Fixing a torn fly screen or damaged security mesh

The short answer: the mesh decides the fix

What the mesh is made of decides how it gets fixed. Fibreglass and pet mesh are insect screens. They sit in a light frame, held in a groove by spline, which Rolltrak describes as flexible tubing wedged tightly into the frame, and a handy owner can patch them or replace them. Stainless steel mesh and perforated aluminium sheet are security infills. The National Security Screen Association (NSSA) lists both among the materials a security door can use, along with steel and aluminium grilles.

That split matters because a security screen stays a security screen only while it matches what was tested. The NSSA says the compliance label shows the screen was manufactured and tested to the Australian Standard for security screens, and that it meets requirements for materials, construction and the locking system.

So work out which mesh you have first. Our flyscreens use fibreglass as standard, or pet mesh where there are animals. Fibreglass is soft and flexible and won't rust, rot or corrode. If the mesh is stiff and metallic, or the screen carries a compliance label, treat it as security mesh.

Small holes in fibreglass or pet mesh: patch them

A small hole in the middle of a fibreglass fly screen is the easiest repair there is. RiteScreen, a US screen maker, says patches can repair small holes or tears when the surrounding mesh is still in good condition, and it rates adhesive peel-and-stick patches as good for fibreglass or soft mesh.

Size and position both count. RiteScreen's checklist before patching covers tears longer than an inch (about 25 mm), holes wider than a pencil eraser, worn or brittle mesh around the damage, and mesh pulling away from the spline. It also warns that if the hole is close to the frame or fraying at the edges, a patch might not hold, and insects can still get in around loose edges. A small, clean hole mid-panel is the case a patch suits.

Take the screen out so you can work on it flat. Rolltrak says to use the pull tab and not to force the screen out, or the frame may be kinked or damaged.

1. Lift the screen out by its pull tab, without forcing the frame.
2. Lay it on a table or bench covered with a sheet or towel.
3. Clean around the hole with mild soap and water.
4. Trim frayed edges so the tear doesn't keep spreading.
5. Fit the patch following the instructions on its pack.
6. Let the adhesive dry fully before you refit the screen.

Repair tape and stick-on patches: fine as a stopgap

Screen repair tape works, for a while. RiteScreen says repair tape works well for temporary fixes, and warns that it can collect dust or curl at the edges. Its view of adhesive patches is close to that: quick to apply, but they can peel over time in hot or humid weather. RiteScreen also says a patch on a busy spot like a sliding door needs to hold up to daily use and direct sunlight, so plan on a proper repair later.

For a longer lasting repair on fibreglass, RiteScreen lists sew-on patches stitched with nylon thread as suited to fine tears, though they take more time and care. Metal patches with wire tabs are for aluminium insect mesh, and they're harder to blend in.

A quick fix is still worth doing straight away. Queensland Health's dengue advice is to screen living and sleeping areas, and it notes that dengue mosquitoes bite quietly during the day. It also says towns in north and central Queensland with the dengue mosquito are prone to outbreaks when travellers bring the virus in. A taped hole keeps them out until the screen is patched properly or re-meshed. If the same screen keeps needing patches, RiteScreen's advice is that replacing the mesh may be faster than patching it again and again.

Long tears in a fly screen: re-mesh the frame

When the tear is long, sits near the frame or the mesh has gone brittle, replace the whole panel of mesh and keep the frame. You need new mesh, a spline roller, a flathead screwdriver and a trimmer or sharp blade for the excess mesh. Rolltrak says the old spline can go back in if it's still in good condition. If it's damaged or hard, use new spline of the same thickness.

Keep the mesh square and don't over-tighten it. Rolltrak's tip is to hold the mesh on the inside edge of the frame while rolling in the third side, which stops the mesh over-tensioning the frame and bowing the sides. Rolltrak's spline roller instructions also say to keep moderate tension on the mesh and follow the lines in the weave to keep it square.

Aluminium insect mesh needs one extra step. Rolltrak says to trench it into the groove with the roller before the spline goes in, because aluminium mesh will tear if this isn't done correctly. Pet mesh is a thicker, stronger fibreglass that gives a little rather than tearing, and it fits wherever standard fibreglass goes, so it suits a screen the dog keeps pushing through.

1. Take the screen out and lay it on a covered, flat surface.
2. Press a flathead screwdriver into a corner to lift the old spline, then peel it out around the frame.
3. Pull out the old mesh and clean the frame, and the spline if you're reusing it.
4. Lay the new mesh over the frame with at least 5 cm overlapping each edge.
5. Square the mesh with one side, roll the spline into the groove, then do the next side.
6. On the third and fourth sides, hold the mesh on the inside edge as you roll, and refit the pull tab between mesh and spline.
7. Trim the spare spline, push it down into the corner, then trim the excess mesh along the frame.
8. Check the swivels, clips or plungers, then refit the screen the way it came out.

Security mesh: a patch won't make it a security screen again

A hole or cut in stainless steel or perforated aluminium security mesh can't be patched back into a security screen. The NSSA says the term security door can only be used if the door can be shown to meet the Australian Standards, and its rule for buyers is short: if it isn't labelled, it isn't a security door. Screens installed to the standard are designed to withstand knife shear, jemmy, probe, corrosion, pull and impact tests. A patch, or a new section spliced into the old mesh, is something those tests never saw.

The NSSA applies the same thinking to a deliberate opening. Once a pet door is installed within a security door, it says, the door is no longer compliant with Australian Standards, because the opening compromises its security.

The makers' warranties point the same way. SCREENGUARD's warranty doesn't apply to damage caused by accident or by alteration to the original product in any part. Crimsafe's excludes alteration of the product in any way. Amplimesh's excludes product alteration, and repair or service by anyone who isn't an authorised Amplimesh dealer. Read your own warranty before anyone touches the mesh.

Dents, bulges and loose mesh in a security screen: leave them to the supplier

Damage to a security screen that isn't a hole still belongs with the supplier or a repairer. SCREENGUARD warns that a mesh panel is tensioned in its frame and that even a pressure washer can distort it. A dent or bulge is a sign the panel has been pushed out of shape, so leave it for the supplier rather than pressing it back by hand.

The frame is built to hold the mesh in. The NSSA says a security frame should have a deep, sturdy receiver channel so the infill can't easily be pushed out, with corners reinforced by internal corner stakes or fully welded joints. Prying that channel open to re-seat loose mesh works against the very part that keeps the infill in place.

In Queensland, the QBCC lists fabricating and installing security screens and doors within the scope of its glass, glazing and aluminium licence. The NSSA strongly advises against installing a security door yourself, because compliant doors are made and installed to very tight tolerances with specialised fixings. These owner steps are safe:

• Photograph the damage from both sides of the screen.
• Check for the compliance label and note what it says.
• Find the invoice, which names the supplier and the product.
• Read the warranty terms before booking anyone to work on it.
• Leave the mesh alone: no glue, tape, cutting or prying at the frame.

When a new screen is the better choice

Replacement makes more sense than repair once the mesh itself is past it. RiteScreen says that if screen mesh is cracking or faded, even a good patch won't hold, and that a screen coming apart in more than one spot may be faster to re-mesh than to keep patching.

For a security screen under warranty, the supplier's terms decide. Prowler Proof, for example, says it doesn't do repairs under its warranty and replaces the product instead. Amplimesh's warranty is offered by the authorised dealer named on the invoice, so that business is your first call.

We make flyscreens in fibreglass or pet mesh, and security doors and screens, all made to measure and manufactured in Cairns. Onsite, we replace locks, wheels, tracks, closers, hinges, triple locks and patio bolts. Tell us what's damaged and which mesh it is through the quote form on our contact page, see what an onsite repair visit covers, and check the areas we serve. If you're choosing between a fly screen and a security screen for that opening, our fly screen vs security screen guide sets them side by side, and the range of mesh page explains each infill. For other faults, see security screen door lock not working, and for routine care, how to clean security screens.