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.

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We are pleased to annouce that Zaun has passed Cyber Essentials Plus. This means our IT systems have undergone a hands-on technical verification passing the following five technical controls:

1. Firewalls
2. Secure configuration
3. Security update management
4. User access control
5. Malware protection

Cyber Essentials is an effective, Government backed scheme that helps to protect organisations, whatever their size, against a whole range of the most common cyber attacks. Certification gives peace of mind that your defences will protect against the vast majority of common cyber attacks simply because these attacks are looking for targets which do not have the Cyber Essentials technical controls in place.

Cyber Essentials Plus still has the Cyber Essentials trademark simplicity of approach, and the protections you need to put in place are the same, but for Cyber Essentials Plus a hands-on technical verification is carried out.

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Under BS EN 10244, metal coatings used on fences have to adhere to specific requirements. These include:

– The type, grade and quality of coating must be stated at the time of ordering.

– The mass of the coating must be expressed per unit of the surface area of bare wire.

– The coating must be smooth and evenly distributed, without any bare patches or signs of cross-contamination.

This quality standard means that wire fencing must be adequately tested to ensure compliance. Ultimately, this prevents poor quality products from making it onto the European marketplace and ensures consumers have access to reliable products, which we’re certain you’ll agree is important when it comes to security fencing.

How does BS EN 10244 improve the quality of steel fencing?

Fences tend to be on the receiving end of a lot of inclement weather at all times of the year in the UK. Rain, sleet, snow, hail, frost and wind can all impact even the toughest of fences, which is why it is so important to have adequate protection against the elements. In the fencing industry, the purpose of zinc alloys is to provide the best possible corrosion resistance. Most zinc alloys consist of around 95% zinc and 5% aluminium, although variations which can contain up to 20% aluminium are available.

Zinc alloys have been proven to provide incredible resistance to corrosion in comparison to other galvanised steel coatings. When combined with aluminium, it is thought that zinc coatings can improve the lifespan of a steel fence by anything up to four times.

The beauty of zinc alloy coatings is that they don’t require any additional powder coating and won’t even require regular maintenance or cleaning. Zinc wire will remain corrosion-free even after welding. It’s the most economical way to get more out of your fences.

When to consider zinc-coated fences

Rust prevention is a huge factor when maintaining any steel fence, and the materials/coating methods of a fence will have a huge impact on its longevity. If you install a steel fence without any protection, atmospheric conditions will cause the fence to rust more quickly.

Zinc alloy fences should be employed whenever you need durability and need to protect against high levels of corrosion (in an outdoor area with heavy rainfall, for example).

Sites like prisons, MoD buildings, mental health secure units and other government institutions require reliable, corrosion-resistant fencing. Sensitive buildings/areas cannot afford their fences to have any weak links caused by corrosion.

Find out more

Contact Zaun today if you would like to upgrade and replace your existing fencing or require corrosion-free fencing for a new project. As BS EN 10244-compliant fencing stockists, we’ll be happy to discuss the latest zinc-coated options and provide advice on the right products for your endeavour.

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But what benefits does this treatment for fencing deliver?

Extends lifespan

The financial investment installing security fencing brings means you need it to last a long time. While top-quality standard fencing will do this, powder coating will add years to its overall lifespan. This is down to the complex organic layer powder coating, helping protect the metal underneath. This means it stands up better to the corrosion which being outside in all weathers brings. Powder-coated perimeter fencing is also much more resistant to graffiti, and this also helps it last longer.

Custom and noticeable fencing

Another benefit of powder coating your fencing is the huge range of colours you can choose from. At Zaun, for example, we have 60 standard finishes and 1000 non-standard colours to select from! This means you can create a truly custom look for your high-security fencing without any hassle. Opting to coat your fencing in a bright colour also helps to make it stand out more. This can come in handy for marketing purposes or simply so people can spot it easily.

Powder Coating Fences = Low maintenance

You might be keen on getting fencing installed to protect your business, but high maintenance requirements are not as desirable. Luckily, powder-coated fencing is low maintenance, and this means you do not have to spend lots of time or money on keeping it looking great. One example of this is the ability of powder coating has to resist UV induced colour change or fading. This means you do not have to divert resources into having the colour touched up regularly.

Contact Zaun for powder coating fences.

Here at Zaun, we are proud to offer BS EN 134838:2005 accredited powder coating as one of our services. Our experienced team can powder coat your security fencing to make it stand out and give greater longevity. If you would like to find out more, get in touch at sales@zaun.co.uk.

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There are two methods to apply metallic coatings: a hot-dipped coat and an electro-plating finish. The wire first moves through a melted zinc wash until the steel wire has the correct coating thickness required; it then passes through a final zinc-aluminium wash where it then will be left to cool. The steel wire then moves through a chemical solution that contains the corresponding ions of the metallic coating, where electricity then dissolves the anodes in the metal and transfers the ions onto the wire. This process and the Bezinal 2000 advanced zinc-alu alloy give any wire product superior corrosion resistance and are one of the highest specs of galvanized wire currently available. It has a tensile strength of 450 N/mm² to 1100 N/mm², a minimum coating weight of 50g/m², with an average of 75g/m².

Why use Beznial 2000?

With Bezinal 2000 cathodic protection, thin coating, smooth surface finish, and a high-temperature performance staying strong up to the exposure of 350°C, it’s the perfect cost-effective choice that’s undergone rigorous testing. Under salt spray tests, Bezinal 2000 coated wires lasted up to 2,000 hours before the appearance of just 5% Dark Brown Rust, whereas simple Zinc coated wires lasted less than 500 hours. Under heat tests, it’s typical for regular hot-dipped galvanized (HDG) wires to experience alloy layer growth, exposing the wire to brittle alloy layers that can reduce the lifespan of the wire and create harmful and dangerous material waste, especially when the product is bent. However, Bezinal 2000 coated wires are entirely immune to this phenomenon due to an inhibiting action of the aluminium. Tests have repeatedly shown no layer growth with Bezinal 2000 coatings on tests ranging up to 245 °C for over 30 days. While under Kesterinch tests inside a controlled cabinet, where wires are exposed to simulated industrial pollution and volcanic activity, Bezinal 2000 offers the best performance, beating regular zinc wires by up to 8 times, lasting 160 cycles of exposure before just 5% of dark brown rust sets in once again.

What can it be used on?

Bezinal 2000’s advanced zinc-alu alloy can be applied on wires intended for a wide variety of uses. It has already been used on spiral knotted fences, wire fencing for small animal cages, slope meshes (hexagonal meshes), sheep fencing on farmland, chain link fences, vineyard wire, and even gun nails for longer life spans. It has also been used on Zaun’s ArmaWeave woven mesh high-security fencing, which was specifically designed to be installed on sites of critical national importance (CNI) in the UK, which has been tested and approved for UK government use by CPNI and various other government departments such as the MoD.

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At Zaun, we are leaders in creating high-quality security fencing and we offer a range of robust and secure fencing options including Double skin 358 and HiSec SR2. Both of these fencing materials have been developed to provide superior security, with unique features, high-quality manufacturing and innovative technology. We take a look at the benefits of each security fencing option and which is best suited to your project.

HiSec SR2

Our HiSec SR2 is our premier high-security system which is designed especially for high profile sites that need serious perimeter protection. We worked alongside the Home Office to develop a fencing solution that was visible, difficult to climb and reduced the effectiveness of any attacks. HiSec SR2 fencing has also been Secured by Design approved and can provide the same level of protection as double skin 358 mesh but it is just a single panel. If you are looking for a secure fencing solution, HiSec SR2 fencing is SR rated for B2 and is included in the Red Book from the Buildings Research Establishment (BRE), achieving the security rating B3 under issue 8 (SR2 under issue 7), so you can rely on it for high performance.

Double Skin 358

For sites that need a more robust security fencing system, a double skin system can be the best choice. Our Double Skin 358 fencing is made from two layers of HiSec 358 welded mesh and both panels are welded together. This means it is difficult to climb and difficult to cut using standard hand tools. Our Double Skin 358 fencing is extensively used in prisons, where security is of the utmost importance. Double skin 358 fencing exceeds UK prison specifications.

Security fence installation

HiSec SR2 is a cheaper option than Double Skin 358 when it comes to installation costs and it also has no additional clamp bars. Compared to standard 358 mesh security fencing, HiSec SR2 has a similar installation process and fewer bolts. As Double Skin 358 has more fixings, it takes longer to install and costs more due to the amount of fixings and the use of two panels, but it could still offer increased protection for high-security sites.

The ideal security fence

When you are choosing a security fence, it is important to look at what specifications are required. For a site that requires LPS1175 or a guaranteed delay time such as a water treatment works or a data centre, HiSec SR2 is a strong, visible and cost-effective fencing choice. For areas that need extra security measures, like prisons and military buildings, a double skin fence like Double Skin 358 might be a better option. Depending on where you are trying to secure, both Double Skin 358 and HiSec SR2 are manufactured to the highest standards and designed to offer maximum protection for your property.

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The danger of this is that as rust spreads, it breaks down the metal and weakens it. This is not a desirable feature in security fencing as it automatically makes it more vulnerable to attack, with intruders more able to bypass your defences.

For this reason, the latest security fencing is treated with a powder coating, offering premium protection against weather and contaminants and ensuring your metal fences stay in mint condition. However, those concerned with maximising fence lifelines should pay particular attention to the products they purchase to ensure that the protection treatments used to meet certain standards.

What is BS EN 13438?

BS EN 13438 is a British Standard last updated in 2013 that applies to varnishes and paints, such as powder coatings, designed for use with galvanised steel products. The standard sets particular performance requirements for the powder coatings used, allowing purchasers to know that the products using them can be relied upon.

At Zaun, we recommend that you specify that the product used meets this British Standard when selecting a powder coating to be used on your security fences. BS EN 13438 means that the coating has been tested in-depth with analysis covering various attributes, including film thickness and pre-treatment requirements. It also means that it has undergone stringent quality control processes and destructive testing to prove its ability to remain resilient under duress.

What is powder coating?

Powder coating is effectively a kind of coating that is primarily applied as a free-flowing, dry powder. Unlike traditional liquid paint delivered through an evaporating solvent, these powder coatings are applied electrostatically before being cured by ultraviolet light or heat. The powder used may be a thermoset or thermoplastic polymer, but either way, it will provide a more robust finish than standard paint. Additionally, enterprises using security fences can brand their defences in their company colours, as powder coating can offer a wide selection to choose from.

Anti-corrosive properties

Depending on where your security fence is located, it may have to contend with more than just rust. Acids and chemicals in airborne pollution in industrial areas can eat into fencing, as can salt, wind, sand, and humidity in coastal regions.

We here at Zaun offer Duplex Marine Coatings for sites that are near the coastline or open water. This enables fences to be treated with powerful protection against corrosion, giving them a life span of over 15 years. However, the correct level of coating must always be matched to the environmental elements the fence will be subjected to ensure its longevity. Contact our team today for further information or to discuss your specifications.

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What is the BS EN 14974:2019 standard?

In simple terms, this is a safety standard designed with skate parks in mind. As you would expect, its main aim is to make skate parks safer to use and safer to enjoy. It is a broad-ranging standard for the building and operation of such parks.

It should be noted that no safety standards can ever make skate parks 100% accident-free. The very nature of the activity which takes place in them makes occasional sprains, falls and mishaps hard to prevent. This safety standard does, though, ensures skate parks are built so that the likelihood of accidents is reduced.

Following this standard is also key to keep skate park owners within the law. Under UK legislation, skate park owners are normally only liable for damages if they can be proved negligent. However, by taking the required steps, such as following this standard, it is unlikely this will happen in the event of an accident.

What does it mean in terms of fencing?

An essential part of any skate park is the fencing which gets installed on-site. BS EN 14974:2019 covers fencing in such facilities and sets out certain conditions to follow. Finger traps can be a real danger when skateboarding, for example, and can see skaters trap fingers when riding. To help combat this, the standard stipulates that any gap between the safety channel and handrail is less than 89mm. This leaves too small a gap for people to trap fingers in.

Which products are compliant?

If you are responsible for operating a skate park, it really is essential only to use products that comply with this standard. This keeps you in line with the law, makes your park a safer place to be and stops you from being held liable in most cases for any accidents. But what compliant products are there to consider?

The best choice for many in terms of fencing is Zaun’s Spectator Rails. They can be manufactured to BN ES 14974:2019 standards for total peace of mind and enhanced safety, but this standard must be specified at the time of order to ensure compliance. The compliant rails are supplied with extended clamp bars at the end and corner posts to meet the relevant guidelines.

Contact Zaun today for compliant Spectator Rails.

If you need great value products that comply with BS EN 14974:2019, get in touch today at sales@zaun.co.uk. Our top-quality Spectator Rails are the ideal solution to make your facility more appealing to use and legally compliant.

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In short, they are all essentially the same product; Galzal, Bezinal, Crapal and Galfan are all trademarks and brand names, just from different wire suppliers.

What are these products?

All these names refer to wire (or other steel products) that has been galvanised in an alloy of Zinc and aluminium as opposed to normal galvanising that is just zinc. We will refer to it as a zinc-al coating.  The alloy is typically 95% zinc and 5% aluminium (Zn95Al5), but variations up to 20% aluminium have been made.

While traditional galvanised coatings deliver a good level of service life, zinc-al has been shown to offer superior corrosion resistance compared to its zinc-coated steel counterpart. In addition, 5% aluminium can double life, and 10% increase life four-fold (in salt-spray tests).

Sometimes the name will be followed by the term “class A”.  Class A refers to the zinc/aluminium coating thickness as detailed in BS EN 10244-2. This thickness varies with wire diameter, but as a typical example class A on 4mm is 275g/m2.  Zinc-al could also be supplied as class D with a much thinner coating, but generally, as a premium product, it is class A.

How was it born?

It all started in the 1970s when research was carried out to look at the effectiveness of zinc coatings that contained a percentage of aluminium and various tests were conducted with zinc coatings containing up to 15% of aluminium. It became clear that zinc that contained 5% aluminium delivered great corrosion resistance. Still, it proved difficult in the early days to solve the issue of unwetted bare spots that detracted from the commercial usefulness of the coating as a product.

It was subsequently discovered that when a rare earth mischmetal that contained cerium and lanthanum was added, it resolved the problem of wettability whilst improving coating ductility and fluidity at the same time. It was this mischmetal formulation that led to the creation of the product that was named Galfan⁽³⁾

Why Galfan⁽³⁾?

GalFan has been a recognized trademark since 1981 when the International Lead Zinc Research Organization (ILZRO) managed to obtain worldwide patents relating to this new alloy for anti-corrosion coating. The product’s name was derived from a comment made by the head of the French Steel Information Centre, who described the product as “galvanisation fantastique”, subsequently shortened to GalFan.

How is it different to other pre-galvanised wire?

Zinc-al delivers improved corrosion protection compared to like for like thickness of standard pre-galvanised wire, typically, it is applied thicker to give substantially enhanced life.

Additional powder coating is not required on any products manufacture in Zinc-al. The high-performance coating alone provides enough protection for installation on-site and increases the fence’s lifespan without the need for maintenance or cleaning.

Zinc-al wire can be used with excellent life expectancy even after welding with the cathodic reaction, effectively healing any damage from spot welding.  Thus generally, today, panels that will be painted have a simple zinc coating to class D, whereas panels that will be used in their galvanised state should be made from zinc-al wire.

Why and when you need it

Preventing rust should always be a consideration for any steel fence that is installed. The materials and treatment methods used will have a major impact on the longevity of the fence.

Without protection, any steel product will rust over time due to atmospheric conditions. The level and speed of corrosion will depend on the environment in which the product is installed.  If you do not know the corrosion rate of your site, you can find out using this easy to use corrosion map (Corrosion Map).

Zinc-Al is typically required for sites where durability is required and minimal maintenance and cleaning will occur, but an enhanced level of corrosion protection is still required. Usually these sites are MOD sites, mental health units, prisons and other government institutions. It is important for these sites that the fencing installed lasts, as they cannot afford for there to be any weaknesses in the perimeter due to corrosion.

What products are typically available with this level of protection?

• HiSec 358
• HiSec DualSkin
• HiSec Prison
• HiSec Super 6

References

(1) Bezinal – registered trademark of Bekaert

(2) Crapal – registered trademark of ArcelorMittal Bissen & Bettembourg

(3) Galfan – registered trademark of Galfan Technology Centre LLC

(4) Galzal – registered trademark of Zaun Limited

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This standard has been produced by the British Standards Institute. The BSI is appointed by the government as the national standards body. As the world’s first of its kind, the BSI was established in 1901. The BSI uses a collaborative approach, engaging with government bodies, industry experts, trade associations and consumers to develop standards.

What fences is it used on?

The standard is widely used on a variety of fences, including railings. In addition, it is used on mild steel (low carbon steel fences), designed to be long-lasting and strong. Available in a range of heights and grades and is often used for perimeter demarcation.

What does the standard cover?

The BS 1722-9 covers requirements for protective treatment. However, it doesn’t cover maintenance of the fence after installation. The standard is in place to cover the minimum requirements for quality and materials of the more common types of metal railing to ensure satisfactory service for the purchaser. When railings are bought that have been manufactured to the BS 1722-9 standard, it is guaranteed that they have followed the British standard.

The standard also helps manufacturers and installers by removing unnecessary minor variations in the demands of purchasers. It details specific requirements for fence components and also how the fence should be constructed. In addition, it includes requirements for the size of components and the permissible tolerances on size.

What changes have been made to BS1722 Part 9?

The BS1722 Part 9 was updated in 2006. The new version included some major changes, such as the removal of flat posts. It also included the removal of requirements for angle corner posts. In this version, they are specified as for line posts. It also includes revision of the requirements for gates. The installation and construction requirements have also been simplified to be in line with current practice.

Why is the BS1722 Part 9 important?

The BS1722 Part 9 is important as it helps improve the quality and safety of products and systems and ensures the health and safety of workers. For example, steel fences that don’t follow these standards are likely to be poor and even dangerous.

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