⦁ Weak Substrate: Aged concrete strength: C20 (vs. modern C50 standard); standard nails caused cracking.
⦁ High Humidity & Corrosion: Tropical rainforest climate (85%+ humidity + salt spray) rusted carbon steel nails within 6 months.
⦁ Installation Constraints: Narrow frame gaps (≤30mm) required nails: 200mm length × ≤Φ6mm diameter.
Custom Requirements:
⦁ Anti-crack high-low double thread structure (enhanced grip in weak concrete)
⦁ Ultra-slim shank (200mm × Φ5.8mm) with bend resistance
⦁ Tropical-grade anti-corrosion (salt spray test ≥1,000 hours)
Tedun Technical Solution
Product Design:
Name: TEDUN-BR2025 Tropical Anti-Crack Concrete Nail
Structure:
⦁ Head: Phillips drive (compatible with local impact drills)
⦁ Shank:
- Front 30mm: High-profile thread (pitch 2.5mm, depth 0.4mm) → Aggressive bite into weak substrate
- Middle 140mm: Double-low thread (staggered pitch 1.8mm/2.0mm) → Stress dispersion to prevent cracking
- Rear 30mm: Smooth shank → Accommodates frame expansion
Material:
⦁ 4140 alloy steel + Hot-dip galvanizing (≥25μm) + Sealer coating → 3x salt spray lifespan
Patents Applied:
Dual-Thread Stress Dispersion Tech: Reduces substrate stress by 30%.
Stepwise Anti-Corrosion Process: Zinc layer + nano-sealer fills micropores; passes ISO 9227 salt spray test (1,024 hours).
Key Project Milestones
Phase Action Timeline Deliverables
Requirement Confirmation On-site substrate sampling (São Paulo lab) 3 days Concrete Strength Degradation Report
Prototype Design 3D modeling + FEA stress analysis 5 days Bend simulation video + load distribution map
Trial & Testing Brazil-simulated environment tests:
⦁ Damp heat cycling (40°C/95% RH)
⦁ Salt spray (1,024h) 12 days Test report compliant with NBR 15575 (Brazilian National Standard)
Mass Production & Delivery Dedicated line: 200k units; shipped to Port of Santos 18 days Portuguese installation guide + anti-counterfeit QR code
Performance Comparison (Tedun Custom vs. Local Brazilian Brand)
Metric Tedun Custom Nail Local Competitor Improvement
Tensile Strength 8.2 kN 5.6 kN +46%
Salt Spray Resistance 1,024 hrs (no rust) 480 hrs (partial rust) +113%
Substrate Cracking Rate 0% (C20 concrete) 15%~22% Fully resolved
Installation Efficiency ≤4 sec/nail ≥7 sec (frequent jamming) +75%
Value Delivered
⦁ Cost Savings:
Eliminated rework costs from cracking (saved >$12,000 USD).
Extended maintenance cycle from 1 year to 5 years.
⦁ Accelerated Timeline:
3 workers completed 15-day workload in 6 days (150% efficiency gain).
Tedun Customization Capabilities Validated
⦁ Rapid Patent Integration: Dual-low thread tech from design to mass production in 23 days.
⦁ Localization: Compatible with Brazilian tools (Phillips drive) & standards (NBR 15575).
⦁ Full Traceability: Laser-etched batch numbers; QR code links to coating thickness/test reports.
Key Insight: For tropical aging structures, material + structure + process triple-customization outperforms single-parameter adjustments.
Tedun’s Latin America Tropical Material Library includes zinc-nickel alloy coatings and humidity-resistant sealants for rapid deployment.
This case demonstrates Tedun’s technical prowess in resolving extreme environmental and structural challenges.
