What Is Intercrimp (Lock Crimp)?

Intercrimp (also called lock crimp) is a wire screen crimping pattern in which extra crimps are formed in the wire between each weaving intersection, adding rigidity and resistance to lateral wire movement that prevents the mesh from distorting under heavy loads in coarse vibratory screening applications. While standard pre-crimped wire has bends only at the points where warp and weft wires cross, intercrimp adds one or more additional bends in each wire segment between crossings, effectively stiffening each span of wire into a small corrugated beam.

The extra crimps serve as mechanical stiffeners. In a standard pre-crimped screen at 4 mesh (4,760 micron opening), each wire span between intersections is relatively long and can flex or bow under the weight of material. In an intercrimp screen at the same mesh size, the intermediate crimps break each long span into shorter, stiffer segments that resist bending. The result is a screen panel that stays flat and maintains consistent aperture sizes even under heavy loads of rock, aggregate, recycled material, or other coarse, heavy feed stocks.

Intercrimp vs. Standard Crimp Comparison

Why Intercrimp Matters in Vibratory Screening

In coarse screening applications, the physical demands on the screen are extreme. Intercrimp construction addresses the specific challenges that standard crimp cannot:

• Prevents screen sag under load — In aggregate and mining operations, the weight of material on the screen deck can cause standard crimped mesh to sag between support rails. Sagging changes the screen geometry, creates uneven material distribution, and can lead to premature failure at stress concentration points. Intercrimp keeps the screen flat.
• Resists lateral wire movement — The intermediate crimps lock each wire segment in position, preventing the wires from shifting laterally under the sliding motion of heavy material. This maintains consistent aperture sizes throughout the screen's service life.
• Absorbs impact energy — Heavy rocks and debris impacting the screen surface generate significant point loads. The corrugated wire segments in intercrimp mesh distribute this impact energy more effectively than straight wire spans, reducing wire breakage.
• Maintains openings at large mesh sizes — At very coarse mesh sizes (2-6 mesh), the openings are large and the wire spans between intersections are long. Without intermediate crimps, these long spans can distort, changing the effective opening size. Intercrimp maintains aperture accuracy across the full panel.

Intercrimp screens are used on vibratory screeners from Midwestern Industries, Cleveland Vibratory, Rotex, and other manufacturers serving mining, aggregate, recycling, construction, and heavy industrial applications.

Related Glossary Terms

• Crimp — The bend in wire that locks screen intersections
• Pre-Crimped Wire — Wire crimped before weaving for uniform openings
• Flat Top Weave — Smooth-surface crimp that reduces blinding
• Plain Weave — Standard over-one, under-one weave pattern
• Scalping — Removing oversize material from a feed stream
• Open Area Percentage — Proportion of screen that is open space

Intercrimp / Lock Crimp FAQs

What is intercrimp wire mesh used for?

Intercrimp (lock crimp) wire mesh is used for coarse vibratory screening applications, typically 2 to 16 mesh, where the screen must support heavy material loads without sagging or distorting. Common applications include aggregate screening, mining scalping, recycling, construction material grading, and any heavy-duty operation where large, heavy particles impact the screen surface.

What is the difference between intercrimp and standard pre-crimp?

Standard pre-crimp places one crimp at each wire intersection only. Intercrimp adds one or more additional crimps between each intersection. These intermediate crimps act as stiffening ribs that prevent the wire from flexing between crossing points, creating a significantly more rigid screen panel. Standard pre-crimp is sufficient for most general screening, while intercrimp is specified for heavy loads, large open areas, or high-impact conditions.

Does intercrimp reduce open area compared to standard crimp?

The extra crimps do slightly reduce effective open area compared to standard pre-crimp at the same mesh size and wire diameter. However, the reduction is usually small (2-5%) because the intermediate crimps are relatively minor bends. The rigidity benefit far outweighs the minimal open area loss, especially in coarse mesh applications where open area is already high.