Reprint from Fastener World Magazine, Vol. 171

Fastening thin metal sheets has presented challenges since screws were first used to connect things. If the metal sheet is very thin the connection is challenging because there isn’t enough thickness to provide sufficient thread engagement, and, thus the ability to withstand stripping. On the other hand, as sheet or gauge thickness increases self-piercing is no longer an option and either a pilot hole is required to accommodate a thread forming or cutting screw or a tapped hole must be prepared to accept a machine screw. In many instances, particularly in construction, the time it would take to prepare each joint to accept such designs is prohibitively long. What, therefore, is the solution to this dilemma?