensile	Result
Panel 1	UK	3.96 – 3.99	4.9 kN	~75%	PASS
Panel 2	Turkey	3.76 – 3.77	2.4 kN	36.64%	FAIL
Panel 3	China	3.86 – 3.90	0.8 kN	12.21%	FAIL

Panels 2 and 3 are currently being sold into the UK market, despite failing at less than half, and in one case less than one-sixth, of the strength of the UK-manufactured panel. How do we know? Because the manufacturers approached us directly and sent these very samples as their best examples. They even told us which UK fencing companies they already supply.

“These weren’t random imports. The manufacturers sent us these samples as their best panels to prove quality. They still failed.”

Why Weld Strength Is the Real Gatekeeper

“A mesh fence is only as strong as its weakest weld.”

1. The weakness is at the joints

In a mesh panel, the points where wires cross are welded. If those welds are poorly made, for example under-penetrated, porous, or inconsistent, they will fail well before the wire itself breaks. This is exactly what we saw in Panels 2 and 3.

2. Wire thickness ≠ panel strength

Thicker wire alone doesn’t always guarantee security. In our test, the Chinese panel used almost the same wire size as the UK panel, but it still failed at just 0.8 kN. The reason, its welds could not sustain the load.

3. Real-world loads demand reliable welds

From crowd loading to climbing attempts, fences experience repeated stresses and sudden impacts. If welds crack or shear under these loads, the perimeter is compromised. International standards specify testing because weld quality is mission-critical.

4. Quality control makes the difference

Strong panels require not just the right design, but also rigorous inspection and destructive sampling. That’s what ensures every batch performs consistently, not just on paper.

What to Ask Your Supplier

• Weld shear test data – not just wire diameter.
• Batch quality control – how often are destructive tests run?
• Standards compliance – do they meet BS 1722 requirements?

Watch the Test for Yourself

It is not the size of the wire that keeps a site secure, it is the strength of the weld. In our tests, the UK panel withstood more than double the destructive load of the Turkish panel, and over six times that of the Chinese panel.

The Turkish panel had the thinnest wire (average 3.765 mm), around 5.3% thinner than the UK panel (average 3.975 mm). It performed better than the Chinese panel (average 3.88 mm), but still failed at less than 40% of the overall tensile strength. The Chinese panel failed at less than 13% of the overall tensile strength. The UK panel passed at 4.9 kN, equal to 75% of the tensile strength.

You can see the results for yourself in the video below:

Final Word

Don’t be misled by numbers on a datasheet. A panel can look the same and feel the same but when tested, weak welds fail well before the wire does.

If you’re responsible for protecting a perimeter, insist on weld test data, not just wire thickness. It is the welds that stand between a secure site and a serious breach.

We invite you to visit our mesh manufacturing facility and see a destruction test in person. Contact us today to arrange your visit.

The post Who’s Really Protecting Your Perimeter? appeared first on Zaun Limited.

The ability to offer protection through innovation has always been at the heart of all our product designs and HiSec Super 10 is no different. The world’s first single skin fencing system rated to LPS 1175 B3 (SR2) and Secured by Design was designed in January 2013, since then it has gone on to protect projects and assets around the globe. So let’s talk a little more about HiSec Super 10.

The secret is in the Verticals

Maybe we shouldn’t tell you this but the secret to our HiSec Super 10 is in the vertical wires on the fencing panel. Manufactured at our factory in the West Midlands on our own in-house rigid mesh machine, 10mm hot rolled then cold drawn coil is straightened and cut into lengths matching the height of the fence. These wires are then electro-welded to the horizontal 4mm wires to form the 358 mesh design.

These 10mm vertical wires form the backbone of the panel, delaying any form of attack by a would-be intruder using toolset B from Issue 8 of LPS 1175. This includes attack tools such as bolt cutters, drills, hammers, hacksaws and cutting pliers.

But what about the single skin

Well, that too is down to the 10mm vertical wires. With the added delay from a 10mm vertical wire at 76.2mm wire centres across the width of the panel, the need for another panel or any additional clamp bars and hardware to delay an attacker is obsolete. Not only does this help reduce the cost of protection in manufacturing but can also help to reduce installation costs on site.

Installation is at least 30% quicker than similar double-skin B3 (SR2) fencing systems in the marketplace because only one panel needs to be installed. The single-panel design also offers greater visibility and aesthetics as it allows ease of sight for CCTV and other detection systems which can be mounted to the rear of the panel.

Well that all sounds great but anything else

Actually yes, by manufacturing all the components ourselves HiSec Super 10 benefits from a lower embodied carbon than other systems. Our rigid mesh machine is run entirely by our solar panels that produce more electricity than we use so we are net positive on our electrical use during spring, summer and autumn. By bringing all the materials into the factory we are removing a major carbon footprint from the manufacturing chain in the form of onward transport to others of a separate panel as we supply the entire fencing system directly to our customers straight from our own manufacturing which reduces the carbon miles of the fencing system.

HiSec Super 10 is a Made in Britain fencing system that helps to support and generate social value through the employment of a local workforce that adds wider financial and nonfinancial value back into the area creating social capital. By specifying and using HiSec Super 10 on your projects you are helping to promote UK manufacturing, greener construction products and raising security to a tested and approved standard.

The post Let’s Talk – HiSec Super 10 appeared first on Zaun Limited.