The Importance of Fasteners in New Pallet Manufacturing
When it comes to new pallet manufacturing, don’t underestimate the role of nails.
Youtube from Virginia Tech on nail retention test
You might think we have a few screws loose for being so passionate about fasteners. The fact is that while they don’t add a lot to the cost of a pallet, they can have a considerable impact on pallet durability. The bottom line is don’t take fasteners for granted. Ensure your pallet supplier isn’t scrimping on fastener quality to shave a quarter or two off the price of the pallet to the detriment of the long-lasting pallets you need. Let’s take a closer look at steel fasteners and pallets.
The Role of Fasteners in Pallet Construction
Simply put, fasteners bind the wooden components of the pallet together. They include driven nails and staples, bolts, wood screws, and lag screws. Most pallets utilize one of two types of nails: helically-threaded (drive-screw) nails and annularly-threaded (ring-shanked) nails. Heavy skids or pallets might use lag screws, for example.
Helically threaded nails feature continuous spiral threads along the shank, making them ideal for automated pallet manufacturing. Their design provides better bending resistance, which is crucial when working with medium and high-density hardwoods. On the other hand, annularly-threaded nails come with numerous rings along the shank that help grip the wood and prevent nail withdrawal. These are often recommended for low-density hardwoods and most softwoods due to their superior withdrawal resistance, although helically threaded nails are also used successfully by many pallet manufacturers for softwood.
Fastener Quality and Pallet Durability
The quality of fasteners directly influences two critical aspects of pallet durability: withdrawal resistance and shear resistance. According to Virginia Tech, withdrawal resistance refers to the ability of nails to secure the deck board to the stringer, preventing separation. This is particularly important in softwoods, where the wood fibers are less dense and more prone to pull-through, where the board separates from the pallet and is “pulled through” the nail head. Factors such as wire diameter, the difference between thread diameter and wire diameter, and the number of helices per thread length significantly impact withdrawal resistance.
Shear resistance, on the other hand, pertains to the fasteners’ ability to withstand horizontal impacts, such as when forklift tynes slam a pallet. High-quality fasteners resist bending and breaking, ensuring the pallet maintains its structural integrity even under stress. The Morgan Impact Bend Angle Nail Test (MIBANT) is a standard method to evaluate fastener performance, measuring the force required to bend or pull out a nail. Fasteners that withstand greater forces contribute to more durable and reliable pallets.
The Importance of Nail Head Quality
The quality of the nail head also plays a crucial role in pallet durability. A well-formed nail head ensures the deck board is securely fastened to the stringer, preventing it from pulling through. Poor-quality nail heads can lead to several issues, including an increased risk of deck board displacement and accelerated wear and tear. If the nail head is weak or improperly shaped, it may fail to hold the deck board firmly, leading to structural weaknesses that compromise the entire pallet. This can result in pallets that break apart more easily during handling and transportation, increasing the likelihood of product damage and additional costs for repairs or replacements.
Underformed Nail Threads and Retention Properties
Another critical factor affecting pallet durability is the formation of nail threads. Sometimes, nail producers don’t replace dies frequently enough. When nails are produced using excessively worn dies, the resulting threads may be underformed, lacking the proper depth needed for optimal retention.
Underformed threads do not grip the wood as effectively, reducing the fastener’s withdrawal resistance. This means the nails are likelier to loosen over time, especially in environments where pallets are subject to frequent movement and stress. Thread quality is crucial, and you need a pallet manufacturer who monitors fastener quality.
The Virginia Tech Example: A Clear Demonstration
An insightful study by Virginia Tech highlights the tangible benefits of investing in higher-quality nails. The researchers compared 11.5-gauge bulk nails with 12.5-gauge collated nails in a standard GMA pallet using Best Load™ pallet design software. The results were striking: pallets built with 11.5-gauge nails lasted twice as many trips before requiring repairs and twice the number of trips before needing replacement compared to those made with 12.5-gauge nails. This improvement translates to 85.6% more durable pallets, showcasing how even a modest increase in nail quality can significantly extend pallet lifespan.
Fasteners may seem minor in pallet manufacturing, but their impact on pallet durability and performance is substantial, so, yes, we are a little screwy about fasteners. By prioritizing high-quality nails, manufacturers can enhance operational efficiency, reduce waste, and extend the lifespan of their pallets. As demonstrated by research from Virginia Tech and industry best practices, investing in better fasteners yields significant returns in the form of more durable, reliable, and cost-effective pallets. Don’t take pallet nails for granted—contact us to find out more.
