A mesh welding machine FAT checklist helps you verify welding accuracy, mesh size, wire feeding, cutting, stacking, safety, and documentation before the line leaves the supplier’s factory. For overseas buyers, this is the last low-cost moment to catch mechanical, electrical, and production issues before sea freight, installation delays, and site rework make every problem expensive.
Mesh Welding Machine FAT Checklist Scope
A mesh welding machine FAT checklist is a pre-shipment test plan for automatic mesh welding machines. It should confirm the machine matches the contract, runs your actual wire sizes, reaches the agreed output, holds weld quality, passes safety checks, and ships with the documents your engineers need for installation and commissioning.
Do the Factory Acceptance Test with the same seriousness you’d give a production trial. A supplier running a neat 3-minute demo with easy wire and slow speed doesn’t prove much. You need measured results: diagonal tolerance, mesh pitch, weld pull strength, cut length, stack height, cycle time, alarm response, and spare parts identity.
For buyers comparing a Chinese mesh welding machine supplier, the FAT also protects commercial terms. If the purchase contract says 3.0-6.0 mm wire, 100 x 100 mm to 300 x 300 mm grid spacing, 6 m finished mesh length, and automatic stacking, then those points need to appear in the FAT record with photos, videos, and signed values.
| FAT Area | What To Check | Acceptable Evidence |
|---|---|---|
| Contract match | Machine model, wire range, mesh size, welding width | Nameplate, layout, signed specification |
| Mechanical build | Frame, straightening, feeding, cutting, stacking | Inspection photos and run test |
| Welding result | Nugget consistency, pull test, visual weld condition | Test samples and recorded settings |
| Electrical system | PLC, HMI, servo, cabinet, wiring marks | Component list and cabinet photos |
| Safety | Guards, emergency stops, interlocks | Function test video |
| Shipment readiness | Packing, documents, spare parts | Packing list and manuals |
The best FAT is not long for the sake of being long. It is specific. A plant making reinforcing mesh for precast panels has different priorities from a factory making fencing panels or AAC slab mesh. For example, an AAC panel mesh welding line must control wire position tightly because cage assembly errors can show up later during panel cutting, not during the first welding run.
Mesh Welding Machine FAT Checklist Contract
Start with identity. Confirm the machine model, welding width, line direction, voltage, frequency, air pressure, cooling method, PLC brand, servo brand, transformer quantity, electrode layout, and agreed automation level. This sounds routine. It isn’t. One wrong voltage or one missing automatic discharge table can turn into a 4-week installation problem at the buyer’s site.
Ask the supplier to place the purchase contract, final technical agreement, and machine nameplate in the same video frame. Then verify the line against the General Arrangement drawing. If your foundation plan, cable trench, air line, and cooling loop were already prepared from a drawing, this step prevents a nasty surprise when the container arrives.
Use a simple contract match table during the FAT:
| Item | Contract Requirement | FAT Finding | Pass/Fail |
|---|---|---|---|
| Welding width | Example: 3,000 mm | Measure on machine | |
| Longitudinal wire diameter | Example: 3.0-6.0 mm | Test actual wire | |
| Cross wire diameter | Example: 3.0-6.0 mm | Test actual wire | |
| Mesh length | Example: 6,000 mm | Measure cut mesh | |
| PLC/HMI | Example: Siemens or Mitsubishi | Cabinet inspection | |
| Line voltage | Example: 380 V, 50 Hz, 3-phase | Cabinet label | |
| Air pressure | Example: 0.6-0.8 MPa | Gauge reading |
If your civil work isn’t done yet, review our mesh welding machine installation checklist before approving shipment. FAT proves the line can run at the supplier’s factory; installation planning proves your site can accept it without improvising anchor bolts, transformer capacity, compressed air, or cooling water after unloading.
Small mismatch, big pain.
A 3,000 mm mesh machine that physically needs 18 m of straight line space doesn’t care that your production hall drawing shows 15.5 m. A transformer cabinet placed on the wrong side doesn’t care that your cable tray is already welded. Check those things while the line is still on the supplier’s floor.
Mesh Welding Machine FAT Checklist Accuracy
Wire feeding is where automatic mesh welding machines either earn their keep or waste operators’ time. During FAT, test the wire diameters, wire surface condition, and straightening quality that match your real production. Bright low-carbon wire behaves differently from ribbed reinforcing wire. Oiled wire behaves differently from rusty wire. A supplier’s “easy wire” can hide weak feeding stability.
For longitudinal wires, check the pay-off stand, straightening rollers, guide tubes, wire positioning comb, and clamp timing. The wire should enter the welding area without twisting, climbing over another wire, or scratching badly against guide hardware. For cross wires, watch the hopper, magnetic feeder or step feeder, separator, push mechanism, and drop position. One cross wire landing 5 mm off position every 20 cycles is enough to create a pallet of rejected mesh.
Measure accuracy with tools, not eyesight.
| Accuracy Point | Practical FAT Method | Typical Target |
|---|---|---|
| Mesh width | Tape measure across finished panel | Within contract tolerance |
| Mesh length | Measure 5 finished pieces | Usually +/- 3-5 mm |
| Grid pitch | Measure 10 openings in a row | Error should not accumulate |
| Diagonal difference | Measure both diagonals | Often <= 5-8 mm, depending size |
| Cross wire position | Check first, middle, last wire | No visible drift |
| Edge overhang | Measure left and right ends | Symmetrical unless specified |
Run at least three mesh sizes if your contract covers a wide range. One small pitch, one middle pitch, one large pitch. For a commercial mesh producer, I’d rather see a 30-minute mixed-size test than a beautiful 5-minute run at one easy setting. Changeover time matters too; your operators need to know whether a pitch change takes 8 minutes at the HMI or 45 minutes with wrenches.
This is also the right time to confirm product fit. A factory producing anti-crack plaster mesh, for instance, may care more about fine wire feeding and flat stacking than heavy-duty bar handling. In that case, an anti crack wire mesh welding line should be tested with the thin wire range and small mesh opening you’ll actually sell, not only the thickest wire in the brochure.
Watch the scrap.
During one FAT run, collect the first 10 pieces after startup and the next 10 pieces after the line reaches steady operation. If early pieces are poor but later pieces are fine, your commissioning team needs to know the warm-up behavior. If every fifth piece is off, look at servo timing, cross wire separation, pneumatic cylinder speed, or wire straightness before signing.
Mesh Welding Machine FAT Checklist Welds
Welding quality is the heart of the FAT. Pretty mesh isn’t enough. The welds need repeatable fusion, stable current, clean electrode contact, and enough strength for handling, transport, and the final application. If a panel breaks apart during stacking or cage assembly, the automatic line becomes a very expensive wire arranging table.
Set the welding current, welding time, pressure, and cooling water flow according to the test wire. Record the parameters from the HMI. Then run the machine at the agreed production speed. Pull random samples from the beginning, middle, and end of the test batch. Don’t let the supplier choose only the best-looking piece. You choose.
For resistance welding, ISO 669:2016 covers resistance welding equipment mechanical and electrical requirements, while the Occupational Safety and Health Administration machine guarding rules explain why moving welding and cutting areas need physical protection for operators. You can reference OSHA’s machine guarding guidance here: OSHA Machine Guarding.
Use this weld test routine:
1. Mark 20 weld points from different panel areas.
2. Check weld appearance for burn-through, cold welds, heavy splash, or electrode sticking.
3. Bend selected wires near the joint to see whether the weld separates too easily.
4. Run a pull or shear test if your specification requires numeric strength.
5. Record welding current, time, pressure, water temperature, and speed.
| Weld Defect | Likely Cause | FAT Response |
|---|---|---|
| Cold weld | Low current, short weld time, weak pressure | Adjust parameter and retest |
| Burn-through | High current, long weld time, poor wire contact | Reduce heat input |
| Heavy splash | Dirty wire, unstable pressure, electrode wear | Clean wire path and inspect tips |
| Weld sticking | Electrode face damage or cooling issue | Dress electrode and check water |
| Uneven welds by row | Transformer/cylinder imbalance | Compare row settings and pressure |
Electrode life also deserves attention. A FAT won’t prove 6 months of wear, but it can show whether the electrode holders are aligned and cooled correctly. Ask the technician to remove one upper and one lower electrode after the test. Look for uneven contact marks. A clean circular mark is good. A contact scar on one edge tells you pressure is not centered.
For reinforcing mesh and fencing panels, weld strength needs to be high enough for loading, storage, transport, and installation. For AAC mesh cages, the weld also needs to survive cage transfer, spacer placement, and casting preparation. A weak weld might pass a quick visual inspection, then fail when a worker lifts the cage from one corner. That failure lands in your factory, not the supplier’s showroom.
Keep one signed mesh sample.
Cut out a sample section, tag it with wire diameter, mesh pitch, machine settings, date, and inspector name. Keep one sample with the supplier and ship one with the machine if possible. When your site team starts commissioning, they have a physical reference instead of arguing from memory over a video clip.
Mesh Welding Machine FAT Checklist Safety
Automatic feeding, welding, cutting, turning, and stacking are the parts buyers pay for, so test them under rhythm. A mesh line that welds well but needs two operators constantly correcting cross wires isn’t automatic in any useful sense. During FAT, count operator touches: wire loading, parameter entry, wire correction, mesh removal, alarm reset, and stacking adjustment.
Run the line for a sustained period, not only a short burst. For export projects, we usually recommend 30 minutes per key product size when the schedule allows it. If the line stops, log the stop reason. An honest stop log is useful. A deleted alarm history is a red flag.
Check these automation points:
| Function | FAT Check |
|---|---|
| HMI recipe | Save and recall at least 2 mesh sizes |
| Servo feeding | Confirm pitch repeatability after speed change |
| Cross wire loading | Test low-level alarm and refill behavior |
| Cutting unit | Check burr, cut length, blade timing |
| Stacker | Count stack quantity and alignment |
| Alarm screen | Confirm clear fault names, not only fault codes |
| Manual mode | Jog each major axis safely |
| Remote support | Confirm PLC/HMI access method if included |
Safety deserves its own witness test. Emergency stop buttons should stop hazardous motion. Guard doors should trigger interlock response. Light curtains, if included, should stop the related motion when interrupted. The machine should restart only through a controlled reset process, not by surprise when air pressure returns.
The European Commission’s Machinery Regulation (EU) 2023/1230 sets safety expectations for machinery placed on the EU market, including protective measures and documentation. If your project is for the European Union, ask for the CE file scope, risk assessment, electrical drawings, and Declaration of Conformity before shipment. The official regulation text is available from EUR-Lex.
A practical note: don’t only test the big red buttons. Test the boring stuff too. Open the cabinet door and check wire labels. Check the grounding bar. Confirm fan direction in the electrical cabinet. Verify that pneumatic tubes are numbered or at least routed cleanly. These details make site troubleshooting faster when your maintenance engineer is standing beside the line at 9 p.m. with production waiting.
Remote support should be agreed before shipping. If your plant blocks outside network access, tell the supplier early. A Siemens PLC, Mitsubishi PLC, or Delta servo system can be diagnosed remotely only when the network path, software version, and access permission are clear. Otherwise, “online support” becomes a phone call with blurry photos.
Mesh Welding Machine FAT Checklist Documents
A machine can pass mechanical testing and still fail the export handover. Missing documents delay installation, customs clearance, operator training, maintenance, and spare parts purchase. Your FAT should include a document review before the supplier starts packing the line.
At minimum, request the English operation manual, electrical schematic, pneumatic diagram, wearing parts list, lubrication points, foundation drawing, installation layout, packing list, PLC/HMI backup policy, and maintenance schedule. If the machine uses branded components, ask for exact part numbers. “Servo motor” is not enough. “Panasonic 1.5 kW servo motor, model number on nameplate” is useful.
Use a document checklist like this:
| Document | Why It Matters |
|---|---|
| Final layout drawing | Confirms floor space and line direction |
| Foundation drawing | Guides anchors, leveling, and trench work |
| Electrical drawing | Helps diagnose faults after installation |
| Pneumatic diagram | Speeds valve and cylinder troubleshooting |
| Spare parts list | Prevents wrong electrode or blade orders |
| Operation manual | Trains operators before commissioning |
| Packing list | Matches crates with container loading |
| FAT report | Connects test results to acceptance payment |
Packing inspection is not cosmetic. Check rust prevention, film wrapping, wooden crate marks, center-of-gravity marks, lifting points, loose part labels, and cabinet protection. Electrical cabinets need moisture protection. Precision guide rails need anti-rust oil. Spare electrodes and blades should be packed in marked boxes, not buried in a crate with bolts and random brackets.
Ask for container loading photos. Every crate should be visible with mark numbers. For long machines, confirm which parts are removed for shipment and how they’ll be reassembled. A welding gantry, mesh pulling unit, cross wire feeder, and stacker can look obvious in the supplier’s workshop. After 35 days at sea, three crates at your site, and a local forklift team in a hurry, clear labels save time.
Payment terms often connect to FAT acceptance. Be precise. Instead of “machine approved,” write “machine approved for shipment after listed corrections are closed.” If there are minor open items, document who owns them, the deadline, and the proof required. For example: “Supplier to replace cracked HMI screen protector and send photo before packing.” No drama. Just control.
Mesh Welding Machine FAT Checklist Decision
The final decision should be based on production evidence, not mood. A friendly technician, a clean workshop, and a smooth video call are nice. They don’t replace measured mesh samples and a signed punch list. For overseas buyers, the FAT decision usually falls into one of four categories.
Use this acceptance matrix:
| FAT Result | Decision | Commercial Action |
|---|---|---|
| All key items pass | Approve shipment | Release shipment payment per contract |
| Minor issues only | Conditional approval | Supplier closes items before packing |
| Major performance issue | Hold shipment | Retest after correction |
| Safety or spec mismatch | Reject FAT | Escalate contract review |
Major issues include unstable welding, failure to run contracted wire size, incorrect machine voltage, missing automation, unsafe guard behavior, or mesh dimensions outside agreed tolerance. Minor issues include missing labels, small paint damage, manual wording errors, spare part marking problems, or packing mark changes. Don’t mix the two. Treating every defect as a crisis slows the project; treating major failures as “can adjust later” moves risk to your factory.
The mesh welding machine FAT checklist should end with names, dates, signatures, photos, videos, test data, and a correction list. Keep the file organized by section. Your installation engineer should be able to open the FAT folder months later and find the welding current used for 4.0 mm wire, the tested pitch, the alarm screen video, and the signed packing list without asking five people.
One more point: test the operator interface in the language your team will use. If the HMI is English, check that the alarm names are understandable. “Axis 2 positive limit” helps. “Fault 37” doesn’t. If the line will be used by Spanish, Arabic, Russian, or Vietnamese operators, agree whether translation is included before FAT. Translation after shipment is possible, but it is rarely the best use of commissioning time.
A good FAT doesn’t make installation unnecessary. It makes installation predictable.
Mesh Welding Machine FAT Checklist FAQ
What is mesh machine FAT?
Mesh machine FAT is a Factory Acceptance Test done at the supplier’s factory before shipment. It checks machine specification, welding quality, mesh accuracy, automation, safety, documents, and packing against the purchase contract.
How long should FAT take?
A serious FAT usually takes one full working day for a standard automatic mesh welding machine. Complex lines with automatic stacking, multiple mesh sizes, or cage production may need two to three days.
Which wire should be tested?
Test the same wire diameter, surface condition, and mesh pitch you plan to produce after installation. If the contract covers a wide range, test the thinnest wire, thickest wire, and one common production size.
Should buyers attend FAT onsite?
Onsite FAT is best when the order is high value or the first machine from a supplier. Video FAT can work if the supplier shows live measurements, continuous running, cabinet inspection, sample testing, and packing evidence.
Can FAT replace commissioning?
No. FAT proves the machine works before shipment, while commissioning proves it works in your factory with your foundation, power, air, cooling, wire, operators, and production schedule.
YZ Welding builds automatic mesh welding machines for construction mesh, AAC panels, steel bar truss, and related welded wire products. If you’re preparing a mesh welding machine FAT checklist for an export project, we can align the FAT items with your mesh drawings, wire range, plant layout, and acceptance terms before the machine is packed.
