What Are Sheet Metal Screws – Sheet Metal Screw Types, Uses, Sizes & Comparison with Others

2024.11.21

There is a type of screw specifically designed for sheet metal applications. Understanding sheet metal screws with their features, types, construction (head, slot & point), sizes, and differences between sheet metal screws and wood or machine screws.

What Are Sheet Metal Screws?

A sheet metal screw is used to fasten thin metal sheets together and or secure metals with other materials like plastic and wood. Its defining characteristic is a fully threaded shank with sharp threads designed to pierce solid materials easily. Sheet metal screws work by creating their own mating threads as they’re driven, combining digging and fastening actions in a single operation. They’re engineered to provide excellent holding power while minimizing material displacement and distortion.

What Are Sheet Metal Screws Made Of?

Stainless steel is one of the most common sheet metal screw materials because of its corrosion resistance and durability. Carbon steel and zinc-plated materials are also popular choices, and brass, copper, and others are sometimes used.

Can You Put a Nut on a Sheet Metal Screw?

No. Standard sheet metal screw threads are incompatible; there are no nuts for this type of screw. When they drive into the metal piece, the material around the screw will deform.

Can I Use a Sheet Metal Screw in Wood?

Yes. While sheet metal screws can be used in wood, they may not always be the best choice for every application. When you are short of the right screws, you can use a sheet metal screw temporarily.

What Are Sheet Metal Screws Used For?

Although sheet metal screws are specialized fasteners primarily designed for fastening metal sheets, their unique design and threading allow them to securely connect various components in a wide range of applications.

  • Metal Fabrication: Sheet metal screws provide a strong connection between metal sheets. They are often used in the fabrication of metal structures, such as frames, brackets, and enclosures.
  • HVAC Systems: In heating, ventilation, and air conditioning (HVAC) systems, sheet metal screws are used to assemble ductwork and other metal components, allowing for efficient airflow and system performance.
  • Automotive Applications: They are used to attach metal parts, such as body panels and brackets.
  • Roofing: particularly for securing metal roofing panels to the underlying structure, to help prevent leaks and provide stability against wind and weather conditions.
  • Electrical Enclosures: Secure covers and panels on electrical enclosures, protecting sensitive components from environmental factors.
  • Appliances: Many household appliances, such as refrigerators and washing machines, utilize sheet metal screws to hold together metal parts.
  • DIY Projects: For hobbyists and DIY enthusiasts, sheet metal screws are a go-to fastener for various projects involving metal, wood, and plastic.
  • Industrial Equipment: Assemble machinery and equipment, providing reliable connections that can withstand vibrations and heavy loads.

Types of Sheet Metal Screws

The main types of sheet metal screws are self-tapping and self-drilling screws.

Self-Tapping Sheet Metal Screws

Self-tapping screws can create their own mating threads when they are driven into a pre-drilled pilot hole or punched hole. Pre-drilling is required to prevent the material from splitting or cracking during installation. The screw’s sharp, pointed tip helps guide it into the pilot hole, and the threads then cut into the material, forming a secure connection. This type is ideal for thinner sheet metals and situations where a clean, flush finish is desired. The pre-drilled hole ensures minimal material displacement and a tighter fit. While offering excellent holding power, they are not suitable for thicker materials where the screw might struggle to tap effectively.

Self-Drilling Sheet Metal Screws (TEK® Screws)

Self-drilling screws, often referred to as TEK® screws, are used without the need for pre-drilling. They feature a drill-bit-like point at the tip that allows them to drill a hole as they are driven in. This simplifies and speeds up the fastening process considerably. The screw’s threads then engage with the newly created hole, securing the materials together. This type is suited for thicker gauge metals and situations where pre-drilling is impractical or time-consuming. The self-drilling action generates swarf (metal shavings), so some cleanup might be necessary after installation. Their design makes them highly effective for various metals and even some plastics.

Sheet Metal Screw Point Types

Point Type

Characteristics

Best Applications

Type A

Coarse threads with gimlet (tapering) point

Thin metals (0.015″ to 0.050″ thick), wood, drilled/punched holes, resin-impregnated plywood

Type AB

Fine threads with gimlet point, combines Type A point with Type B thread design

Fragile materials, a wider range of applications, follow Type B limitations

Type B

Blunt tip, spaced threads, larger root diameter with finer thread pitch

Heavier metals (0.050″ to 0.200″ thick), plastics, plywood, non-ferrous castings

Sheet Metal Screw Head Types

Head Type Characteristics Best Applications
Flat Countersunk design, Phillips or slotted drive, and self-drilling options available Projects requiring flush surface finish, countersunk holes, and smooth appearance
Hex Six-sided head design, used with nuts High-torque applications, where wrench/socket usage is needed
Hex Washer Hexagonal head with integrated washer Applications requiring load distribution and prevention of loosening
Oval Slightly rounded top, flush sitting, additional girdles Visible applications, where wind resistance and aesthetics matter
Pan Rounded head that protrudes, Phillips or slotted drive, various finishes Applications where the head protrusion is acceptable or desired
Truss Extra-wide head with a rounded top, Phillips drive Soft materials, larger holes, where load distribution is needed

Sheet Metal Screw Slot Types

Slot Type Characteristics Tool Requirements Best Applications
Cross (Phillips) Two perpendicular slots forming a “+” shape Phillips or slotted screwdrivers

– General-purpose applications

– Mass production assembly

– Where tool versatility is needed

– Most industrial and consumer applications

Slotted (Flat) Single straight slot forming “-” shape Flathead screwdriver

– Simple assembly tasks

– Traditional woodworking

– Where only basic tools are available

– Projects requiring quick installation

Square Recessed quadrilateral shape Square-drive tool

– High-torque applications

– Precision installations

– Professional Construction

– Where slip resistance is crucial

Sheet Metal Screw Sizes Chart

Size Thread Diameter (Decimal) Thread Diameter (Nearest Fractional)
#4 0.112″ 7/64″
#6 0.138″ 9/64″
#8 0.164″ 11/64″
#10 0.190″ 3/16″
#12 0.216″ 7/32″
#14 0.250″ 1/4″

Sheet Metal Screw vs Wood Screw: What Are the Differences?

Sheet metal screws and wood screws are designed for different purposes; here, we’ll list the differences between them for easier selection.

Feature Sheet Metal Screws Wood Screws
Primary Use Metal, hard plastics, and sometimes wood Specifically designed for wood materials
Thread Design More threads per inch, threaded along the entire length Fewer threads per inch, threaded about two-thirds of the length
Shank Characteristics Threaded to the top, may slightly flare near the head Smooth shank beneath the head, a noticeable flare near the head
Self-Tapping Ability Can be self-tapping Not self-tapping
Pilot Hole Requires pilot hole (unless self-drilling) Works with a narrower pilot hole
Head Style Slots or Phillips heads are available Flat or domed, slots or Phillips heads
Holding Power Higher strength for metal and heavy materials Lower strength, designed to prevent wood splitting
Cost Slightly more expensive Less expensive

Sheet Metal Screws vs Machine Screws: What Are the Differences?

Compared to another common fastener – a machine screw, when should you use a sheet metal screw? Take a look at the comparison between them.

Feature Sheet Metal Screws Machine Screws
Primary Use Joining sheet metal and various materials (metal, wood, plastics) Precision applications in machinery and electronics
Installation Method Self-tapping or self-drilling; cuts its own threads Requires pre-threaded or tapped holes
Thread Design Sharp, aggressive threads for cutting into the material Uniform, precise threads for matching tapped holes
Head Style Pan, round, flat, or hex head with Phillips or combo drive Flat, round, pan head with slotted, Phillips, or specialized drives
Material Options Carbon steel, galvanized, or stainless steel Steel, brass, and various metals with different coatings
Additional Hardware Generally used without nuts Often used with corresponding nuts
Application Precision Moderate precision requirements High precision requirements

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