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A
nail consists of a metal rod or shank, pointed at one end and usually
having a formed head at the other, that can be hammered into pieces of
wood or other materials to fasten them together. A nail is usually made
of steel, although it can be made of aluminum, brass, or many other
metals. The surface can be coated or plated to improve its corrosion
resistance, gripping strength, or decorative appearance. The head,
shank, and point may have several shapes based on the intended function
of the nail. Of the nearly 300 types of nails made in the United States
today, most are used in residential housing construction. The average
wood frame house uses between 20,000 and 30,000 nails of various types
and sizes.
Nails
are intermediate products which constitute a very essential component
in the
construction industry and in some manufacturing concerns. Nails
are important items in building construction, carpentry and wood
joinery. It is therefore reasonable to assume that the growth in the
construction industry. carpentry and wood joinery generate high demand
for nails. The shortage of supply from existing industries and the
importation of the products call for a urgent need to set up of more
nail factory.
Nails
are divided into three broad categories based on their length. In
general nails under 1 inch (2.5 cm) in length are called tacks or brads.
Nails 1-4 inches (2.5-10.2 cm) in length are called nails, while those
over 4 inches (10.2 cm) are some-times called spikes. These categories
are roughly defined, and there is considerable crossover between them.
Raw Materials
Most
nails are made of steel. Aluminum, copper, brass, bronze, stainless
steel, nickel ,silver, monel, zinc, and iron are also used.
Galvanized
nails are coated with zinc to give them added corrosion resistance.
Blued steel nails are subjected to a flame to give them a bluish oxide
finish that provides a certain amount of corrosion resistance. So-called
cement-coated nails are actually coated with a plastic resin to improve
their grip. Some brads are given a colored enamel coating to blend in
with the color of the material they are fastening.
The Manufacturing Process
Most
nails are made from coils of metal wire. The wire is fed into a
nail-making machine which can produce up to 700 nails per minute. The
nails may then be further twisted or formed, cleaned, finished, and
packaged.
Forming
1
Wire is drawn from a coil and fed into the nail-making machine where it
is gripped by a pair of gripper dies. The shape of the head of the nail
has been machined into the end of the dies.
2
While the dies clamp the wire in place, the free end of the wire is
struck by a mechanical hammer. This deforms the end of the wire into the
die cavity to form the head of the nail.
3
With the wire still clamped in the dies, a set of shaped cutters strike
the opposite end of the nail, forming the point and cutting the nail
free from the rest of the wire coming off the coil.
4
The dies open and an expelling mechanism knocks the nail into a
collection pan below the machine. The free end of the wire is drawn from
the coil and fed into the machine. The cycle then begins again.
Additional forming
5
Nails with helical twists, serrations, or other surface configurations
are fed into other machines that roll, twist, stamp, or cut the required
forms. This may be a purely mechanical process or may require heating
the material before forming.
Finishing
6 The nails are cleaned in a rotating barrel filled with hot caustic soda.
This
removes any oil from the forming machine and cleans up any small metal
scraps, or nippings, that might be clinging to the nails.
7
Many nails are given a final bright finish before being packaged. This
is accomplished by placing the nails in a rotating drum of hot sawdust
to lightly polish the surface of the nails. Other nails may be passed
through an open flame in an oven to give them a blued finish. Galvanized
nails are dipped into a tank of molten zinc in a process called hot-dip
galvanizing. A zinc coating may also be applied by heating the nails to
about 570°F (300°C) in a closed container filed with a powder composed
of zinc dust and zinc oxide. Other coated nails are either dipped or
sprayed to obtain their final finish.
8 Depending on the tolerances desired, some specialty nails may also require an additional heat treating step.
Packaging
9
Magnetic elevators convey the finished nails to weighing machines which
drop them into open cardboard boxes. As they are dropped in, a magnetic
field aligns them so they stack in neat rows. After they are packaged,
the nails are demagnetized. Nails are usually sold in boxes of 1, 5, 10,
25, and 50 pounds. Smaller nails, such as brads, are sold in 2-ounce or
4-ounce boxes and are packaged without being magnetically aligned.
Once
the nail is formed,it may also go through a mechanical deformation
process whereby threads are rolled into the shank surface. This last
step is what differentiates “deformed-shank” (or threaded-shank) nails
from plain-or smooth-shank nails . Most steel nails are produced from
steel wire. Some producers of wire nails use purchased steel wire as a
starting raw material and are known as nonintegrated producers, whereas
some producers utilize their own facilities to produce wire for nails,
using steel wire rod as their starting material; these producers are
called “integrated producers.”
The
common plain-shank nails for general construction work of interest are
usually manufactured from mild steel containing 0.16-0.29% cold worked
annealed wire.
In
the Nigerian market, nail product of carbon steel is characterized by
buckling and sometimes brittle fracture. These problems have encouraged
massive importation of foreign made nails from developed countries like
china, Canada and the United State of America which has resulted in a
huge amount of foreign exchange loss to the Nigerian economy and less
trust in made in Nigeria nails. The demand for local mass produced
commodity nails is dependent on the fluctuations in the market, which
varies with the economy subject to this competition from foreign
manufacturers tending to reduce profits.
There
is no data on the supply and demand of nail in Nigeria, like we have
already stated, the demand is dependent on the growth of the
construction industry and based a deficit of 16,000,000 in housing
supply, it is fair to say that Nigeria has a large , growing and
sustainable market for nail.
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