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Fracture Characterization of Threaded Rebar and Coupler

Conference Paper · February 2016

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Annasaheb Dange College of Engineering and Technology Ashta Government Polytechnic Malvan
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 Fracture Characterization of Threaded Rebar and
Coupler
Prof.(Dr.) Suresh Abasaheb Patil
Professor, Dept. of Mechanical Engineering.
ADCET, Ashta.
[email protected]

Mr. Bhushan Shivaji Walunj

Mr. Nivedhan Sudhakar Gandhi
Dept. of Mechanical and Automation Engineering Dept. of Mechanical and Automation Engineering
ADCET, Ashta. ADCET, Ashta.
[email protected] [email protected]
[email protected]

Abstract— The old method of connecting reinforcement bars Couplers require less amount of steel as compared to lap
with lap joints continuity in reinforced concrete need not be splicing. Around 3%-5% steel is saved per splicing.
always appropriate. The main advantages of simplicity and We know that the time is also major parameter in the
economy in lap splicing is limited to smaller diameter bars, The construction of the building. In case of the skyscrapers and
mechanical couplers provides the solution for splicing when large
road bridges every single day matters. And we know that
diameters bars are involved.
splicing the bars with help of wires takes a time. In case of
Spliced rebar performs like continuous reinforcement. couplers this time can be saved.
Splicing enhances strength mechanically, independent of Couplers are the solution for many problems which occurs in
concrete. Therefore providing ductility in RCC structures the building construction.
independent of the concrete’s condition. Proven cyclic
performance of spliced rebars offers strength during artificial,
seismic or other natural events. The continuity of spliced rebar MANUFACTURING OF COUPLERS
offers excellent provision for grounding the electric current.
Step 1:-
Designer friendly: The coupler reduces rebar congestion and 1. The ends of the bars to be jointed are cut square and
improves the flow & consolidation of concrete. It even offers enlarged by cold forging to increase their diameter so as to
greater flexibility in design options. The ease in detailing of ensure that the joint is tough than the bar. The couplers are
reinforcement, especially in reinforcement congestion zones usually supplied attached to the reinforcing bar.
reduces the reinforcement fixing errors, thus detailing and fixing 2. First we use the upsetting machine to thicken the rebar at
of seismic reinforcement becomes effortless. Moreover the its ends as shown in Fig. 1.
workability with higher steel-to-concrete ratio allows 3. The use the steel bar threading machine to make thread
optimization of the size of RCC structural members.
on the end of rebar's.
Contractor's preference: The coupler offers quality, cost and 4. Connect the two rebar end with the upsetting rebar
time saving. Their installation requires no special skills or couplers.
equipments. Compared to lapping, simple mechanical ways in Advantages:-
adopting mechanical splicing accelerates construction schedules 1. This system enlarged the strength of rebar at its end.
for optimum cost and efficiency. 2. It can be used link the rebar whose diameter is from 12
mm to 40mm.
Index Terms—Coupling, splicing, reinforcement, ductility,
3. It has High efficiency, simple structure, small volume,
optimum sizing.
lightweight and easy operation.
INTRODUCTION 4. It is also suitable for hot working environment.
Construction determines development of a country. The
aesthetic view of infrastructure leaves an impression of
development, use of couplers provide a wide scope as far as
building design is concerned.
Steel is very expensive and construction activities require
large amount of steel. Increasing expense of steel is an area of
concern. Use of couplers helps to overcome this issue.

151
 TABLE 1 Rebar diameter vs Thread pitch

Rebar Diameter (mm) Thread pitch

(mm)
12 2.0
16 2.5
20 3
25 3.5
32 4.0
40 4.0

SPLICING PROCESS

Fig. 1 Upset forging machine.

1. Cutting

Details of the upset forging machine

1. Rebar diameter range- 12mm to 40mm
2. Oil pump flux- 5L/min Fig. 4.1 Reinforced bar
3. Electric motor power- 4kW
4. Piston movement distance- 100 mm The end of the reinforcing bar is swan cut shown in fig 4.1.
5. Out dimensions (mm)- 225*570*1100
6. Weight - 597 Kg. 2. Cold Forging

Step 2:-
The threading machine is used for cutting threads
externally on the component by chasing method shown in Fig. Fig. 4.2 Enlarged bar
2. HSS tangential chasers are used as cutters. The component
remains stationery and Die head rotates. Threads can be cut on Swan cut of reinforcing bar is enlarged by the cold forging
this machine it depends upon the type of chasers. For given thus, increases its core diameter shown in fig 4.2.
diameter of rebar bar particular pitch is given TABLE 1.
3. Threading

Fig. 4.3 Enlarged threaded bar

Then standard metric threads are cut over the enlarged end and
covered by plastic caps to protect the thread of rebar shown in
fig 4.3.

4. Splicing

Fig. 2 Rebar threading machine.

Detailed technical information of the rebar threading Fig. 4.4 Assembly of coupler and two bars
machine
Finally splice the rebar by using threaded couplers shown in fig
1. Rebar diameter range- 12mm to 40mm 4.4
2. Mains voltage(v)- 3 phase
3. Weight- 1263 Kg. MATERIAL USED
Material used for the production of the couplers is DIN
Thread cutting tools (Chaser) 17200Gr. C45

TABLE 2 Chemical properties of material.

Chemical Properties

% carbon 0.42-0.50
% Sulphur 0.045 max
% Phosphorus 0.045 max
Fig. 3 threading tool.
% Manganese 0.50- 0.80
% Silicon 0.15- 0.35
152
 Mechanical properties (Turn the coupler and the lock nut onto the short threaded
rebar)
1. Grade- C45 Used where both rebars are not rotatable, then starter bar is
2. Condition- Rolled, Annealed, water quenched, oil threaded for the full coupler lock nut length t screw coupler
quenched and lock nut onto the extended threads.
3. Yield strength (MPa)- Rolled -460 Annealed -330
SIZE OF COUPLERS
4. Tensile strength- Rolled -750, Annealed -540, water
quenched -2270, oil quenched -1980 TABLE 3. Approximate dimensions of Threaded couplers
5. Elongation A5(%)Rolled -18, Annealed -30
6. Hardness HRC Rolled -58, Annealed- 55 Bar outer dia. Length (mm) Thread size
7. Quenching Temperature- Rolled- 820, Annealed- 860 dia.(mm) (mm)
8. Bend ability Min..recommended bending radius (<= 16 26 40 M20*2.5
900) 20 32 48 M24*3.0
25 40 60 M30*3.5
TYPES OF COUPLERS
30 50 72 M36*4.0
Based on the process of splicing couplers are classified into 40 62 90 M45*4.0
4 parts.
TABLE 4.Approximate dimensions of pressing couplers
1. Rotatable rebar splice Bar dia. Outer Length Inside diameter
dia
(mm) (mm) (mm) (mm)
(Threaded rebar and coupler) 16 31 118 21
20 36 130 25.5
25 45 150 30.8
32 56 192 38.8
(Turns the rebars into the couplers to connect) 40 70 240 46
Used where the connecting rebar can be rotated, then
end of the bars are threaded upto half the length of the
coupler. TABLE 5 COUPLER UNDER UTS

2. Non rotatable Rebar splice Gauge Ultimate UTS Fracture Dist. From
Dia. Load center
mm KN N/mm2 mm
(Threaded rebar and coupler) 16 129 642 TMT bar 190
20 196 624 TMT bar 128
25 336 684 TMT bar 98
32 550 684 TMT bar 143
(Turn the coupler onto short threaded rebar) 40 800 637 No Fracture No Fracture
Used where both rebars are not rotatable, then starter
bar is threaded for the full coupler length so screw
coupler onto the extended threads.

3. Different diameter splice COST ESTIMATION

Cost of the coupler is from 5 Rs to 2000 Rs per piece. It

depends on the type of the coupler.
(Threaded rebars of different diameters and coupler) If we consider the wastage of the steel in overlapping
splicing process then the cost of the coupler is negligible.
Basically 3%-5% steel bar is overlapped on other bar so if we
(Turn the rebar into coupler to connect) will use the couplers this much amount of steel will be saved.
Used to connect rebars of different diameters by using In same approximate budget only we can use the couplers.
reducing coupler. ADVANTAGES OF USING COUPLERS
4. Non rotatable rebar splice with lock -Nut 1. The traditional method of joining reinforcement bars with
lap joints continuity with reinforced concrete can’t be always
appropriate. Advantages of economy and simplicity in lap
splicing is limited to smaller diameter bars, the mechanical
(Threaded rebars, coupler and nut)
couplers provide the solution for splicing when large
diameters bars are involved.

153
2. Spliced rebar performs like continuous reinforcement.
Splicing enhances mechanical strength, independent of
CONCLUSION
concrete. Therefore providing ductility in RCC structures
independent of the condition of concrete. Proven cyclic As we have seen above use of the coupler is easy and
design friendly. Even it is tough & safe to use. Though
performance of spliced rebar offers strength during natural, manufacturing cost of couplers in budget of construction will
seismic or artificial events. The continuity of spliced rebar increase, but 3% to 5% steel we be saved which was wasted in
offers excellent provision for grounding electric current. overlapping. The cost of saved steel is more than that of the
3. Designer friendly: The coupler reduces rebar congestion manufacturing cost of couplers. So we can than those couplers
and improves the flow & consolidation of concrete. It offers a are free. They are not only free but they are profitable. Due to
huge variety in design options. The ease in detailing of its all advantages and no cost this method is more useful than
the earlier one.
reinforcement, particularly in reinforcement congestion zones
reduces the reinforcement fixing errors, making detailing and
fixing of seismic reinforcement effortless. Moreover REFERENCES
workability with high steel-to-concrete ratio ensures optimum [1] Bertero, V., Miranda, E. and Thompson, C. (1990),
sizing of RCC structural members. Cyclic behaviour of shear wall boundary elements
4. Contractor's preference: The coupler ensure low cost, high incorporating prefabricated welded wire hoops. National
quality and time saving. Fixing couplers doesn’t requires any institute of standards &n technology, New York
special skills or equipments. Compared to lapping, simple
[2] Cheok, G.S. and Stone, W.C. (1994), Performance of a
mechanical ways in adopting mechanical splicing accelerates
1/3 scale model precast concrete beam-column cllections
construction schedules for optimum efficiency and cost. subjected to cyclic inelastics loads. Report no,4,Nistir 5436,
5. Increase tensile and compressive capacities of long columns June 1994
and beams where the designed tensile loadings are greater
than normal loadings. Tension couplers are so far the best [3] Saatcioglu, M. and Grira, M. (1996), Concrete columns
solution for tensile piles and tensile columns. confined with welded reinforcement grids. Ottawa varelton
6. Eliminates congestion of steel bars in heavily reinforced Earthquake research center, Report OCEERC 96-05.
columns and core wall of building. Thus minimizing
[4] Englekirk, Robert E, (2003), Seismic Design of
formation of "honeycomb" in concrete structures. Reinforced and precast concrete buildings. John wiley & sons,
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reinforcements facilitates easier flow of concrete.
8. Reduces cost and increases speed of slip and jump from [5] Ozbakkaloglu,T. Naumoski, and Saatcioglu, M. (2005),
work system in the construction of core walls and towers. Response of reinforced concrete frame buildings to blast
9. Avoids strains, corrosion and breakage of starter bars left loading. Proceedings of the CSCE annual conference, Toronto.
for further extension of building and bridges.
10. For construction of structure like bridges in highly
congested area where structure could be constructed in stages
allowing constant flow of traffic.
11. Provide connections for starter bars for underground
beams and slabs in the construction of diaphragm wall to
prevent breakage of precast starter bars during the bending
process to avoid tedious concrete hacking.
12. Where spacing between bars is insufficient for lapping,
e.g. in construction of micropiles.
13. Reduces size of concrete section and ensures maximum
utilization of expensive floor space in office towers.
14. Where a full tension splice is required, e.g. in connecting
precast members to cast-in-site members.

RESULT
From Table 5 we observed that after the application of load
and stress on the bar, fracture was observed in the TMT bar
spliced with coupler. But in none of the cases fracture was
observed in coupler.

154

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