Layer cage Material Comparison

Detailed Explanation
1. Electro‑welded Mesh (Cold‑galvanized)
• Usually made by welding the wire first and then electro‑plating a thin zinc layer.
• Advantage: Low cost and smooth appearance.
• Disadvantage: The zinc coating is very thin, so corrosion resistance is poor. In humid poultry houses, it rusts quickly. Not recommended for long‑term projects unless budget is extremely tight and the environment is dry.
2. Hot‑dip Galvanized Mesh
• The welded panel is dipped into molten zinc, forming a thick protective layer.
• Advantage: Thick coating, good corrosion resistance, long service life (15‑20 years). This is the most common choice in the market.
• Disadvantage: Surface may be rough with zinc drips; welded joints may have slightly thinner zinc coverage, which can be potential rust starting points.
3. Post‑Hot‑dip Galvanized Mesh
• The term “post‑” emphasises that the welding is done before galvanizing – the same process as standard hot‑dip galvanizing.
• In practice, there is no significant difference in performance between this and regular hot‑dip galvanized mesh. The distinction is only to contrast it with “pre‑galvanized” (i.e., wires galvanized before welding).
4. Aluminium‑Zinc Alloy Mesh (e.g., Galfan)
• Wires are first coated with a zinc‑aluminium alloy (typically 5% or 10% Al) and then welded. During welding, a dense Fe/Al(Zn) intermetallic layer forms, perfectly protecting the welded joints.
• Advantages: Corrosion resistance is 5‑10 times better than hot‑dip galvanizing. The surface is smoother and more elastic, reducing foot and feather injuries to birds. Although the initial cost is higher than electro‑welded mesh, it is slightly cheaper than hot‑dip galvanized mesh. Considering its ultra‑long service life (20+ years), the long‑term total cost is often the lowest.