When working with heavy-duty mesh, cutting it to size is often necessary to meet specific project requirements.
For woven and welded wire mesh with apertures larger than 6mm, an angle grinder is one of the most efficient tools available. It ensures clean, precise cuts while maintaining the integrity of the material.
This guide explores how to effectively cut heavy-duty mesh, focusing on both woven wire mesh and welded mesh with reference to The Mesh Company’s range of products.

Understanding Heavy-Duty Mesh
Heavy-duty mesh is defined by its strong wire construction and relatively large apertures. These properties make it ideal for demanding applications such as fencing, industrial reinforcements, and animal enclosures.
We have loads of options available. For we have selected these examples for the purpose of this article:
- A robust woven mesh with a corrosion-resistant finish, ideal for outdoor or harsh environments.
- The thick 1.6mm wire ensures strength without compromising flexibility.
- Known for its balance of strength and ease of use, this woven mesh is perfect for projects requiring durable materials.
This listing gives several good welded mesh examples:
Galvanised Steel Weld Mesh Rolls
- A variety of welded meshes featuring durable construction and rust-resistant coatings.
- Available with aperture sizes over 6mm, suitable for fencing or structural reinforcements.
Tools Required for Cutting Mesh
Essential Tools:
- Angle Grinder: A reliable power tool equipped with a cutting disc designed for metal.
- Metal-Cutting Disc: Use a thin disc for precision cutting and minimal material wastage.
- Clamps: Secure the mesh to a sturdy work surface to ensure stability during cutting.
- Safety Gear: Always wear protective gloves, goggles, and ear protection.
Step-by-Step Guide to Cutting Heavy-Duty Mesh
Preparation:
Measure and Mark
- Use a tape measure and marker to define the cutting line. Ensure accuracy to avoid wasting material.
- Tip: For woven wire mesh, align the cut along the wire pattern to simplify the process.
Secure the Mesh
- Clamp the mesh to a flat, stable surface such as a workbench or heavy table.
- Ensure the clamps are tight enough to prevent movement but avoid over-tightening to prevent warping.

Cutting Woven Wire Mesh:
Position the Angle Grinder
- Hold the grinder firmly and align the cutting disc with the marked line. Start at one edge.
- For meshes like the 11.1mm hole option, the thicker wire requires steady pressure.
Make the Cut
- Turn on the angle grinder and guide it along the marked line. Maintain a consistent speed and pressure to ensure a clean cut.
- For larger apertures like those in the 6.87mm hole option, the process may require slight adjustments to navigate the thicker wires effectively.
Refine the Edges
- After cutting, use a grinding or sanding disc to smooth the edges. This step is crucial for ensuring safety during handling.

Cutting Welded Mesh:
Align the Grinder with Weld Points
- For meshes such as Galvanised Steel Weld Mesh, focus on cutting through the welded joints for easier separation.
- The fixed intersections in welded mesh add stability, but they may require additional pressure when cutting.
Maintain Consistent Pressure
- Apply firm, even pressure to avoid bending or distorting the mesh.
- Work methodically along the marked line to achieve a straight edge.
Check and Smooth the Edges
- Inspect the cut edges for burrs or sharp points. Use a sanding attachment to refine the finish.
Tips for Cutting Different Types of Mesh
Choose the Right Cutting Disc
- For stainless steel woven mesh, use a cutting disc specifically designed for harder metals to prevent wear.
- For galvanised welded mesh, a general-purpose metal disc works well, but ensure it’s thin for precise cuts.
Avoid Overheating
- Excessive heat can weaken the galvanisation or compromise the structural integrity of the wire. Pause occasionally to let the material cool.
Handle with Care
- After cutting, the edges of the mesh can be sharp. Always wear gloves when handling or installing the material.
Comparison of Mesh Types for Cutting
Woven Wire Mesh:
- Advantages: Flexible and easier to handle, ideal for projects requiring intricate cuts.
- Challenges: The thick wires in heavy-duty meshes like the 11.1mm hole option require more effort to cut. Also, whereas welded mesh is joined at the weave, woven mesh is loose and become unattached when cut against the weave.
Welded Mesh:
- Advantages: Strong and rigid, making it suitable for large-scale applications like fencing.
- Challenges: The welded intersections add stability but require precise cutting to maintain a clean edge.
Safety Precautions
- Wear Proper PPE: Protective gloves, goggles, and ear defenders are essential.
- Work in a Ventilated Area: Cutting metal produces sparks and dust, so ensure proper ventilation.
- Secure the Work Area: Keep bystanders and flammable materials away from the workspace.
- Inspect Tools Regularly: Check the angle grinder and cutting disc for wear and tear before use.
Cutting Heavy-Duty Mesh Checklist
Task | Details | Complete? |
---|---|---|
Measure and Mark | Use a tape measure and marker to define the cutting line clearly. | ☐ |
Secure the Mesh | Clamp the mesh to a stable surface to prevent movement during cutting. | ☐ |
Check the Tools | Ensure the angle grinder and cutting disc are in good condition. | ☐ |
Wear Safety Gear | Put on gloves, goggles, and ear defenders to protect yourself. | ☐ |
Position the Grinder | Align the cutting disc with the marked line before starting the cut. | ☐ |
Make the Cut | Apply steady pressure while guiding the grinder along the marked line. | ☐ |
Smooth Edges | Use a grinding or sanding disc to remove burrs and sharp edges. | ☐ |
Inspect the Cut | Check for clean edges and ensure the piece matches the required size. | ☐ |
Cool the Mesh | Allow the material to cool after cutting to maintain its structural integrity. | ☐ |
Clean Up | Remove debris and ensure the workspace is tidy and safe. | ☐ |
Why Choose The Mesh Company for Heavy-Duty Mesh?
At The Mesh Company, we offer an extensive range of high-quality woven and welded wire meshes. This is apparent from even the most cursory glance at our site.
Our products, such as the 11.1mm hole stainless steel and galvanised steel welded mesh, are designed to meet the demands of heavy-duty applications.
With our expertise and commitment to customer service, we provide guidance to ensure you choose the right mesh for your project.
Cutting heavy-duty mesh, whether woven or welded, requires the right tools, technique, and preparation. With an angle grinder and proper safety measures, you can achieve clean, precise cuts tailored to your needs. The Mesh Company’s wide range of robust and versatile meshes ensures you’ll find the perfect solution for your project.
Explore our range at www.themeshcompany.com and get expert advice to guide your purchase.
As always, thank you for checking out our blog. We hope that this helps you with your project. We try to launch a couple of new guides every week. Eventually we will have covered everything there is to cover about mesh.
You may be interested in our blog that explores how to build a chicken coop.
Our goal for our blogs and help guides is to answer as many questions as possible to help to explain the possibilities of mesh to our customers.
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