Fracture Characterization of Threaded Rebar and

Coupler
Prof.(Dr.) Suresh Abasaheb Patil
Professor, Dept. of Mechanical Engineering.
ADCET, Ashta.
sureshapatil@rediffmail.com

Mr. Bhushan Shivaji Walunj

Mr. Nivedhan Sudhakar Gandhi

Dept. of Mechanical and Automation Engineering

ADCET, Ashta.
b9420033348@gmail.com
ias_bhushan@india.com

Dept. of Mechanical and Automation Engineering

ADCET, Ashta.
nivedhangandhi@gmail.com
Couplers require less amount of steel as compared to lap
splicing. Around 3%-5% steel is saved per splicing.
We know that the time is also major parameter in the
construction of the building. In case of the skyscrapers and
road bridges every single day matters. And we know that
splicing the bars with help of wires takes a time. In case of
couplers this time can be saved.
Couplers are the solution for many problems which occurs in
the building construction.

Abstract The old method of connecting reinforcement bars

with lap joints continuity in reinforced concrete need not be
always appropriate. The main advantages of simplicity and
economy in lap splicing is limited to smaller diameter bars, The
mechanical couplers provides the solution for splicing when large
diameters bars are involved.
Spliced rebar performs like continuous reinforcement.
Splicing enhances strength mechanically, independent of
concrete. Therefore providing ductility in RCC structures
independent of the concretes condition. Proven cyclic
performance of spliced rebars offers strength during artificial,
seismic or other natural events. The continuity of spliced rebar
offers excellent provision for grounding the electric current.

MANUFACTURING OF COUPLERS
Step 1:1. The ends of the bars to be jointed are cut square and
enlarged by cold forging to increase their diameter so as to
ensure that the joint is tough than the bar. The couplers are
usually supplied attached to the reinforcing bar.
2. First we use the upsetting machine to thicken the rebar at
its ends as shown in Fig. 1.
3. The use the steel bar threading machine to make thread
on the end of rebar's.
4. Connect the two rebar end with the upsetting rebar
couplers.
Advantages:1. This system enlarged the strength of rebar at its end.
2. It can be used link the rebar whose diameter is from 12
mm to 40mm.
3. It has High efficiency, simple structure, small volume,
lightweight and easy operation.
4. It is also suitable for hot working environment.

Designer friendly: The coupler reduces rebar congestion and

improves the flow & consolidation of concrete. It even offers
greater flexibility in design options. The ease in detailing of
reinforcement, especially in reinforcement congestion zones
reduces the reinforcement fixing errors, thus detailing and fixing
of seismic reinforcement becomes effortless. Moreover the
workability with higher steel-to-concrete ratio allows
optimization of the size of RCC structural members.
Contractor's preference: The coupler offers quality, cost and
time saving. Their installation requires no special skills or
equipments. Compared to lapping, simple mechanical ways in
adopting mechanical splicing accelerates construction schedules
for optimum cost and efficiency.
Index TermsCoupling, splicing, reinforcement, ductility,
optimum sizing.

INTRODUCTION
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.

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TABLE 1 Rebar diameter vs Thread pitch

Rebar Diameter (mm)

12
16
20
25
32
40

Thread pitch
(mm)
2.0
2.5
3
3.5
4.0
4.0

SPLICING PROCESS
1.

Fig. 1 Upset forging machine.

Details of the upset forging machine

1. Rebar diameter range12mm to 40mm
2. Oil pump flux5L/min
3. Electric motor power4kW
4. Piston movement distance- 100 mm
5. Out dimensions (mm)225*570*1100
6. Weight 597 Kg.

Cutting

Fig. 4.1 Reinforced bar

The end of the reinforcing bar is swan cut shown in fig 4.1.
2.

Step 2:The threading machine is used for cutting threads

externally on the component by chasing method shown in Fig.
2. HSS tangential chasers are used as cutters. The component
remains stationery and Die head rotates. Threads can be cut on
this machine it depends upon the type of chasers. For given
diameter of rebar bar particular pitch is given TABLE 1.

Cold Forging

Fig. 4.2 Enlarged bar

Swan cut of reinforcing bar is enlarged by the cold forging

thus, increases its core diameter shown in fig 4.2.
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

machine
1.
2.
3.

Rebar diameter rangeMains voltage(v)Weight-

Fig. 4.4 Assembly of coupler and two bars

Finally splice the rebar by using threaded couplers shown in fig

4.4

12mm to 40mm
3 phase
1263 Kg.

MATERIAL USED
Material used for the production of the couplers is DIN
17200Gr. C45

Thread cutting tools (Chaser)

TABLE 2 Chemical properties of material.

Chemical Properties
% carbon
% Sulphur
% Phosphorus
% Manganese
% Silicon

Fig. 3 threading tool.

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0.42-0.50
0.045 max
0.045 max
0.50- 0.80
0.15- 0.35

(Turn the coupler and the lock nut onto the short threaded
rebar)
Used where both rebars are not rotatable, then starter bar is
threaded for the full coupler lock nut length t screw coupler
and lock nut onto the extended threads.

Mechanical properties
1.
2.
3.
4.
5.
6.
7.
8.

Grade- C45
Condition- Rolled, Annealed, water quenched, oil
quenched
Yield strength (MPa)- Rolled -460 Annealed -330
Tensile strength- Rolled -750, Annealed -540, water
quenched -2270, oil quenched -1980
Elongation A5(%)Rolled -18, Annealed -30
Hardness HRC Rolled -58, Annealed- 55
Quenching Temperature- Rolled- 820, Annealed- 860
Bend ability Min..recommended bending radius (<=
900)

SIZE OF COUPLERS

TABLE 3. Approximate dimensions of Threaded couplers

Bar
dia.(mm)
16
20
25
30
40

TYPES OF COUPLERS
Based on the process of splicing couplers are classified into
4 parts.
1.

(Turns the rebars into the couplers to connect)

Used where the connecting rebar can be rotated, then
end of the bars are threaded upto half the length of the
coupler.

Thread size

40
48
60
72
90

M20*2.5
M24*3.0
M30*3.5
M36*4.0
M45*4.0

TABLE 5 COUPLER UNDER UTS

Non rotatable Rebar splice

Gauge
Dia.
mm
16
20
25
32
40

(Threaded rebar and coupler)

(Turn the coupler onto short threaded rebar)

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.

Length (mm)

TABLE 4.Approximate dimensions of pressing couplers

Bar dia.
Outer
Length
Inside diameter
dia
(mm)
(mm)
(mm)
(mm)
16
31
118
21
20
36
130
25.5
25
45
150
30.8
32
56
192
38.8
40
70
240
46

Rotatable rebar splice

(Threaded rebar and coupler)

2.

outer dia.
(mm)
26
32
40
50
62

Ultimate
Load
KN
129
196
336
550
800

UTS

Fracture

N/mm2
642
624
684
684
637

TMT bar
TMT bar
TMT bar
TMT bar
No Fracture

Dist. From
center
mm
190
128
98
143
No Fracture

COST ESTIMATION

Different diameter splice

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
will use the couplers this much amount of steel will be saved.
In same approximate budget only we can use the couplers.

(Turn the rebar into coupler to connect)

Used to connect rebars of different diameters by using
reducing coupler.
4.

ADVANTAGES OF USING COUPLERS

1. The traditional method of joining reinforcement bars with
lap joints continuity with reinforced concrete cant be always
appropriate. Advantages of economy and simplicity in lap
splicing is limited to smaller diameter bars, the mechanical
couplers provide the solution for splicing when large
diameters bars are involved.

Non rotatable rebar splice with lock -Nut

(Threaded rebars, coupler and nut)

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2. Spliced rebar performs like continuous reinforcement.

Splicing enhances mechanical strength, independent of
concrete. Therefore providing ductility in RCC structures
independent of the condition of concrete. Proven cyclic
performance of spliced rebar offers strength during natural,
seismic or artificial events. The continuity of spliced rebar
offers excellent provision for grounding electric current.
3. Designer friendly: The coupler reduces rebar congestion
and improves the flow & consolidation of concrete. It offers a
huge variety in design options. The ease in detailing of
reinforcement, particularly in reinforcement congestion zones
reduces the reinforcement fixing errors, making detailing and
fixing of seismic reinforcement effortless. Moreover
workability with high steel-to-concrete ratio ensures optimum
sizing of RCC structural members.
4. Contractor's preference: The coupler ensure low cost, high
quality and time saving. Fixing couplers doesnt requires any
special skills or equipments. Compared to lapping, simple
mechanical ways in adopting mechanical splicing accelerates
construction schedules for optimum efficiency and cost.
5. Increase tensile and compressive capacities of long columns
and beams where the designed tensile loadings are greater
than normal loadings. Tension couplers are so far the best
solution for tensile piles and tensile columns.
6. Eliminates congestion of steel bars in heavily reinforced
columns and core wall of building. Thus minimizing
formation of "honeycomb" in concrete structures.
7. Speedier concrete casting as larger space between
reinforcements facilitates easier flow of concrete.
8. Reduces cost and increases speed of slip and jump from
work system in the construction of core walls and towers.
9. Avoids strains, corrosion and breakage of starter bars left
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.

CONCLUSION
As we have seen above use of the coupler is easy and
design friendly. Even it is tough & safe to use. Though
manufacturing cost of couplers in budget of construction will
increase, but 3% to 5% steel we be saved which was wasted in
overlapping. The cost of saved steel is more than that of the
manufacturing cost of couplers. So we can than those couplers
are free. They are not only free but they are profitable. Due to
its all advantages and no cost this method is more useful than
the earlier one.
REFERENCES
[1] Bertero, V., Miranda, E. and Thompson, C. (1990),
Cyclic behaviour of shear wall boundary elements
incorporating prefabricated welded wire hoops. National
institute of standards &n technology, New York
[2] Cheok, G.S. and Stone, W.C. (1994), Performance of a
1/3 scale model precast concrete beam-column cllections
subjected to cyclic inelastics loads. Report no,4,Nistir 5436,
June 1994
[3] Saatcioglu, M. and Grira, M. (1996), Concrete columns
confined with welded reinforcement grids. Ottawa varelton
Earthquake research center, Report OCEERC 96-05.
[4] Englekirk, Robert E, (2003), Seismic Design of
Reinforced and precast concrete buildings. John wiley & sons,
New Jersey.
[5] Ozbakkaloglu,T. Naumoski, and Saatcioglu, M. (2005),
Response of reinforced concrete frame buildings to blast
loading. Proceedings of the CSCE annual conference, Toronto.

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.

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