Enhancing Steel Nails: Exploring Coatings for Corrosion Resistance, Functionality, and Aesthetics

Intro.

Steel nails play a significant role as vital components in construction and manufacturing, finding their utility across a diverse array of applications. To ensure these nails measure up to the standards of durability, functionality, and aesthetics, a variety of different coatings are applied. In this blog post, we’ll overview the most popular and significant nail coatings, uncovering their roles in furnishing corrosion resistance, elevating aesthetics, and amplifying the overall performance of steel nails. So, without further ado, let’s get started.

Corrosion-Resistant Coatings.

The methods employed to safeguard steel nails from corrosion are as diverse as the applications they serve. These coatings form a protective barrier between the nail and its surrounding environment, effectively preventing the onset of rust and granting the nails an extended lifespan. This is the list of coatings that are used to protect steel nails from corrosion.

1. Vinyl

This type of coating provides the smallest amount of corrosion protection; however, the primary purpose of the vinyl is to act as a lubricant during the installation of the nail. The protection from rust comes as a bonus feature. Usually, the vinyl coating is used in combination with electro-galvanized coating, offering better corrosion resistance and holding power as a result.

2. Electro-galvanizing

Bright nails are submerged in an electrolyte solution, and an electric current is used to deposit a layer of zinc onto the surface, providing some corrosion protection. After the process, the nails get a bright, shiny, electroplated zinc coating, which is usually covered in a microscopic chromate coating. The standards set by ASTM International say that the minimum coating thickness of an electro-galvanized nail should not be less than 12 micrometers (μm).

At Litnaglis Company, we have our electro-galvanizing line where we can control the thickness of the zinc layer applied to the nails. We always exceed the ASTM set requirement by putting 15 micrometers (μm) on our electro-galvanized nails, making them more resistant to corrosion. However, even a thicker layer is not enough to fully protect the steel nails from corrosion in the long run. The coating serves mainly to enhance the product’s cosmetic appearance and is not recommended for outdoor use.

3. Hot-Dip Galvanizing

Starting in 2020, our company has been able to provide clients with hot-dip galvanized products. These products undergo a process where nails are immersed in molten zinc, resulting in a robust coating that forms a strong bond with the steel through a metallurgical reaction. This zinc coating delivers a dual layer of protection, serving as both a barrier and a sacrificial coating. If the coating incurs damage, the zinc’s sacrificial properties shield the underlying steel from harm. The industry benchmark for hot-dip galvanized nails is ASTM A153 Class D, with a zinc coating requirement of at least 43 micrometers (μm) on average. The only drawback of hot-dip galvanization is that the zinc layer is spread unevenly during the process, resulting in thinner layers on some nail parts, which may be the weak points for corrosion.

Hot-dip galvanized nails find their optimal use in scenarios necessitating exceptional corrosion resistance, such as outdoor exposure or in tandem with pressure-treated wood (CCA and ACQ). Notably, within the realm of treated wood applications, hot-dip galvanized nails stand as the sole carbon steel fasteners recognized by building codes. However, the layer of zinc in hot-dip galvanized products is not enough when exposed to highly corrosive coastal environments. The only solution to this problem is to use certified stainless steel products.

4. Phosphate Coating

A delicate layer of zinc phosphate on the nail’s surface yields a modest yet essential degree of corrosion protection. However, the main objective of this coating focuses primarily on increasing the nail’s ability for pull-out resistance. This coating, meticulously applied, serves to fortify the nail’s anchoring capabilities because of its uneven and rough surface. By enhancing the nail’s pull-out resistance, the coating ensures that the nail remains securely in place even under significant stress or external forces. This not only increases the overall durability of the nail but also minimizes the risk of structural failures or accidents, making it suitable for both residential and industrial use.  Unfortunately, the Litnaglis company does not offer nails coated with a phosphate layer; however, if you need such a coating, you can easily find many products on the internet. This particular example is taken from a Canadian nail manufacturer’s Duchesne product page.

Aesthetic Enhancements.

Nail aesthetic enhancements go beyond the traditional view of nails as purely functional components. While the primary purpose of nails remains to secure materials together – the fusion of form and function adds a new dimension to their role. These enhancements acknowledge that a nail’s impact extends beyond its practical application, shaping the overall look and feel of the final product.

Painted Coating.

Painted steel nails are available in a range of colors, allowing them to blend seamlessly with the materials they are used on or to add a decorative touch. This aesthetic customization enhances the overall visual appeal of the finished project. As a bonus, the paint coating is a barrier against moisture, reducing the likelihood of rust and corrosion. This is particularly important for nails used in outdoor or humid environments where exposure to moisture is a concern. But even the thickest paint coatings cannot completely prevent the corrosion process from occurring. That’s when the combination of coatings comes in handy.

Hybrid Coatings.

Combination Coatings

Nail combination coatings involve applying multiple types of coatings or treatments to a single nail. These combinations are designed to provide a comprehensive set of benefits that address various aspects such as corrosion resistance, aesthetics, functionality, and specialized requirements. For example, the most common combination of coatings is electro-galvanized nails coated in a layer of vinyl. Electro-galvanized nails with a vinyl coating are commonly used for framing because they strike a balance between functionality, protection, and price. They provide the necessary strength and reliability required for framing applications while addressing potential issues related to corrosion and wood damage. For additional strength and durability, different nail shank types can be applied for maximum efficiency.

One of our company’s most popular products is Plastic Strip Framing Nails, which can be adjusted with plenty of coating and nail-type options to fit the customer’s needs.

Conclusion.

The world of nail coatings and finishes is rich with innovation and possibilities. From protecting against rust to enhancing visual appeal and providing specific functionality, these coatings play a crucial role in optimizing nail performance for various applications. As you select the right nail coatings for your projects, keep in mind the environmental conditions, aesthetics, and intended usage to ensure the perfect balance between corrosion resistance, aesthetics, and functionality.