Zap Screwlok

MECHANICAL SPLICES
FOR REINFORCED
CONCRETE
CONSTRUCTION
PROJECTS

Technical Data
And
Performance
Review
January 2007

Zap Screwlok
MECHANICAL SPLICES
LIST OF CONTENTS

PAGE 3

INTRODUCTION AND OVERVIEW

PAGE 4 & 5

MECHANICAL SPLICES and LAP SPLICES

PAGE 6

WELDED JOINTS

PAGE 7

ZAP SCREWLOK BACKGROUND AND DESCRIPTION

PAGE 8

ZAP SCREWLOK BENEFITS

PAGE 9 & 10

TEST DATA AND TEST PROTOCOLS

PAGE 11

QUALITY STANDARDS INSTALLATION - SPECIFICATION

Barsplice Products, Inc.

4900 Webster Street
Dayton, OH 45414
Phone: (937) 275-8700
Fax: (937) 275-9566
E-mail: bar@barsplice.com
www.barsplice.com

Zap Screwlok
MECHANICAL SPLICES
INTRODUCTION AND OVERVIEW
Creating structural continuity within the reinforcement system on construction projects
can be critical. High performance mechanical splices are often essential in helping
safeguard against the unexpected and / or catastrophic effects of stress overload.
Type 1 Mechanical Splices
According to the ACI Building Code and Commentary, the maximum reinforcement
stress used in design under the code is the specified yield strength. To ensure
sufficient strength in splices so that yielding can be achieved in a member, and thus
brittle failure avoided, mechanical connections should develop at least 125% of the
specified yield. The 25% increase above the specified yield strength was selected [by
ACI] as both an adequate minimum for safety and a practical maximum for economy.
The SL series of the Zap Screwlok mechanical splice system complies with the Type
1 full mechanical splice requirement of ACI 318 for 125% x specified yield, when used
to connect standard uncoated bars that conform to ASTM A615 Grade 60 or ASTM A
706.
Type 2 Mechanical Splices
The Type 2 series of the Zap Screwlok mechanical splice system complies with the
higher performance definitions for Type 2 mechanical splices. Applications for Type 2
mechanical splices include structures that may have to withstand the effects of seismic
loading or high wind loading, impact and blast, or other dynamic condition.
Zap Screwlok is the system of choice for highly congested areas, where it might be
impractical or impossible to install a threaded-type coupler or a similar device. The Zap
Screwlok System is also convenient for use on the project site in case of unplanned
splicing or as a supplemental splicing system.
A series of screws, when tightened, embed into the bars while the high tightening force
causes the rebar profile to interlock with a wedge in the coupler body. Rebar ends may
be sheared, flame-cut or sawed.

Zap Screwlok
MECHANICAL SPLICES
MECHANICAL SPLICES and LAP SPLICES
STRENGTH
TYPE OF SPLICE
LAP
MECHANICAL
CODE
REQUIREMENT
FOR STRENGTH

100% x fy

TYPE 1
125% x fy

EQUIVALENT
STRESS IN ASTM
A615 Grade 60

60,000 psi

75,000 psi

TYPE 2 ACI
100% x fu

TYPE 2 UBC
Lesser value
160% x fy or
95% x fua

90,000 psi

Lesser value
96,000 psi or
95% x fua

fy = specified yield strength of reinforcement.

fu = specified (minimum) ultimate tensile strength of reinforcement.
fua = actual ultimate tensile strength of reinforcement.

LAP LENGTH [Ref. ACI 318-05 for lap length design]

Class A lap splice1.0 ld
Class B lap splice1.3 ld
ld =
ld
db
fc
t
e
s

cb
Ktr
Atr
fyt
s
n

3
fy
40 fc

t e s
cb + Ktr
db

db

= development length of deformed bars in tension.

= nominal bar diameter.
= square root of specified compressive strength of concrete.
= reinforcement location factor =1.3 or 1.0, depending on location.
= coating factor = 1.5 or 1.2 or 1.0, depending on coating and cover.
= reinforcement size factor = 0.8 or 1.0 depending on bar size.
= lightweight aggregate concrete factor = 1.3 or 1.0 depending on concrete.
= spacing or cover dimension.
= transverse reinforcement index.
= total cross sectional area of all transverse reinforcement within spacing s.
= specified yield strength of transverse reinforcement.
= maximum center-to-center spacing of transverse reinforcement within ld.
= number of bars being spliced along the plane of splitting.

Ktr = Atr fyt

1500sn

MECHANICAL SPLICES and LAP SPLICES

ITEM

COMMENTS

DEVELOPMENT
STRENGTH

DESIGN
VARIABLES

CONCRETE
ELEMENT
DESIGN

DYNAMIC
OVERLOAD

SEISMIC
PROVISIONS

CONGESTION

SPLITTING

SPALLING

Lap splices, by nature, can only be designed to develop 100% x

specified yield.
Mechanical Splices, as a minimum, are design to develop 125%
x specified yield.
ACI 318-05 rules for lap splice designs are complicated because
there are twelve (12) factors or more that affect the tensile
development length.
The performance of a mechanical splice is independent of the
surrounding concrete; independent of the bar spacing, the
concrete cover and the splice location.
Minimizing structural element size is often an objective of
architects and engineers. Building code requirements for lap
splices can compromise this objective.
By butting bars end-to-end and using a mechanical butt splice,
space can be saved.
Cyclic loading, such as that induced into the reinforcing system
during high wind, seismic activity or other dynamic condition,
can result in the failure of lap splices. Performance depends
upon the quality and compaction of the surrounding concrete.
The use of lap spices in seismic zones generally is disallowed.
Lap splices can not withstand inelastic strain excursions
because the ensuing destruction of the bond with the concrete
will result in the ineffectiveness of the lap.
As part of seismic qualification protocol(s), mechanical splices
are cyclically loaded.
By using mechanical splices, lap bars are eliminated and rebar
congestion is minimized. This results in improved space for
pouring and vibrating thereby enhancing concrete consolidation,
lowering concrete placement costs and improving in-place
concrete quality.
When a tensile load is applied to a lapped bar embedded in
concrete, a complex stress pattern is generated within the
concrete between and around the lapped bar. There is a
resulting tendency for the bar to cause splitting of the concrete
cover in the plane of the lap, especially under severe loading
conditions.
If spalling of concrete cover occurs around the lapped bar by
fire, corrosion or another mechanism, the effectiveness of the
lap is compromised because the performance of a lap is 100%
dependent upon the concrete that surrounds it.

In these cases, the use of mechanical splices has clear advantages

because load transfer between the rebars is independent of the concrete.
This is verified by in-air testing.
5

Zap Screwlok
MECHANICAL SPLICES
WELDED JOINTS

In the event that there are requirements to connect reinforcing bars to structural steel,
the use of a STRUCTURAL CONNECTOR is recommended. For information on
different types of Structural Connectors that are available, please contact BarSplice
Products, Inc.
The use of bar-to-bar welded joints must always be approached with due caution.
ASTM A 706 bars or equivalent must be used to achieve consistent performance.
Welding directly to ASTM A615 is generally not recommended.
ACI 318-05 has no provisions for Type 2 performance-based welds.
Welded rebar joints are not permitted by ACI 318-05 to be used within a distance
equal to twice the member depth from the column or beam face for special moment
frames or from sections where yielding of the reinforcement is likely to occur as a result
of inelastic lateral displacements.

When using the Zap Screwlok System, there are no bar chemistry
restrictions; bars may be ASTM A615 [or equivalent] or ASTM A 706.
All of the quality problems associated with welding are avoided.
There are no bar chemistries to establish; no weld qualification procedures to
follow; no pre-heat or post-heat requirements, no radiographs to be
performed and no risks of burns and accidental fires.

Zap Screwlok
MECHANICAL SPLICES

ZAP SCREWLOK BACKGROUND AND DESCRIPTION

The Zap Screwlok System was introduced into the U.S. construction market place in
1995 as a popular alternative to various rebar mechanical splice systems, welded
joints, and traditional lap splices. Today, the Zap Screwlok System is in wide spread
use, both domestically and internationally, as a preferred means of creating structural
continuity in reinforcing steel systems.
The Zap Screwlok device comprises of a steel sleeve with sides converging internally
to create a wedge shape. A series of screws, placed opposite the wedge, are provided
to force the reinforcing bar into the wedge. At the time of installation, the rebar
deformations become interlocked with the internal profile of the coupler body.
Concurrent with rebar-coupler interlock, the points on the screws embed into the
surface of the reinforcing bars, thereby providing a second mechanism by which the
splice device attaches to the bar.
Two series have been developed:

TYPE 1

Zap Screwlok System

FULL MECHANICAL SPLICE

PER ACI 318
125% x SPECIFIED YIELD
ASTM A615 Grade60 and/or ASTM A706

ACI

TYPE
2

150% x SPECIFIED YIELD

ASTM A615 Grade60
SPECIFIED TENSILE
STRENGTH
ASTM A706: 80,000 psi minimum

UBC

SL
SERIES
MEETS
AND
EXCEEDS

TYPE 2
SERIES
MEETS AND
EXCEEDS

BLACK BAR

MEETS AND
EXCEEDS

LESSER VALUE:
160% x SPECIFIED YIELD
95% x ACTUAL TENSILE
ASTM A615 Grade60 and/or ASTM A706

The ZAP Screwlok Type 2 series, and transitions, are ICC classified as Type 2 per
Legacy Report ER-5461.
Zap SL is a Shorter Length coupler compared to the Type 2 Zap Screwlok. The
body shape, cross-sectional area and screw torque values are equal.

Zap Screwlok
MECHANICAL SPLICES
ZAP SCREWLOK BENEFITS
SUMMARY OF BENEFITS
1
2
3

Design
Choices

SL series Short Length for 125% x Specified Yield Grade 60.

Rebar
Compatibility

ASTM A 615 bars.

Field
Advantages

No special weather restrictions.

Type 2 series for higher strength applications.

ASTM A 706 bars
No specialized equipment or power.
No heat.
No welding.

Replacement
for lap

Eliminates rebar lap.

Reduces congestion.
Improved space for pouring and vibrating.
Enhanced concrete compaction.
Higher development strength.
Minimal detailing, more flexibility in the field.

Convenience
and
Assembly

Simple in nature, and easy to understand.

Usage and
Applications

Primary mechanical splice.

The system does not require rebar rotation during assembly.

No specialized installation equipment or threading equipment.
An additional system to help with fast - track schedules.
Suitable for unplanned splices and design changes.
A repair splice
More field construction options.

Access

It is suitable for tight access areas.

The system is suitable for splicing between fixed points.

Zap Screwlok
MECHANICAL SPLICES
TEST DATA AND TEST PROTOCOLS
SL SERIES TEST DATA
SL series test data is shown in ZAP SCREWLOK SL SYSTEM TEST DATA.
9 The results exceed the Type 1 specifications of ACI 318-05 and UBC 97 that
require a full mechanical splice to develop 125 percent of the specified yield
of the bar.
TYPE 2 SERIES TEST DATA
TYPE 2 series test results are shown in ZAP SCREWLOK SYSTEM TEST DATA.
Special Provisions for Seismic Design are addressed in Chapter 21 of ACI 318-05.
Section 21.2.6.1 states that Mechanical Splices shall be classified as either Type 1 or
Type 2. A Type 2 splice is required to conform to the same strength provisions for Type 1
and develop the specified tensile strength of the spliced bar.
9 The results exceed the specified tensile strength of Grade 60 bar, namely
90,000 psi, thereby satisfying both the Type 1 and Type 2 specifications of
ACI 318-05.
UBC
The 1997 Uniform Building Code (UBC 97), in section 1912.14.3.4, requires a full
mechanical splice to develop 125 percent of specified yield, fy, of the bar.
The use of reinforcement in members resisting earthquake-induced forces is addressed
in section 1921.2.5. Restrictions are imposed upon the use of A 615 reinforcement per
1921.2.5.2. Under these restrictive conditions, section 1921.2.6.1.2 classifies
mechanical connections according to strength. A Type 1 mechanical connection meets
the strength requirements of 1912.14.3.4. A Type 2 mechanical connection develops in
tension the lesser value of 95 percent of the actual ultimate strength or 160 percent of
specified yield, fy, of the bar.
9 For bar sizes #4 through #11, the Zap Screwlok Type 2 series has been
qualified to the Type 1 and Type 2 tensile requirements of the Uniform
Building Code (UBC 97) as reported in ICCs Legacy Report ER-5461.

ZAP SCREWLOK TEST DATA AND TEST PROTOCOLS

SLIP TESTS
Slip testing was incorporated into a comprehensive test program conducted for ICC
Evaluation Services. Report UDR-TR-97-17, issued by the University of Dayton
Research Institute, UDRI, describes the test program.
9 All results are less than 0.010 inches thereby meeting DOT slip-value criteria.
CYCLIC STRESS REVERSAL TESTS
Sizes #10 and #11 were stress reversal fatigue tested at UDRI using ASTM A 615 bars
and ASTM A 706 bars. Load-displacement curves were generated by UDRI at the start
and end of each series of cycles. Final slip was determined from digital data.
10,000-stress reversal cycles from 25,000 psi in compression to +25,000 psi in
tension was performed by CalTrans as part of their mechanical splice evaluation tests.
9 The results satisfied CalTrans requirements.
9 CalTrans approved Zap Screwlok Type 2 series.
HIGH CYCLE TENSILE FATIGUE TESTS
A series of high cycle tensile fatigue tests were performed at UDRI. Michigan DOTs
specifications require that all splices tested shall develop a fatigue strength of 83 MPa
(12 ksi) tension for more than 1,000,000 cycles.
To be considered for special high fatigue strength usage, all splices tested are
required to develop a fatigue strength of 124 MPa (18 ksi) tension for more than
1,000,000 cycles.
Black and epoxy bars were tested in accordance with Michigan DOT requirements.
Specimens were first fatigue tested for one million cycles at the standard 12-ksi
range. The same specimens were then fatigue tested a second time at the high
fatigue range of 18 ksi. Report UDR-TR-97-44 shows the actual number of cycles for
each stress range and the cumulative number of cycles for each specimen. In the case
of #8 Zap Screwlok, one specimen was subjected to a fatigue range of almost 24-ksi;
this is a higher fatigue range than that required by Michigan DOT or than that defined
by AASHTO.
9 In each case, it was reported that there was No damage, No slippage and No
failure.

10

Zap Screwlok
MECHANICAL SPLICES
QUALITY STANDARDS - INSTALLATION - SPECIFICATION
QUALITY STANDARDS
Barsplice Products, Inc. is certified to the Quality Standards of ISO 9001:2000 to
Design, Manufacture and Test Mechanical Splices for Concrete Reinforcing Bars and
Accessories.
BPI is certified by ASME as a Material Organization: Quality System Certificate
Number QSC-589.
INSTALLATION
Installation instructions are included with each shipment from BPIs manufacturing
plant.
HOW TO SPECIFY
Specific: Rebar mechanical splices shall be ZAP SCREWLOK as manufactured by
BarSplice Products, Inc. [specify SL or TYPE 2].
Generic: Rebar mechanical splices shall be [specify Type 1 or Type 2] comprised of a
steel sleeve with internal wedge, installed by tightening cone point screws until the
heads twist off at a prescribed torque. Parts shall be manufactured to the quality
requirements of ISO 9001:2000.
MANUFACTURER NAME AND ADDRESS
BarSplice Products, Inc.
4900 Webster Street
Dayton, OH 45414
www.barsplice.com
Tel: (937) 275-8700
Fax: (937) 275-9566
e-mail: bar@barsplice.com
All products described herein are supplied in accordance with BPIs standard Terms and Conditions of Sale. While
the information contained in this document and exhibits is believed to be accurate at the time of publication, BPI
reserves the right to make changes, design modifications, corrections and other revisions as it seen fit, without
notice. This document is of a promotional nature only. Aspects of structural design, evaluation of product fitness for
use, suitability or similar attributes are the responsibility of others.

11

ZAP SCREWLOK

SYSTEM
TYPE 2 SERIES (BLACK)
AND

EPOXY COATED SERIES

SHEAR SCREW
AND WEDGE
MECHANICAL
CONNECTIONS
FOR
REINFORCING
BARS

PERFORMANCE
TEST
DATA
January 2007

BarSplice Products, Inc., 4900 Webster Street, Dayton OH 45414, USA

z Tel: (937) 275-8700 z Fax: (937) 275-9566 z E-mail: bar@barsplice.com

INTRODUCTION
Barsplice Products, Inc. has conducted a series of tests on reinforcing bar mechanical splice sizes No.
4 through No. 14. The tests have been conducted on black and epoxy coated Zap Screwlok
Mechanical Splices. The purpose of the testing is to ensure that products are manufactured to the
quality standards of BPI's ISO 9001:2000 Quality System and are capable of exceeding strength
requirements of various Building Codes.

TENSILE TEST PROCEDURE

Test specimens were loaded monotonically in tension to failure to determine the capability of the splice
system. The tests were conducted in accordance with "Standard Test Methods and Definitions for
Mechanical Testing of Steel Products", ASTM A370. The testing was performed to exceed the Type 2
strength requirements of ACI (American Concrete Institute) 318, Section 21.2.6.1, namely the specified
tensile strength of Grade 60 reinforcing bar. This equates to 150% x specified yield strength of Grade
60 bar or 90,000 psi.
All monotonic tension tests were carried out in a 600 kip Forney universal testing machine, located at
the Barsplice Products, Inc. in-house laboratory. Current calibration certificates for the test machine
are on file. All testing of mechanical splices at the Barsplice in-house lab is controlled within the BPI
ISO 9001:2000 Quality System.

COMPRESSION TEST PROCEDURE

Test specimens were loaded monotonically in compression to exceed the strength requirements of ACI
(American Concrete Institute) 318, Section 12.14.3.2, namely 125% x specified yield strength of Grade
60 reinforcing bar.
All Compression tests were carried out in a 200 kip Satec universal testing machine, located at the
independent testing laboratory of A-Lab Inc., Dayton, OH.

TEST RESULTS
Results of the tension testing are summarized in Table 1.
Results of the compression testing are summarized in Table 2.
The reinforcing steel used in these tests conforms to the requirements of ASTM A615, Grade 60.

SUMMARY
(1) Tension test specimens exceeded the Type 1 strength requirements of ACI 318, Section
12.14.3.2, namely 125% x specified yield strength of Grade 60 rebar.
(2) Tension test specimens exceeded the TYPE 2 strength requirements of ACI 318-05,
Section 21.2.6.1, namely the specified tensile strength of Grade 60 rebar. ASTM A615,
Grade 60 has a specified tensile strength of 90,000 psi which is equivalent to 150% x
specified yield.
(3) The TYPE 2 strength requirements stated in the 1997 Uniform Building Code (UBC) were
met*, namely the lesser value of 160% x specified yield strength of Grade 60 rebar or 95%
x actual tensile strength of the rebar.
(4) Compression testing exceeded the minimum strength requirements of ACI 318, Section
12.14.3.2, namely 125% x specified yield strength of Grade 60 reinforcing bar.
* Bar size #14 has not yet been evaluated by ICC to the UBC strength requirements.

TABLE 1: TENSILE TEST RESULTS

TYPE 2 /
EPOXY
ZAP SIZE

No. 4

No. 5

No. 6

No. 7

TEST ID
NUMBER

BAR
TYPE

4T281

BLACK

4T282
4T284

BLACK
EPOXY

4T292

BLACK

4T293

BLACK

4T294

EPOXY

4T295

EPOXY

5T522

BLACK

5T523

BLACK

5T528

EPOXY

5T530

EPOXY

5T531

EPOXY

5T536

BLACK

5T546

BLACK

6T467

EPOXY

6T481

BLACK

6T482

EPOXY

6T497
6T499
6T507

BLACK
BLACK
EPOXY

6T514

BLACK

6T519

BLACK

6T524

BLACK

7T223

BLACK

7T225

BLACK

7T226

BLACK

7T233

BLACK

7T244

BLACK

7T260

BLACK

7T264

BLACK

PEAK STRENGTH
STRESS % GRADE
IN REBAR 60 SPEC.
(psi)
YIELD
110,444
184 %
115,720
193 %
118,561
198 %
104,539
174 %
105,643
176 %
110,589
184 %
105,219
175 %
109,914
183 %
114,931
192 %
113,736
190 %
113,454
189 %
111,222
185 %
109,753
183 %
104,712
175 %
104,342
174 %
107,784
180 %
103,498
173 %
108,932
182 %
109,725
183 %
112,805
188 %
112,171
187 %
109,168
182 %
105,556
176 %
104,709
175 %
102,907
172 %
101,721
170 %
109,138
182 %
106,259
177 %
113,074
188 %
103,263
172 %
106,704
178 %
113,501
189 %
112,960
188 %
99,247
165 %
114,952
192 %
115,694
193 %
112,727
188 %
110,995
185 %
108,609
181 %
104,770
175 %
100,670
168 %
100,450
167 %
106,268
177 %
107,280
179 %
105,144
175 %
103,228
172 %
108,043
180 %
109,077
182 %
109,391
182 %
102,734
171 %
105,909
177 %
102,938
172 %

TYPE 2 /
EPOXY
ZAP SIZE

No. 8

No. 9

No. 10

No. 11

TEST ID
NUMBER

BAR
TYPE

8T344

BLACK

8T351

BLACK

8T355

BLACK

8T368

BLACK

8T369

BLACK

8T372

BLACK

9T268

BLACK

9T271
9T272

BLACK
BLACK

9T287

BLACK

9T289

BLACK

9T301

BLACK

9T307

BLACK

9T310

BLACK

9T312
10T197

BLACK
BLACK

10T236

BLACK

10T237

BLACK

10T238

BLACK

10T240

BLACK

10T246

BLACK

10T247

BLACK

10T248

BLACK

11T452

BLACK

11T455
11T463

BLACK
BLACK

11T479

BLACK

11T489

BLACK

11T494

BLACK

11T503

BLACK

PEAK STRENGTH
STRESS % GRADE
IN REBAR 60 SPEC.
(psi)
YIELD
109,836
183 %
104,962
175 %
102,246
170 %
111,686
186 %
109,411
182 %
106,205
177 %
115,222
192 %
102,371
171 %
109,192
182 %
108,064
180 %
109,408
182 %
105,365
176 %
106,342
177 %
106,367
177 %
105,642
176 %
103,684
173 %
104,508
174 %
106,399
177 %
105,805
176 %
106,124
177 %
105,398
176 %
99,858
166 %
107,825
180 %
102,046
170 %
107,158
179 %
107,776
180 %
100,310
167 %
113,199
189 %
113,069
188 %
112,865
188 %
115,195
192 %
109,258
182 %
111,232
185 %
110,836
185 %
114,046
190 %
111,434
186 %
112,125
187 %
114,335
191 %
115,065
192 %
106,625
178 %
107,683
179 %
110,400
184 %
103,532
173 %
106,776
178 %
105,026
175 %
98,334
164 %
101,448
169 %
106,578
178 %
106,532
178 %
103,521
173 %
104,406
174 %
100,002
167 %

TABLE 1 (continued): TENSILE TEST RESULTS

TYPE 2 /
EPOXY
ZAP SIZE

TEST ID
NUMBER

BAR
TYPE

14T213

BLACK

14T214

BLACK

14T221

BLACK

14T240

EPOXY

14T245

EPOXY

14T259

BLACK

14T260

BLACK

No. 14

PEAK STRENGTH
STRESS % GRADE
IN REBAR 60 SPEC.
(psi)
YIELD
98,419
164%
160%
96,068
159%
95,631
158%
94,529
155%
93,080
156%
93,813
152%
91,471
159%
95,364
153%
91,747
158%
94,724
153%
91,862
158%
94,800
160%
95,987

TABLE 2: COMPRESSION TEST RESULTS

TYPE 2
ZAP SIZE

TEST ID
NUMBER

BAR TYPE

No. 4

4T87

BLACK

No. 5

5T152

BLACK

No. 6

6T144

BLACK

No. 7

7T80

BLACK

No. 8

8T116

BLACK

No. 9

9T77

BLACK

No. 10

10T82

BLACK

No. 11

11T152

BLACK

PEAK STRENGTH
STRESS IN
% GRADE 60
REBAR (psi)
SPEC. YIELD
118,560
198 %
117,680
196 %
117,110
195 %
148,120
247 %
136,330
227 %
118,080
197 %
120,140
200 %
104,630
174 %
104,730
175 %
120,330
201 %
120,000
200 %
120,890
201 %
120,830
201 %
120,960
202 %
120,740
201 %
120,980
202 %
120,780
201 %
121,050
202 %
121,070
202 %
121,120
202 %
120,480
201 %
120,890
201 %
120,960
202 %

ZAP SCREWLOK

'SL'
SYSTEM

SHEAR SCREW

TYPE 1
MECHANICAL
CONNECTIONS
FOR
REINFORCING
BARS

PERFORMANCE
TEST
DATA
January 2007
BarSplice Products, Inc., 4900 Webster Street, Dayton OH 45414, USA
z Tel: (937) 275-8700 z Fax: (937) 275-9566 z E-mail: bar@barsplice.com

INTRODUCTION
Barsplice Products, Inc. (BPI) has conducted a series of tests on reinforcing bar
mechanical splice sizes No. 4 through No. 18. The tests have been conducted on
uncoated Zap Screwlok SL Mechanical Splices. The purpose of the testing is to
ensure that products are manufactured to the quality standards of BPI's ISO 9001:2000
Quality System and are capable of exceeding strength requirements of various Building
Codes and Departments of Transportation.
TENSILE TEST PROCEDURE
Test specimens were loaded monotonically in tension to failure to determine the
capability of the splice system. The tests were conducted in accordance with
"Standard Test Methods and Definitions for Mechanical Testing of Steel Products",
ASTM A370. The testing was performed to exceed the strength requirements of the
American Concrete Institute ACI-318, Section 12.14.3.2, namely 125% x specified yield
strength of Grade 60 reinforcing bar.
All monotonic tension tests were carried out in a 600 kip Forney universal testing
machine, located at the Barsplice Products, Inc. in-house laboratory. Current
calibration certificates for the test machine are on file.
TEST RESULTS
Results of the tension testing are summarized in the following Table.
The reinforcing steel used in these tests conforms to the requirements of ASTM A615,
Grade 60.

SUMMARY
(1) All tension test specimens exceeded the Type 1 strength requirements of ACI 318,
Section 12.14.3.2, namely 125% x specified yield strength of Grade 60 rebar.

BarSplice Products, Inc., 4900 Webster Street, Dayton OH 45414, USA

z Tel: (937) 275-8700 z Fax: (937) 275-9566 z E-mail: bar@barsplice.com

SUMMARY OF ZAP SCREWLOK 'SL' TEST RESULTS

January 2007
TABLE 1:
LOAD
STRESS PERCENTAGE
ZAP SL
DEVELOPED IN REBAR
OF fy
SIZE
(lbs.)
(psi)
GRADE 60
20,691
103,454
172%
20,230
101,150
169%
21,770
108,848
181%
22,417
112,085
187%
#4
21,910
109,550
183%
19,730
98,650
164%
22,010
110,050
183%
21,520
107,600
179%
21,420
107,100
179%
31,470
101,516
169%
30,778
99,284
165%
32,895
106,113
177%
32,674
105,401
176%
32,981
106,390
177%
#5
32,643
105,299
175%
32,280
104,129
174%
33,370
107,645
179%
32,320
104,258
174%
32,820
105,871
176%
33,190
107,065
178%
46,950
106,705
178%
47,990
109,068
182%
49,630
112,795
188%
47,430
107,795
180%
48,360
109,909
183%
#6
48,860
111,045
185%
48,760
110,818
185%
47,480
107,909
180%
48,120
109,364
182%
45,820
104,136
174%
48,310
109,795
183%
61,330
102,217
170%
61,360
102,267
170%
62,260
103,767
173%
64,520
107,533
179%
61,230
102,050
170%
66,430
110,717
185%
#7
67,290
112,150
187%
67,120
111,867
186%
61,460
102,433
171%
63,030
105,050
175%
62,050
103,417
172%
59,940
99,900
167%

LOAD
STRESS PERCENTAGE
ZAP SL
DEVELOPED IN REBAR
OF fy
SIZE
(lbs.)
(psi)
GRADE 60
85,690
108,468
181%
85,500
108,228
180%
87,030
110,165
184%
85,740
108,532
181%
87,290
110,494
184%
83,510
105,709
176%
75,920
96,101
160%
#8
80,510
101,911
170%
84,160
106,532
178%
84,150
106,519
178%
85,400
108,101
180%
85,590
108,342
181%
81,990
103,785
173%
80,440
101,823
170%
81,690
103,405
172%
101,770
101,770
170%
103,780
103,780
173%
107,840
107,840
180%
109,680
109,680
183%
103,462
103,462
172%
106,220
106,220
177%
108,676
108,676
181%
97,447
97,447
162%
107,400
107,400
179%
#9
104,063
104,063
173%
100,950
100,950
168%
103,142
103,142
172%
105,885
105,885
176%
99,959
99,959
167%
103,836
103,836
173%
97,616
97,616
163%
98,033
98,033
163%
99,590
99,590
166%
100,847
100,847
168%

BarSplice Products, Inc., 4900 Webster Street, Dayton OH 45414, USA

z Tel: (937) 275-8700 z Fax: (937) 275-9566 z E-mail: bar@barsplice.com

TABLE 1 (continued):

#10

#11

141,210
141,750
126,740
133,840
126,710
126,440
129,680
133,231
133,120
133,290
133,610
135,950
136,220
134,850
133,680
133,389
133,560
176,600
173,190
172,269
177,119
174,999
172,641
174,600
177,450
168,829
176,250
177,540
170,230
170,190
174,210
171,180
170,439
170,130
168,521
169,319
169,861
167,990
153,610
158,930

111,189
111,614
99,795
105,386
99,772
99,559
102,110
104,906
104,819
104,953
105,205
107,047
107,260
106,181
105,260
105,031
105,165
113,205
111,019
110,429
113,538
112,179
110,667
111,923
113,750
108,224
112,981
113,808
109,122
109,096
111,673
109,731
109,256
109,058
108,026
108,538
108,885
107,686
98,468
101,878

185%
186%
166%
176%
166%
166%
170%
175%
175%
175%
175%
178%
179%
177%
175%
175%
175%
189%
185%
184%
189%
187%
184%
187%
190%
180%
188%
190%
182%
182%
186%
183%
182%
182%
180%
181%
181%
179%
164%
170%

#14

#18

193,280
185,150
208,580
184,840
196,000
354,400
353,352
371,708
368,940
340,520
344,320
351,924
356,164
338,020

85,902
82,289
92,702
82,151
87,111
88,600
88,338
92,927
92,235
85,130
86,080
87,981
89,041
84,505

143%
137%
155%
137%
145%
148%
147%
155%
154%
142%
143%
147%
148%
141%

This product is intended for use on uncoated reinforcing bars only.

Ongoing product developments may result in higher tensile performance than shown above.

BarSplice Products, Inc., 4900 Webster Street, Dayton OH 45414, USA

z Tel: (937) 275-8700 z Fax: (937) 275-9566 z E-mail: bar@barsplice.com