What is the concrete nail production line?
The concrete nail production line involves several machines and a series of operations to manufacture high-quality, high-strength concrete nails. The concrete nail is also called steel nail made of high-carbon steel wire. It has a straight fluted and smooth shaft and a round flat head. Concrete nails are used in various construction and building applications, particularly in concrete and masonry work. It is a hard material that can penetrate hard surfaces and withstand the pressure of construction work. But it is not used to hang things on account of its smooth shank.
What is the main machines in manufacturing concrete nails?
The manufacturing of concrete nails involves several types of machinery that have a unique role in production. Here are the main machines involved:
- Wire drawing machine. It is used to reduce the steel wire rod to the needed diameter for producing concrete nails.
- Annealing furnace. The annealing furnace is used to anneal the steel wire to reduce hardness and improve plasticity and this step prepares for further wire drawing.
- Concrete nail making machine. The machine uses nail mold, pin punch and nail cutter to cut the drawn wire and form the nail head.
- Nail polishing machine. This machine is designed to remove any burrs and imperfections on the nails produced by the concrete nail making machine.
- Heat treatment furnace. The concrete nails are hardened and strengthened within a belt type furnace by heat treatment. This step refines the nail’s microstructure and improves its overall mechanical properties.
- Galvanization equipment. The galvanization equipment coats concrete nails with a thin layer of zinc and increases their service time, which acts as a barrier against moisture and other corrosive elements.
How to produce concrete nails?
There are eight steps in manufacturing concrete nails: wire drawing, annealing, wire drawing again, concrete nail making, nail polishing, heat treatment, galvanization and packaging.
The process of manufacturing concrete nails starts with wire drawing by the wire drawing machine. The wire drawing machine uses a range of different drawing dies to draw high carbon steel wire to reduce to a smaller diameter, such as 4.5mm or 4.0mm. The high carbon steel wire becomes hard during the drawing process and is difficult to draw, so it needs to be annealed to make the wire soft and easy to draw further.
After the initial wire drawing, the steel wire must be annealed in an annealing furnace to reduce hardness and improve plasticity. The steel wire is heated to an appropriate temperature, held for a certain time, and then slowly cooled in the annealing furnace. Annealing can eliminate the internal stress and work hardening of steel wire to prevent deformation and cracking. And the steel wire can be drawn again.
Wire drawing again
The steel wire is then drawn again by the wire drawing machine to get the desired diameter for making concrete nails. The secondary wire drawing after annealing reduces the deformation and cracks of the steel wire in the subsequent process.
Concrete nail making
After wire drawing again, the drawn wire is fed into the concrete nail making machine, which cuts the cold drawn wire into nails with nail cutter and forms nail heads with pin punch. And adjusting the machine can produce different lengths of concrete nails.
The concrete nails made from the concrete nail making machine have burrs and sharp edges. The nail polishing machine uses sawdust, engine oil, paraffin or other materials to remove any burrs, sharp edges and imperfections in concrete nails, ensuring bright surfaces and enhancing their corrosion resistance.
After polishing, they often undergo a heat treatment within belt type furnace to further harden and strengthen them. This process usually involves heating the nails to a high temperature and then rapidly cooling them. Metal heat treatment is one of the crucial processes in mechanical manufacturing. Compared with other processing techniques, heat treatment generally does not change the workpiece’s shape and overall chemical composition. It imparts or improves the performance of the workpiece by changing the microstructure inside the workpiece or changing the chemical composition of the workpiece surface.
To enhance the corrosion resistance of concrete nails, they might be coated with a thin layer of zinc in the galvanization equipment. This galvanization equipment uses electro-galvanizing technology to enhance the corrosion resistance of concrete nails and increase their lifespan.
Finally, concrete nails are packaged in cartons to ensure they are properly stored and protected during transport to a construction site or retail store. Different cartons are packed with different sizes and weights of concrete nails, such as 1 kg, 5 kg, 20 kg or 25 kg per carton.
Quick-Wear Parts List of Wire Drawing Machine
|1||Wire drawing die||15-20 tons||Tungsten carbide|
Quick-Wear Parts List of Concrete Nail Making Machine
|1||Nail cutter||1-2 Months||Alloy/steel|
|2||Nail mould||3 Months||Tungsten carbide/HSS|
|3||Pin punch||6 Months||Tungsten carbide/HSS|