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I am going to mount a shelf on the wall and I'm considering which screw is most suitable.
The shelf needs to withstand a demanding load. There are only provisions for two large screws, and a number of smaller ones.
The wood piece I need to fasten is 25mm wide and 31mm deep.

The picture shows a 5mm and a 6mm screw.
Is a thicker screw always better, or is there a risk of the wood "splitting" (should pre-drill)?

When it comes to nails, they should be 3 times as long as the board you're nailing down.
But screws can be shorter than that, if I recall correctly?
I think the length of the smooth section without threads should correspond to the thickness of the item you're fastening? (with the exception of this screw type which has left-hand threads that I assume are meant to press the "stud" against the wall and should therefore also end up directly in the stud)

Close-up of two metal screws partially threaded into a wooden board, illustrating a comparison between a 5mm and 6mm screw size for shelf mounting.
 
5mm is probably enough. You have to pre-drill, otherwise it will crack.
 
If you pre-drill large enough, it won't split.
You should pre-drill larger for the larger screw compared to the smaller screw.

The question is what you will mount the screw into?
Concrete wall?
Wooden wall?

If it's a concrete wall, you'll need to use a plug, and the screw, including the shelf bracket, should be long enough to be longer than the plug.
 
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D Daaaaaniel said:
If you pre-drill large enough, it will not split. You should pre-drill larger for the larger screw compared to the smaller screw.

The question is what are you attaching the screw to?
Concrete wall?
Wooden wall?

If it's a concrete wall, you will need to use an anchor, and the screw, including the shelf bracket, must be long enough to be longer than the anchor.
I plan to pre-drill regardless of the screw's diameter and use a countersink instead of letting the screw head do the job. The wall is hardboard. Hoping to hit the wooden studs. If I don't, I'm considering using molly anchors (and countersunk screw with metric thread) even though it’s hardboard. I find that the hardboard breaks apart too easily even though it's theoretically supposed to support most things.
 
You must meet the rule, there is no tensile strength at all in masonite. With Molly you increase the strength but not enough for a shelf unless you have thick masonite (about 10+ mm)
 
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tttomten TomasJor said:
You must hit a stud, there's no tensile strength at all in hardboard. Using a Molly bolt increases the strength but not enough for a shelf unless you have thick hardboard (about 10+ mm)
It is 9.8mm.
 
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Masoint is not fun, and unfortunately neither is molly to be honest...

To digress a bit and risk going OT, have you considered tearing down the wall and building a new one?! :)
It might feel a bit overkill to mount ONE shelf, but if you rebuild the wall with OSB/plywood behind the plasterboard, you get a wall strong enough to crucify yourself on, without worrying about where the studs are.
If this is a short-term residence, it might feel overambitious, but if it feels like a more permanent home, it might be worth it.

I'm biased in this matter because a few months ago I moved into a house with masonite walls and am now tearing everything down and rebuilding everything anew.
 
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