Achieving a fence that remains rust‑free and taut for a decade or more requires mastery across four interdependent domains: metallurgical specification, corrosion protection strategy, weave geometry and selvage engineering, and framework integration. Here is how we do it - and why our process sets us apart.
1. The Metallurgical Foundation: Wire Drawing and Material Selection
Quality chain link fabric begins long before the weaving loom starts. It starts with the steel itself. We source high‑tensile, low‑carbon steel wire rod - typically Q195 or Q235 grades - and oversee the entire wire drawing process in‑house. The wire is drawn through a succession of precision‑ground carbide dies to achieve the exact diameter required for the specified gauge. We maintain wire diameter tolerances within ±0.05 mm - a level of precision that ensures consistent mechanical performance across every linear meter of fabric.
Common gauges we produce include 9‑gauge (approximately 3.76 mm), 11‑gauge (approximately 3.05 mm), and heavier 7‑gauge for tension wire applications. Mesh openings - the diamond size - are available from 3/8″ for high‑security installations to 4″ for agricultural and general‑purpose enclosures. The diamond pattern itself is formed by interlocking adjacent wires in a zig‑zag configuration, with each "zig" hooking with the wire on one side and each "zag" with the wire on the other.
2. Corrosion Protection: Galvanization and Secondary Coating Systems
Rust is the single greatest threat to chain link fence longevity. Our approach to corrosion resistance is multi‑layered and specification‑driven.
2.1 Hot‑Dip Galvanization - The Primary Barrier
We apply hot‑dip galvanization in accordance with ASTM A392, the standard specification for zinc‑coated steel chain link fence fabric. The galvanization process can be executed in two configurations:
Galvanized Before Weaving (GBW): The wire is zinc‑coated prior to being woven into fabric.
Galvanized After Weaving (GAW): The completed fabric is immersed in a molten zinc bath.
Under ASTM A392, we offer two distinct coating classes. Class 1 provides a minimum coating weight of 1.2 oz/ft² (366 g/m²), which is suitable for standard residential and light‑commercial environments where moderate corrosion resistance is adequate. For more demanding applications - such as coastal regions, industrial zones, or high‑humidity climates - we recommend Class 2, which features a minimum coating weight of 2.0 oz/ft² (610 g/m²). This higher zinc mass delivers nearly 70% more protection than Class 1, significantly extending the time before any substrate exposure occurs. For framework components such as posts, rails, and braces, we apply hot‑dip galvanization per ASTM F1083, with a minimum zinc coating of 1.8 oz/ft².
2.2 PVC Coating - The Secondary Armor
For applications requiring enhanced aesthetic appeal, color coding, or additional protection against aggressive environmental factors, we apply a polyvinyl chloride (PVC) coating over the galvanized substrate. The PVC is extruded and fused to the galvanized core wire using a thermoset bonding agent, with a minimum thickness of 6 mils (0.006″). This dual‑layer system - zinc plus polymer - delivers exceptional resistance to UV degradation, moisture ingress, and mechanical abrasion. The PVC coating is available in standard colors including black, green, and brown, with RAL matching available upon request.
3. Weave Integrity: Machine Precision and Selvage Engineering
The weaving process transforms prepared wire into the characteristic diamond mesh. Our automated weaving machines interlace the wires vertically and horizontally under controlled tension. This is not a casual operation: the machine settings determine the uniformity of the diamond openings, the consistency of the interlock, and the dimensional stability of the finished fabric.
3.1 Selvage - The Edge That Prevents Unraveling
The edge finish - known as the selvage - is critical to fabric longevity. We offer three selvage configurations:
Knuckle‑Knuckle (KK): The wire ends are interlocked and bent back into a closed loop, creating a smooth, snag‑free edge. This is our standard for most applications.
Twist‑Twist (TT): The wire ends are twisted to form sharp barbs, providing enhanced security and anti‑climb properties.
Knuckle‑Twist (KT): A combination - knuckled on one edge, twisted on the other - offering a balance of safety and deterrence.
Proper selvage engineering prevents edge unraveling, maintains fabric tension at the perimeter, and eliminates sharp protrusions that could compromise coating integrity.
4. Framework and Tensioning - The Structural Skeleton
Even the finest fabric will sag if the supporting framework is inadequate or if tensioning is improperly executed. A fence that remains sag‑free for 10+ years requires a systematically engineered structure.
4.1 Terminal and Line Post Configuration
Terminal posts (end, corner, and gate posts) absorb the entire tensile load of the stretched fabric. We specify Schedule 40 pipe per ASTM F1083 for terminal posts, set in concrete footings below the frost line to counteract uplift and leverage forces.
Line posts support the fabric between terminals. Maximum spacing is 10 feet on center, though we recommend reduced spacing in high‑wind environments. Line posts are typically 1‑5/8″ diameter with 0.055″ wall thickness.
4.2 Top Rail - The Structural Spine
The horizontal top rail serves as a structural spine that ties the line posts together. It is inserted through specialized loop caps on line posts and secured to terminal posts via rail end assemblies and brace bands. The top rail prevents the fabric from sagging between vertical uprights and distributes lateral loads across the entire fence line.
4.3 Tension Wire - The Anti‑Sagging Assurance
Sagging at the bottom of the fence is prevented by a tension wire - typically 7‑gauge coil spring steel wire. The tension wire is installed independently and prior to the fabric, stretched taut between terminal posts, and secured with brace bands. The fabric is then attached to the tension wire using 9‑gauge hog rings at intervals of 18–24″ on center. This tension wire creates a rigid lower edge that resists lifting, pushing, and gravitational creep.
4.4 Fabric Tensioning - The Come‑Along Method
The fabric itself must be stretched to the correct tension - not so loose that it sags, not so tight that it distorts. We utilize a come‑along puller (a hand‑operated winch) attached to a tension bar threaded through the fabric at the terminal post. The fabric is pulled until the diamond knuckles are tight and difficult to flex by hand. At this point, the diamonds become slightly elongated but retain their geometric integrity. The fabric is then secured to line posts with gauge‑appropriate tie wires at 12″ intervals and to the top rail at 18″ intervals.
5. Why Pauleen - Integration, Consistency, Accountability
What distinguishes Pauleen is not any single process step, but the integration of all these steps under one roof. We control the wire drawing. We control the galvanization. We control the weaving, the selvage finishing, and the PVC coating application. This vertical integration eliminates the variability that arises when different suppliers handle different stages of production.
For over a decade, we have refined our process to deliver chain link fence fabric that meets - and often exceeds - the requirements of ASTM A392, ASTM F1083, ASTM F668, and ISO 1461. Our quality control protocols include:
Salt spray testing (minimum 500 hours at 5% NaCl concentration) to validate corrosion resistance
Peel tests for PVC coating adhesion
Tensile strength verification per ASTM A370
Dimensional inspection of mesh size, wire gauge, and fabric height
The result is a product engineered for 10–15 years of outdoor service life - rust‑free, sag‑free, and maintenance‑free.
From Our Factory to Your Project
When you specify Pauleen chain link fence, you are not buying a commodity. You are buying a decade of metallurgical discipline, process rigor, and structural engineering - all encapsulated in a woven steel fabric that will stand, straight and intact, through seasons of wind, rain, and use.
That is the one thing we have done for over a decade. And we intend to keep doing it for many more.