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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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.

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Background

The Middle East is renowned for its large quantity of oil fields, and one of their biggest oil companies required a security update to a 9km site. The site, being the world’s second largest oil field, needed a high security upgrade to ensure the security of the perimeter was maintained.

This oil field provides around half of Kuwait’s crude oil production, roughly producing around 1.7m barrels of oil per day; and is the world’s most important source of energy thus security is of paramount importance.

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But what are 3 of the top locations where this kind of fencing is a requirement?

Zoo

One location where top-class security fencing is a must is zoos. Without this type of fencing installed to protect visitors from wild animals, they would be a perilous place to be! Security fencing for zoos, though, is not just about keeping visitors safe from danger. It can also help keep animals safe from harm and people breaking in when the zoo is closed to steal them. Welded mesh fencing is an option many zoos go for because it is robust, good value, can stand outside in all weathers and looks smart.

Data centres

The world is relying more and more on technology to operate now. Online tech is essential and sees us shopping online, using social media platforms and checking which services a business offers via their website. This online way of life is built upon a network of secure servers in data centres around the UK that handle masses of sensitive personal data each day. Therefore, it is key to protect the data centres these servers are housed in – not only from cybercrime but also from physical theft. The best way to do this is with high-end perimeter fencing. Tough to scale and hard to breach, it is a significant obstacle for would-be intruders.

Schools and colleges

Perimeter fencing is understandably crucial for colleges and schools. This is because both locations have large numbers of children inside who need the best protection. Security fencing for these locations also helps to keep staff and visitors safe. In addition, it stops people from getting onto school or college grounds overnight to cause damage. When combined with other security innovations, such as CCTV, it provides a very effective safety measure for these locations to use.

Top-class security fencing from Zaun

The above are just a few places where effective security fencing is a must. You could also include many others – from playgrounds to airports, waterworks, sports pitches, and beyond. If you need the best mesh security fencing for your site, get in touch with us today at Zaun.

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The importance of utility sites and critical national infrastructure (CNI) to the economy, and the widespread damage a security breach could cause, means it is essential to offer utility sites the highest levels of protection from threats, ranging from opportunistic theft or vandalism to acts of terrorism.

As we are so reliant on utilities such as electricity, we must have effective means of protecting these facilities. There are many ways to ensure the safety and security of these important locations, with trusted perimeter fencing often acting as the first line of defence from potential threats.

Multi-layered security

Utility sites are best secured using a multi-layered system, working from the outside-in with secure perimeter fencing. This works as a deterrent and a barrier that gives on-site security a chance to respond to any threats appropriately.

There are a lot of implementations of perimeter fencing available. Still, we advise going with fencing put through rigorous testing to meet industry standards such as LPS1175, CPNI Approved and PAS 68.

Another consideration for utility sites is finding perimeter fencing that includes a quality guarantee of sorts. This will ensure that the fencing is built to superior quality and is less likely to be compromised due to design flaws.

Maintaining current security measures.

A good perimeter fence is only as useful as its last inspection. Regular maintenance of these fences will ensure that any damage or issues found along the perimeter can be addressed quickly. This will keep the site secure and help protect against more sustained, worrying damage down the road.

Utility stations need to be constantly secure, and perimeter fencing can help with that. The caveat is that it requires the right type of fencing and regular upkeep to keep it in excellent working condition. If you’re interested in perimeter fencing and would like to know more, please contact our team at Zaun today.

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1. Security

Mesh fencing is commonly used as a perimeter wall or security fence. It can offer security purposes to residential, industrial or commercial properties. Mesh is also a popular choice for securing homes, however, this is often combined with a form of fencing that is generally considered more aesthetic. For increased security, some people choose a type of mesh fencing that prevents finger holds or tools being able to cut through, due to the extremely small openings.

2. Public Parks

As mesh fences can be installed in various different colours, some people enjoy the look of it in their local parks. For those who are passionate about plants, a mesh fence is a good alternative to wires for plants that climb, as they can easily take the weight without having to be regularly repaired, unlike the alternative.

3. Animals

Mesh fencing is a popular choice for fencing in animals, no matter what they are. As it’s possible to purchase the fence with different sizes of holes, it can accommodate any form or size of the animal. Some of the most common options are horse fencing, rabbit fencing and chicken coops. It is also an extremely safe option for animals, due to the lack of sharp edges.

4. Highways and railways

One of the main industrial uses of mesh fencing is on highways and railways for security purposes. They are extremely beneficial for preventing damage of the tracks, and also to prohibit animals from crossing over dangerous areas.

To shop our range of premium mesh fencing, don’t hesitate to visit our website, or contact us at Zaun for information and guidance.

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While developed to protect sites of national importance, the latest advanced security fencing can provide robust assistance when safeguarding your local environment. However, when selecting fencing, it is also essential that the chosen product is compatible with the creatures who live close by and do not present a threat to animal life.

In the next sections, we’ll explore how fencing can protect the local environment from artificial threats.

Protecting endangered species

The UK is home to many protected species such as badgers and newts, and enterprises operating in areas inhabiting them must consider any risks to their safety. High-security fencing like ArmaWeave can be particularly effective at keeping areas that may present a threat to these creatures out of bounds. However, some fencing solutions can cause harm to animal life, presenting a possible trap that they can become stuck in when the apertures are too large. ArmaWeave is ideal in this respect as it forms an impenetrable barricade of woven mesh fencing that even smaller animals cannot bypass or become trapped in.

Safeguarding local ecosystems

Enterprises operating in the water industry or near watercourses must protect the supply itself and the flora and fauna it comes into contact with. Open stretches of water may need to be fenced off, defending against possible contamination from harmful chemicals and other kinds of artificial pollution, including fly-tipping.

Fencing can also provide a perimeter around areas where noxious chemicals are stored or may be spilt and where dangerous mechanical equipment is used to protect wildlife nearby from any potential harm.

How security fencing is coated and installed

When selecting secure fencing that may contact animals and effectively keep them out, it is important to pay particular attention to the materials used and how they are installed. Burrowing creatures like badgers may bypass fencing by digging beneath it and tunnelling through to the other side. Although, for this reason, anti-burrowing options should be considered as part of the installation, both concrete sills and backfilled buried fencing are notable solutions that offer strong support.

As mentioned before, any gaps in fencing must be too small for animals to slip through and never large enough for them to become ensnared while attempting to penetrate the defences you’ve put in place for their own safety.

Security fencing can come with different coatings, from powdered metal paints to rust preventatives. Considering that animals attempting to penetrate fencing will likely try to bite through it, any coatings chosen for the fences you install to keep them out must be entirely non-toxic, so they present no danger if ingested.

Experts in fencing solutions

Whether you are a local authority, operating a water treatment facility or are responsible for an area of outstanding natural beauty (AONB), if you require a fencing solution that is considerate of the environment, you can rely on Zaun any assistance required.

You can explore our full range of fencing on our website but don’t hesitate to contact our specialist team today for guidance on selecting the appropriate solution to suit your specific requirements on site.

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Unfenced sections of the perimeter

It goes without saying that perimeter fencing is vital for utility security. It not only stops children from getting into play on-site but also stops intruders from stealing materials or causing mischief. It also provides security for workers on-site. One mistake is not to erect security fencing or have sections that the fencing does not cover. You can also sometimes see broken sections of fencing around a site. All these things are bad for overall security and should be avoided.

Poor visitor management

You can have the best fencing in the world, but that will not amount to much if your visitor management procedures are poor. Controlling who is on-site, where they are going, who they are seeing and why they are there is critical with this in mind. You cannot afford to have lax security around visitors and let people wander around willy-nilly. So take the time to formulate a robust strategy for visitors and ensure reception staff follow it.

Not accounting for hostile vehicles.

Sites of national interest such as utilities can often be the target for terrorist groups or criminals. Their high importance to normal life is the prime reason they become a target. In addition, we are starting to see vehicles used more and more in attacks now – this makes taking hostile vehicle mitigation measures into account a must. But what is this? In simple terms, it sees sites take extra precautions to stop hostile vehicles in their tracks.

Utility security with Zaun

If your utility site is to stay safe, you cannot afford to make any of the above mistakes. Here at Zaun, we can provide top-class mesh security fencing for your perimeter and hostile vehicles mitigation solutions. Get in touch today at sales@zaun.co.uk for more details.

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Barbed wire toppings

Designed to defend important assets, barbed wire provides both a physical and visual deterrent to trespassers. Barbed wire topping can be used in conjunction with Y-shaped brackets and should ideally be fixed at a height at least two metres from ground level.

Concertina razor wire toppings

Concertina razor wire is among the most commonly adopted fence topping and is manufactured from galvanised metal for strength and durability. A wide variety of blade choices is on offer, including harpoon profile and T-spec to bolster security fencing.

Electrical fence toppings

Finally, engineered to provide a physical and psychological barrier, electric fence toppings are a premium solution for sites seeking advanced security levels.

These systems include a fully monitored detection barrier that can issue high-voltage pulses as an active deterrent. Highly flexible, these electrified options allow the site operator to arm different detection zones individually.

The clever construction of electric fence protector barriers is designed to effectively repel unwanted intrusions and make penetration exceptionally difficult to attain.

Experts in onsite security measures

At Zaun, we specialise in providing premium security fencing solutions designed to defend against the most determined and skilled intruders. Our extensive range of security fence toppings is ideal for further enhancing the stopping power of your firm’s perimeter. Contact our specialist team today for guidance on the best security solution for your business.

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Below are some critical physical security measures that every data centre should be employing.

Perimeter security

Like any other sensitive site, data centres need to have a secure perimeter. High-security perimeter fencing will immediately improve data centre security by making it difficult to access the building without using the security gate.

Backup power supply

Another essential security feature of any data centre is a backup power supply. If your main power supply is interrupted for any reason, you need a backup to kick in immediately. This won’t just protect your servers; it will also ensure your security systems remain active.

Natural disaster mitigation

Floods, earthquakes, and forest fires can all present a serious threat to your data centre and its infrastructure. If any of these are a concern in your data centre’s location, you must account for them in the building’s design.

Physical access control

The only people who should have physical access to your data centre and servers should be those with a genuine need. Digital access control systems require security codes, keycards, or other forms of authentication to ensure that only authorised personnel can access restricted areas. They also make it easy to monitor where people are and maintain records of who has accessed each area of your data centre.

Penetration testing

Penetration testing is the most reliable way of auditing digital and physical security. So put, pen-testing involves trying to breach your own defences. If you manage to defeat the security measures you have in place, you will know where the gaps are and where additional measures need to be introduced.

Keeping a data centre secure is about more than just deterring hackers. To maintain the security and integrity of any data stored in a data centre, the location itself needs to be protected. Fortunately, many of the most effective security options are simple and cost-efficient.

Looking for security fencing for your latest data centre project? Contact Zaun today!

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