Mesh count is the number of openings per linear inch (or per millimetre) measured from centre to centre of the wires. For example, 4 mesh means four openings per inch. It is related to the pitch (centre spacing) by mesh = 1 / pitch (in inches).

How do you calculate open area of wire mesh?

For square mesh, open area percentage is (clear opening ÷ pitch)² × 100, where pitch is the centre spacing and clear opening is pitch minus wire diameter. For rectangular mesh, multiply the open fractions in each direction: (clear opening X ÷ pitch X) × (clear opening Y ÷ pitch Y) × 100.

Can this calculator handle both welded and woven mesh?

Yes. The geometry of welded and woven mesh is the same for weight and open area calculations. As long as you know the wire diameter and spacing (or mesh count), the calculator works for both welded and woven products.

What density should I use for different metals?

Typical densities are: carbon steel ≈ 7850 kg/m³, stainless steel ≈ 8000 kg/m³, aluminium ≈ 2700 kg/m³, copper ≈ 8960 kg/m³. The calculator lets you pick a material or enter a custom density if your alloy is different.

Wire Mesh Calculator – Weight, Open Area, Mesh Count & Coverage

How the wire mesh calculator works

This calculator is designed for both welded and woven wire mesh with square or rectangular openings. It can work from either:

Mesh count (openings per inch) and wire diameter, or
Clear opening (gap between wires) and wire diameter.

Key definitions

Mesh count (N): number of openings per linear inch, measured centre to centre.
Pitch (P): centre-to-centre spacing of wires.
Wire diameter (d): thickness of the wire.
Clear opening (a): free space between adjacent wires.
Open area: percentage of the surface that is open (not metal).

Formulas used

1. From mesh count to pitch (imperial input)

If mesh is given in openings per inch:

Pitch in inches: \( P_{\text{in}} = \dfrac{1}{N} \)

Pitch in millimetres: \( P_{\text{mm}} = \dfrac{25.4}{N} \)

2. Clear opening

\( a = P - d \)

where \( P \) and \( d \) are in the same units (mm or inches).

3. Open area

For square mesh:

\( \text{Open area} = \left(\dfrac{a}{P}\right)^2 \times 100\% \)

For rectangular mesh:

\( \text{Open area} = \dfrac{a_x}{P_x} \cdot \dfrac{a_y}{P_y} \times 100\% \)

4. Metal fraction (approximate)

For square mesh with equal pitch in both directions:

\( f_{\text{metal}} \approx 2\frac{d}{P} - \left(\frac{d}{P}\right)^2 \)

Open fraction is then \( 1 - f_{\text{metal}} \).

5. Weight per area

First convert all lengths to metres. For square mesh:

\( w_{\text{area}} = f_{\text{metal}} \cdot \rho \) (kg/m²)

where \( \rho \) is the material density (kg/m³).

6. Panel weight and total weight

Panel area:

\( A = W \times L \)

Weight per panel:

\( W_{\text{panel}} = w_{\text{area}} \cdot A \)

Total weight for n panels:

\( W_{\text{total}} = n \cdot W_{\text{panel}} \)

Typical densities for common mesh materials

Carbon steel: ~7850 kg/m³
Stainless steel: ~8000 kg/m³
Aluminium: ~2700 kg/m³
Copper: ~8960 kg/m³

Practical tips for using wire mesh

1. Allow for tolerances

Actual wire diameters and pitches vary slightly from nominal values. For critical applications (e.g. filtration), always check the manufacturer’s datasheet and consider a safety margin on open area and weight.

2. Square vs rectangular mesh

Square mesh has the same pitch in both directions and is common for fencing and reinforcement. Rectangular mesh is often used where strength is needed mainly in one direction or where a specific flow area is required.

3. Welded vs woven mesh

Welded mesh: rigid, dimensionally stable, ideal for concrete reinforcement and fencing.
Woven mesh: more flexible, common in screens and filters.

4. Estimating cost

If you know the price per kilogram (or per pound), the calculator can estimate cost per panel and total cost. Suppliers sometimes quote price per square metre at a given weight; you can cross-check by comparing the calculated weight per area.

FAQ

How do you calculate wire mesh weight?

Weight is calculated from the metal fraction (how much of the area is steel) multiplied by the material density and panel area. This tool uses a standard approximation that is accurate for most commercial meshes.

What is mesh count?

Mesh count is the number of openings per linear inch. For example, 4 mesh has four openings per inch and 10 mesh has ten openings per inch. Higher mesh count means finer mesh and smaller openings.

Can I use this for rebar mesh in concrete?

Yes, as long as the reinforcement is arranged in a regular grid and you know the bar diameter and spacing. For very heavy reinforcement, bar lap splices and edge bars may add a little extra weight beyond the idealised grid.

Does coating (galvanizing, PVC) change the weight?

Yes, coatings add weight and slightly reduce open area. This calculator assumes bare metal. For galvanized mesh, the extra weight is usually small but can be significant for thick coatings or very fine mesh.

Wire Mesh Calculator

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