Expanded Metal

Expanded Metal

Expanded metal (also called expanded mesh) is a metal grid produced by punching slits into a metal sheet and then stretching (expanding) it. This transforms the sheet into a mesh-like structure without any material loss — the slits open up into diamond-shaped openings. Expanded metal is not a woven fabric but has functional overlaps as ventilation grilles, façade elements, or screens.

Characteristics:

• Material Continuity: Expanded metal is made from a single piece. There are no welds or weaving knots, giving it high strength and stability.
• Rigidity: Unlike wire mesh, expanded metal is relatively stiff, especially when made from thicker sheets. Thin expanded metal can also be rolled and bent.
• Mesh Shape: Mostly diamond-shaped (standard 45° staggered layout), but scales or hexagonal shapes are also possible. The edges at the expanded sections are usually slightly offset in planes, making the mesh three-dimensionally slightly wavy.
• Open Area: Typically ranges from 40–80% depending on the design. The elongated openings can appear more open than comparable square grids.

Applications:

• Façades and Architecture: Expanded metal panels are popular due to their robustness and vandal resistance and offer an interesting aesthetic. They are seen in parking garages, industrial buildings, and also as designed elements in museums or schools. They can act as a second skin, similar to metal mesh, but with a more industrial character.
• Walkways and Flooring: Many grating floors are actually welded from flat steel, but for certain lighter-load applications, expanded metal is used as stage flooring or catwalks (rough surface, slip-resistant).
• Protective Covers: Machine guards, lamp cages, ventilation covers — expanded metal provides good protection and is easier to cut and form to size than woven mesh.
• Screens: Used for coarse screening (e.g., protective screens over gutters or chutes). Finer classification is less common since openings cannot be made as small or uniform as woven mesh.

In GKD’s world, expanded metal often serves as an alternative: If a customer wants a façade cladding, they might consider expanded metal versus metal mesh. Expanded metal is more robust and has a more industrial look; metal mesh is more elegant and transparent. The choice depends on design and technical priorities.

Expanded metal typically offers more economical production for coarse structures because punching and stretching is a continuous process. For fine structures, it becomes less cost-effective.