Aluminum Screen Air Filters — HI Series Washable Industrial Mesh

An aluminum screen air filter is an industrial-grade, permanent filter built from woven or corrugated wire screen media in a rigid metal frame. Unlike disposable fiberglass, paper-pleated, or foam filters, an aluminum screen filter has no media that can tear, compress, or degrade from moisture — it is a structural mechanical component designed to be washed and reinstalled indefinitely. The open wire screen construction delivers extremely low airflow resistance, making these filters the standard choice wherever high face velocity, high temperature, or continuous outdoor-air exposure would destroy a conventional filter.

AMFCO’s HI Series is the most complete line of washable aluminum screen air filters made in the USA. Three media and frame material combinations — HIA (all aluminum), HIG (galvanized steel), and HIS (304 stainless steel) — cover the full range of operating environments from standard commercial HVAC to aggressive industrial, coastal, and high-temperature applications. Standard sizes run from 12×24 through 24×24 in 1-inch, 2-inch, and 4-inch depths; custom sizes are cut to any dimension in 1/16-inch increments.

Use the sections below to shop by material, match a size, or learn which HI Series configuration is right for your application.

HIA Series — Aluminum Screen Filters (Standard Choice)

The HIA Series uses woven corrugated criss-cross aluminum screen media in an extruded aluminum alloy frame. It is the standard HI Series configuration and the most widely ordered aluminum screen filter in the product line. All-aluminum construction makes it corrosion-resistant in most commercial and light-industrial environments, non-magnetic, and compatible with aluminum HVAC housings without galvanic concerns. Temperature rating: 275°F continuous. Most popular sizes below; see the size table for the full range.

• Frame: .030-inch extruded aluminum alloy channel, mitered corners with aluminum pop rivets
• Media: multiple layers of corrugated criss-cross aluminum screen wire — the same media used in OEM economizer filters
• Face grids: 24-gauge aluminum on both sides, preventing media migration at high face velocities
• Corner drain holes: 3 per filter for complete water removal after washing
• UL 900 Class 1: non-combustible, suitable for outdoor air intakes, plenum applications, and fire-coded installations
• Custom sizes available: 1-inch custom, 2-inch custom, 4-inch custom

HIG Series — Galvanized Steel Screen Filters

The HIG Series uses galvanized steel screen wire media in a galvanized steel frame. Galvanized construction delivers a heavier, stiffer filter body that withstands high face velocities and physical handling in industrial environments. The zinc-coated steel provides corrosion resistance comparable to HIA aluminum in most inland applications and is the preferred specification where a grounded (conductive) metallic filter is required. Temperature rating: 325°F continuous — 50°F higher than aluminum, suitable for make-up air units and industrial process ventilation.

• Frame: galvanized steel channel, spot-welded corners
• Media: multiple layers of corrugated criss-cross galvanized steel screen wire
• Temperature rating: 325°F continuous
• Weight: heavier than HIA — preferred where filter retention clips or tracks require a firm fit
• Grounding: conductive throughout — suitable for electrical panel ventilation, control cabinet cooling, and static-sensitive environments
• Custom sizes: available on request

HIS Series — 304 Stainless Steel Screen Filters

The HIS Series uses 304 stainless steel screen wire media in a 304 stainless steel frame. This is the specification for applications where corrosion resistance is critical: coastal installations with salt-laden air, food-processing and pharmaceutical facilities requiring NSF-compatible or sterilizable components, chemical environments with reactive gases, and high-humidity industrial washdown environments. HIS filters can be cleaned with steam, caustic cleaning solutions, and pressure washers that would attack aluminum or galvanized alternatives.

• Frame: 304 stainless steel channel, TIG- or spot-welded corners
• Media: multiple layers of corrugated criss-cross 304 stainless steel screen wire
• Temperature rating: 325°F continuous
• Corrosion resistance: superior to aluminum and galvanized in salt, acid, alkaline, and high-humidity environments
• Cleanability: steam-cleanable, chemical-cleanable, dishwasher-safe at industrial temperatures
• Food and pharma: 304 stainless is FDA-listed for food contact; suitable for food-processing facility ventilation
• Custom sizes: available on request; see Stainless Steel Air Filters for the full stainless range

Custom-Size Aluminum Screen Filters

When a standard 12×24, 16×20, 20×20, 20×25, or 24×24 frame does not fit, AMFCO cuts HIA aluminum screen filters to any specified dimension with ±1/16-inch tolerance. Depths available: 1/4″, 3/8″, 1/2″, 3/4″, 1″, 2″, and 4″. All custom filters use the same five-ply corrugated aluminum screen media, extruded aluminum frame, and aluminum pop-rivet corner construction as the standard HIA line.

Custom galvanized (HIG) and stainless (HIS) sizes are available on request — use the custom filter form and specify your material preference, exact dimensions, and depth.

HI Series Aluminum Screen Filter Specifications

All three HI Series configurations (HIA, HIG, HIS) share the same core construction geometry and use the same woven corrugated criss-cross screen wire media architecture. They differ in the alloy and material of the frame and media wire.

All HI Series filters are non-combustible per UL 900 Class 1 testing and are suitable for use in direct outdoor-air intake paths, mixed-air plenums, and any application governed by ASHRAE 90.1 or local fire codes requiring Class 1 filtration.

Where Aluminum Screen Air Filters Are Used

The low pressure drop, indefinite washability, and structural rigidity of aluminum screen filters make them the specified choice across a wide range of commercial, industrial, and institutional applications. The following covers the most common use cases and why screen wire construction outperforms alternative media in each.

Commercial HVAC Rooftop Units — Economizer Pre-Filters

Every commercial RTU with an economizer (required by ASHRAE 90.1 on virtually all U.S. commercial HVAC since 2010) has a filter slot at its outdoor air intake. OEM specifications for Carrier, Trane, and York all call for a permanent washable aluminum mesh screen at this position. The HIA Series is the aftermarket replacement standard. For exact OEM part number cross-references and brand-specific sizing, see the Economizer Filters hub page.

Make-Up Air Units (MAUs)

Make-up air units condition and supply 100% outside air to commercial kitchens, manufacturing floors, spray booths, clean rooms, and any space with high exhaust volumes. The pre-filter at the MAU intake handles the same 100% outdoor air duty as an economizer pre-filter, but often at higher face velocities and with more aggressive contaminants: kitchen grease mist, metal dust, industrial particulate, agricultural debris. The HIG galvanized steel Series is frequently specified for MAU intake applications due to its greater frame stiffness and 325°F temperature rating.

Generator Set Enclosures and Engine Rooms

Diesel and natural gas generators require large volumes of combustion and cooling air. Generator enclosures have louvered intakes that can accumulate cottonwood, leaves, insects, and coarse debris within a single growing season if unprotected. An aluminum screen filter at the louver opening prevents debris ingestion into the radiator, intercooler, and turbocharger intake while maintaining the airflow volume required for rated output. HIA and HIG filters are specified for this application; HIS stainless is used at coastal generator plants subject to salt-air corrosion.

Electronic Enclosure Cooling — Control Panels and CRAC Units

Electrical control panels, motor control centers (MCCs), and computer room air conditioning (CRAC) units all require filtered ventilation to prevent dust accumulation on circuit boards, bus bars, and power components. The requirement is low pressure drop (fan power is limited in small enclosures), dimensional precision (filter must fill the ventilation opening completely), and washability (replacing disposable filters in energized panels is a safety hazard). Thin HIA panels in 1/4-inch, 3/8-inch, and 1/2-inch depths are custom-cut to match DIN-rail panel ventilation openings, NEMA enclosure louver patterns, and server rack side-panel blanks.

Paint Spray Booths — Intake Side

Spray booth supply air flows through ceiling or wall filters to eliminate turbulence and particulate that would contaminate wet coatings. The intake-side filter (separate from the exhaust side, which uses dedicated paint-overspray media) is typically a coarse pre-filter protecting the booth interior from outdoor particulate. Aluminum screen filters are specified at the intake of both water-wash and dry-filter-type spray booths. HIS stainless steel is preferred in booths that use water-wash systems or solvent cleaning of the intake filter.

Industrial Process Ventilation — Dust and Lint Pre-Filtration

Woodworking facilities, textile plants, paper and printing operations, food processing environments, and pharmaceutical production buildings all generate high volumes of coarse particulate: sawdust, lint, flour, paper dust, starch, or chemical powder. An aluminum screen filter at the air-handling unit or fan coil intake captures coarse particles before they reach downstream HEPA or bag filters, extending high-efficiency filter life by 3–5×. The 4-inch depth HIA and HIG Series filters provide the highest dust-holding capacity and the longest intervals between cleaning cycles in high-load industrial environments.

Cooling Tower Make-Up Air and Basin Filtration

Evaporative cooling towers pull large volumes of ambient air and water across fill media. Aluminum screen panels are installed at cooling tower air intakes to intercept cottonwood seed, leaves, and debris that would foul the fill media and block distribution nozzles. HIS stainless steel is specified in most cooling tower applications due to continuous exposure to high humidity, treated water chemistry, and chlorine-based biocides that would attack aluminum and galvanized finishes over time.

Agricultural and Greenhouse HVAC

Poultry houses, hog facilities, and greenhouses present some of the most demanding pre-filtration conditions: continuous high humidity, ammonia gas, airborne feed particles, and feather and dander loads that can plug a standard pre-filter within days. The HIG galvanized steel Series withstands agricultural environments better than aluminum (which can pit in ammonia-laden air) and is substantially less expensive than stainless for high-quantity agricultural applications. HIA aluminum is acceptable in greenhouse applications where ammonia is not present.

HVAC Furnaces and Air Handlers — Whole-House Aluminum Screen Replacements

Residential and light commercial gas furnaces, split-system air handlers, and heat pumps all use a filter at the return air inlet. Homeowners and facilities managers seeking a permanent replacement for disposable filters in these systems can install an HIA aluminum screen filter instead. The trade-off is lower particle capture efficiency (MERV 1–2 vs. MERV 8–13 for a high-efficiency disposable) but zero ongoing procurement cost and indefinite service life. For residential applications needing higher efficiency, see the Washable Air Filters hub for MERV 4–8 washable options.

Choosing Between HIA, HIG, and HIS — Material Selection Guide

All three HI Series configurations capture the same particle size range and deliver the same low pressure drop. The correct choice is driven by the operating environment, temperature, corrosion exposure, and structural requirements.

HI Series Standard Size Reference

AMFCO stocks the following nominal standard sizes in all three frame materials (HIA, HIG, HIS) and three depths (1″, 2″, 4″). Nominal sizes follow the industry convention: a “20×20×1” filter measures approximately 19-3/4×19-3/4×1 actual, providing clearance in standard nominal-size filter tracks.

Additional standard sizes are available, including 20×20×2 HE Series (HEA202020) for economizer applications. Custom sizes can be ordered in any dimension; AMFCO cuts to the nearest 1/16-inch. To order a custom size, visit the custom filter page.

Selecting the Right Filter Depth: 1-Inch, 2-Inch, or 4-Inch

Filter depth affects dust-holding capacity, service interval, and the available space in the filter track. The chart below provides guidance on depth selection by application.

In applications where both 1-inch and 2-inch filters fit the available track depth, the 2-inch filter is generally preferred because it cuts cleaning frequency roughly in half with no change in initial airflow resistance. The 4-inch filter is the correct choice wherever annual service intervals are needed or maintenance access is difficult (rooftop equipment in winter, generator enclosures in isolated locations).

HI Series Construction — How Aluminum Screen Filters Are Made

Every HI Series filter is handmade to order at AMFCO’s USA manufacturing facility. The production sequence is as follows:

1. Media cutting: Rolls of corrugated criss-cross aluminum (or galvanized or stainless) screen wire are cut to the specific filter face dimensions. The media is pre-formed with a corrugation pattern that creates loft between layers and maximizes dust-holding capacity.
2. Layering: Multiple plies of the corrugated wire screen are stacked in alternating orientations (criss-cross) to increase particle interception probability and structural stability.
3. Face grid application: 24-gauge aluminum (or galvanized / stainless) face grids are placed on the upstream and downstream faces of the media stack, confining the wire media and preventing any individual wire from protruding into the airstream under high face velocity.
4. Frame assembly: The .030-inch extruded aluminum channel frame is cut to length, mitered at the corners, and assembled around the media pack. Aluminum pop rivets secure each mitered corner, creating a rigid rectangular frame that holds its dimension through repeated wash cycles.
5. Drain hole punching: Three corner drain holes are punched in each filter to allow complete drainage after washing.
6. Quality check: Each completed filter is dimensionally verified before shipping. Custom-cut filters are measured to ±1/16-inch tolerance.

The result is a filter with no adhesives, no bonded media, no paper or cardboard components, and no components that can absorb or retain moisture. There is nothing to fail except the wire itself, which would require physical damage or prolonged exposure to a corrosive environment beyond the material’s rating.

Cleaning and Maintenance

Aluminum screen filters require no special tools or cleaning products. Standard practice for HIA and HIG filters:

1. Remove the filter from its housing, noting the airflow direction
2. Dry brush or shake off loose debris
3. Rinse from the clean (downstream) side outward with a garden hose or pressure washer (100–150 PSI) to backflush particles out through the upstream face
4. Apply mild detergent for heavy grease or industrial soiling; let soak 5–10 minutes, then scrub with a nylon brush
5. Rinse until water runs clear
6. Shake off excess water and allow to air-dry before reinstalling in air-handling equipment; in non-HVAC applications (panel cooling, generator enclosures), the filter may be reinstalled damp

HIS stainless steel filters can be cleaned with steam cleaners, caustic solutions (sodium hydroxide up to 5% at ambient temperature), or industrial dishwashers. Avoid concentrated bleach solutions or chlorinated solvents on HIS filters, as prolonged chloride exposure can initiate crevice corrosion on 304 stainless at elevated temperatures.

Cleaning frequency depends on the operating environment. Economizer pre-filters in commercial buildings typically require cleaning twice per year. Generator enclosures in cottonwood-prone regions may need monthly spring cleaning. Industrial pre-filters in high-dust production environments may need weekly or bi-weekly cleaning during peak production.

Frequently Asked Questions: Aluminum Screen Air Filters

What is an aluminum screen air filter?

An aluminum screen air filter is a permanent, washable air filter made from layers of corrugated woven aluminum wire screen media inside an aluminum channel frame. It captures coarse particles — dust, lint, pollen, debris, insects — while delivering very low airflow resistance. Unlike disposable filters, an aluminum screen filter is designed to last 10 years or more with routine cleaning. AMFCO manufactures the HI Series in three material variants: HIA (all aluminum), HIG (galvanized steel), and HIS (304 stainless steel).

What is the MERV rating of an aluminum screen filter?

HI Series aluminum screen filters are rated approximately MERV 1–2. They are designed for coarse pre-filtration, not for fine particulate removal. Their purpose is to protect downstream equipment and high-efficiency filters from large particles, insects, cottonwood, leaves, and heavy dust. For higher filtration efficiency in a washable filter, consider the HF Series MERV 4, EC Series MERV 6, or R8 Series MERV 8.

What is the difference between HIA, HIG, and HIS?

HIA uses aluminum media and an aluminum frame (275°F max); HIG uses galvanized steel media and a galvanized steel frame (325°F max, stiffer, grounded); HIS uses 304 stainless steel media and a stainless steel frame (325°F max, best corrosion resistance). HIA is the standard choice for most HVAC applications. HIG is preferred for high-face-velocity and high-temperature industrial applications. HIS is specified for coastal environments, food processing, pharmaceutical, and chemical environments.

Are custom-size aluminum screen filters available?

Yes. AMFCO cuts HIA aluminum screen filters to any specified dimension with ±1/16-inch tolerance. Depths available include 1/4″, 3/8″, 1/2″, 3/4″, 1″, 2″, and 4″. Custom galvanized (HIG) and stainless (HIS) sizes are available on request. Use the custom filter form to specify your exact dimensions.

How do aluminum screen filters compare to disposable HVAC filters?

Aluminum screen filters have much lower filtration efficiency (MERV 1–2 vs. MERV 8–13 for standard disposable pleated filters) but last 10+ years, require no recurring procurement cost, maintain their dimensional integrity in outdoor air and high-humidity environments, and are UL 900 Class 1 non-combustible — a requirement for outdoor air intake applications. They are designed for pre-filtration and equipment protection, not for IAQ particle capture.

Can I use an aluminum screen filter in my home furnace?

Yes. HIA aluminum screen filters in nominal sizes (16×20, 20×20, 20×25) fit standard residential return-air filter tracks and can replace a disposable filter. The trade-off is lower particle capture efficiency: the screen filter will protect the blower and coil from coarse debris but will not capture fine dust, pet dander, or allergens the way a MERV 8+ filter does. For residential washable filters with meaningful IAQ performance, consider the EC Series (MERV 6) or R8 Series (MERV 8).

What is the maximum temperature for an aluminum screen filter?

HIA aluminum screen filters are rated for continuous service up to 275°F (135°C). HIG galvanized steel and HIS stainless steel filters are rated up to 325°F (163°C). For applications above 325°F, contact AMFCO for high-temperature mesh media options.

How long does an aluminum screen air filter last?

With routine cleaning, an HIA aluminum screen filter lasts a minimum of 10 years; many have been in continuous service for 20+ years. The all-metal, all-inorganic construction has no components that degrade from age. The filter should be replaced only if the wire mesh is physically punctured or torn, the frame is bent beyond the filter track tolerance, or the filter has been in an environment that has caused significant corrosion of the aluminum (e.g., prolonged ammonia exposure). HIS stainless filters in aggressive environments routinely achieve 15–25 year service lives.

What industries use aluminum screen air filters as standard?

Aluminum screen filters are standard pre-filtration components in: commercial HVAC rooftop units (economizer pre-filters), make-up air handlers, industrial process ventilation, paint spray booths (intake side), generator enclosures, electrical control panels and CRAC units, agricultural ventilation, food processing facilities, pharmaceutical and cleanroom ante-chambers, and cooling tower air intakes.