P r o d u c t D e s c r i p t i o n

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2 P r o d u c t D e s c r i p t i o n All BARTEK SYSTEMS Couplers are produced according to ISO9001 Rebar couplers can simplify the design and construction of reinforced concrete and reduce the amount of reinforcement required by avoiding overlaps, this in turn could reduce congestion within the concrete and avoid all its related disadvantages. BARTEK SYSTEMS Standard Couplers are produced from Carbon Steel which have tensile strength more than 600 MPa; for higher requirement of tensile strength BARTEK SYSTEMS Super Couplers can be customized to 800 to 900 Mpa according to any project special requirements. Bartek systems is suitable for mechanical splices with reinforcing bars made according to DIN488:86, BS4449:1997, ASTM A615. Bartek coupler complies with the following bldg. codes & standards: The Deutches Institüt für Normug in its standard DIN 1045 (2001) The British standards Institution, in its standard BS : 1997, section 3, chapter The Association Francaise de Normalisation (AFNOR), in its standard NF A (1999). The American Concrete Institute (A.C.I.), in its standard ACI 318 (Chapter 12: Development and splices of reinforcement) The International conference of Building Officials (I.C.B.O.), in its Uniform Building Code (UBC), Section Index Page 2 Page 3-4 Page 5 Page 6 Page 7-8 Page 9 Page Page 13 Page Introduction -Product Description -Reinforcement Bar Coupler -Coupler Splicing Sytem -Feature Bartek P Parallel direct rolling system Special Coupler Types Threading Types Standard readymade systems & Accessories Couplers Method of Statement Bartek P Method of Statement Hydraulic Press Method of Statement 2

3 R e i n f o r c e m e n t B a r C o u p l e r Lapped joints are dependent upon the concrete for load transfer. For this reason, any degradation in the integrity of the concrete could significantly affect the performance of the joint. The strength of a mechanical splice is dependent on the concrete in which is located. STEEL REBAR CONGESTION IN CONCRETE WITH COUPLERS STEEL REBAR CONGESTION IN CONCRETE WITHOUT COUPLERS BARTEK SYSTEMS COUPLER SPLICING SYSTEM Bartek coupler splicing system is designed for the connection of steel rebars without torque wrench. Fast and simple installation to promote productivity and safety of the connection. The Bartek coupler spliced connection has a higher breaking load capacity than the steel rebar: Bar Break System. Bar break couplers are recommended in areas with seismic activities. The couplers are available in the diameters of 12mm to 50mm. The high strength of the coupler connection is being achieved by cold forging. The upsetted bar end has a larger core diameter than the bar to ensure that the joint is stronger than the bar itself. Parallel metric threads are cut on the enlarged ends. FEATURES Full strength joint allowing full ductile elongation of reinforcing bars. Manual assembly. No torque wrench required. No risk of cross threading quality control is just by visual inspection. Reduce congestion of bars. Speed up construction time. 3

4 BARTEK SYSTEMS COUPLER SPLICING SYSTEM BARTEK SYSTEMS COUPLER DIMENSIONS Product Codes Bar Dia. Coupler External Dia. Coupler Internal Dia. Coupler Length Thread Size Thread Pitch CCBK12160M M CCBK16200M M CCBK20240M M CCBK25300M M CCBK28330M M CCBK32360M M CCBK36420M M CCBK40450M M Other sizes are available upon request Table 1.0 4

5 Bartek P Parallel direct rolling system Bartek P coupler splicing system is designed for the connection of the steel rebars with the torque wrench. The threading process is simple and requires one machine only. The system provides safe and simple installation which promotes the productivity at site. Bartek P coupler spliced connection offers a breaking load capacity at the least equal to that of the used steel rebar. The couplers are available from Ø12mm Ø40mm. Steel Bar Diameter Outer Diameter of Coupler Length of Coupler Size of Thread M16 x 2.5 M18.3 x 2.5 M20.5 x 2.5 M22.5 x 2.5 M25.5 x 3.0 M28.5 x 3.0 M32.5 x 3.0 M36.5 x 3.0 M40.5 x 3.0 Table 1.1 5

6 Bartek Systems Special Coupler Types Large Rebar Small Rebar Reducer Adding length with nuts Adding Length without nuts Anchor Plate Linking Bar Terminator Weldable Couplers Bartek Systems H Hydraulic Pressed Couplers ADVANTAGES: High tensile strength as per German standard (DIN 1045), British standard (BS 8110) Easy and fast application Safe connection which offers breaking load capacity equal to that of the used steel rebar Offers a solution to the steel congestion at the connection point, which facilitates concrete pouring. Standard Parameter for BARTEK H Hydraulic Pressed Couplers Steel Bar Diameter Outer Diameter of Coupler Length of Coupler Table 1.2 6

7 Bartek Systems Threading - Types Bartek Systems Type-A t 2t t This is used where the continuation bar can be rotated. The end of the bars are upset and threaded for half length of the coupler. (1) (2) Screw the coupler to the rear of the thread on the fixed bar and lock tight. The bar end should be central within the coupler. Remove the plastic cap from the coupler. Position and rotate the continuation bar in the coupler. (3) Tighten the joint using wrench on the continuation bar. After tightening there should be more than 2-4mm of the thread exposed, depending on the diameter of the rebar. Bartek Systems Type-B t 2t 2t This is used where it is not possible to rotate the continuation bar. Therefore the thread of the continuation bar is extended to full coupler length. (1) (2) Screw the coupler to the rear of the thread on the continuation bar. Position the continuation bar with the coupler against the end of the first bar. (3) Rotate the coupler from the continuation bar to engage against the rear of the tread on the opposing bar and lock tight. 7

8 (4) Using wrench, rotate the continuation bar to lock the two bar ends against each other. After tightening, the length of exposed thread should not be more than half of the coupler length plus 2-4mm depending on the diameter of the rebar. Bartek Systems Type-C t 2t ⅔t 2 ⅔t This type has an additional locknut and is used where the continuation bar cannot be rotated. The continuation bar is threaded for full coupler length plus the length of the locknut. (1) Screw the locknut followed by the coupler to the rear of the thread on the continuation bar. (2) Position the continuation bar with the coupler against the end of the first bar. (3) Rotate the coupler from the continuation bar to engage against the rear of the thread on the opposing bar and lock (4) Rotate the locknut along the continuation bar. (5) Hold the rebar in its required orientation and with a wrench tighten the locknut against the coupler. 8

9 Standard Readymade Systems & Accessories Rebar Connection System The rebar connection system with the 100% load transmission suitable for both static and dynamic load. Coupler threaded steel coupler system is a natural extension to our rebendable Stabox rebar connection system for rebars 12mm 1 st concrete pour 2 nd concrete pour Bar+ socket incl. coupler cap 2nd Bar thread protection cap 1 st concrete pour Bar 2 nd concrete pour - additional bar Secure protection of the bars by thread protection caps. The use of coupler box ensures precise location of the reinforcement bars and protection and protects the couplers. Simple and easy assembly of the splicing joints. Added splicing joint strength through the interlocked connection between the two concrete pourings. 9

10 M e t h o d o f S t a t e m e n t BARTEK SYSTEMS COUPLERS The procedure consists of three steps: STEP-1 FORGING The bars to be joined are cut to the required size All machines to be prepared for operation & the supervisor must ensure that all safety measures are implemented The surface of the edge must be vertical to the axial line of the steel bar therefore it could be ground flat & straight by disc cutter. Remove any flexure & inspect the bar for any defect or burr. Insert the end of the bar into the cold forging machine, the machine to be operated as per the instruction in the Bartek machine manuals, (The operator has to read and understand the instructions & troubleshooting guide before starting the operation, the same is applicable prior to the operation of the threading machine) Inspection of the forged end has to be carried out as per the following proceedures: 1. The size of the ends should be checked against the following table. Steel Bar Diameter Outer Diameter of Coupler Length of Coupler Table 1.3 COLD FORGED BAR THREADED FORGED BAR II. The concentricity between the end and the steel bar <0.3~1; III. Out of roundness of ends, circumference <1/3; unfilled corner 3*1.5; IV. Loss of end (middle, root), circumference <1/3; unfilled corner 5*1; V. The axial crack in the end is allowable, no more than 3 strips. VI. No transverse crack is allowed. 10

11 Ø Dia. M e t h o d o f S t a t e m e n t STEP-2 THREADING The forged steel bar is now ready for threading by clamping the forged side of the bar in the gripping mechanism of the threading machine. By operating the machine, the cutting head will cut the thread into the end of the forged steel bar. Release the threaded bar from the gripping mechanism. Inspection according to the following. Steel Bar Diameter Size (m) 14 x 2 16 x 2 20 x x x 3 27 x 3 30 x x x 4 39 x 4 45 x 4 Length Teeth Height (H) Table 1.4 Length +2-2 The concentricity between the end of rebar <0.3 of half finished product. The out of roundness of end <1/3, unfilled corner <3x1.5 of half finished product. Loss of end <1/3, loss of middle <5x1 of half finished product. The bias between rebar end thread axes and rebar end axes is less than 0.5mm The length of thread end of rebar is half of the relative size of rebar coupler. The thread if rebar end can be used to connect with the relative siz of coupler, try whether it can pass through smoothly, tight or loose. Crosswise fissure or striation of the thread end of rebar can be accepted <0.015d+0.1, maximum 0.4mm. The crosswise fissure or striation is not allowed more than three; On the thread end of rebar, it is allowed that there is lack of teeth. a. The circle of the end face can allowed lack of teeth. b. The diameter of thread head allowed less of 0.15Hx2 c. The circumference of thread head <1/5 length,1/2 length of thread head <0.25H 11

12 M e t h o d o f S t a t e m e n t STEP-3 ASSEMBLY A coupler needs to be fixed by hand fro one side till-half length of the coupler on the designated threaded bar & protected with the coupler cap. The other threaded rebar to be protected by rebar cap. Later the protective caps can be removed from both sides & other bar can be as well connected by hand. 1 st concrete pour (steel bar 1) 2 nd concrete pour (steel bar 2) 12

13 Ø Dia. M e t h o d o f S t a t e m e n t BARTEK P COUPLERS STEP-1 : PREPARATION Select the type of the threading (Left or Right); Prepare the machine by installing positive or negative idler wheel rest accordingly, the supervisor must ensure that all safety measures are implemented. The bars to be joined are cut to the required size. The surface of the edge must be vertical to the axial line of the steel bar therefore it could be ground flat & straight by disc cutter. Remove any flexure & inspect the bar for any defect or burr. Install the end of the bar & clamp it on the machine. (The operator has to read and understand the instructions and troubleshooting guide before starting the operation) Switch on the machine to start the rib peeling process. Our Rib Peeling / Direct Roll Threading System can carry out two consecutive process at once: i. Produce a smooth surface at the rebar end. ii. Thereafter, the machine will automatically roll thread the smooth end surface of the rebar. Once finished, the machine will stop & retract the threaded rebar ready to be joined later with coupler. The operator can now release the clamp to extract the bar. to the steel bar axial line. Length +2-2 STEP-2 : ASSEMBLY The threaded rebar is now ready for joining; a coupler needs to be initially fixed by hand from one side of the connection till half-length of the coupler on the designated threaded bar. The one side of the connection is ready for use. To achieve a full spliced connection using Bartek P couplers a torque wrench shall be used: i. The torque wrench to be adjusted to the required torque. ii. Turn the threaded bar into the coupler until hand-locked. For verification draw a line on the bar at the coupler location to verify the number of turns required to lock it by wrench later. iii. Tighten with the torque wrench & count the turns until you hear the click sound of the torque wrench. iv. Use the same number of turns + 15% as a guide for the same coupler size to be used. (For example: one & half turns are usually required for Bartek P 32mm couplers.) 1 st concrete pour (steel bar 1) 2 nd concrete pour (steel bar 2) 13

14 M e t h o d o f S t a t e m e n t HYDRAULIC PRESSED COUPLERS This splicing method is recommended for the connection of the existing non-threaded rebars with other rebars; threading is not necessary. STEP-1 : Prepare the existing rebars, the surface of the edge must be vertical to the axial line of the steel bar therefore it could be ground flat & straight by disc cutter. Remove any flexure & inspect the bar for any defect or burr. The machine to be prepared & operated as per the instruction in the Bartek H machine manual, (The operator has to read and understand the instruction & troubleshooting guide before starting the operation): i. Check pressure gauge to ensure proper function. ii. By means of chalk & ruler, mark the press line where the sleeve will be fixed. Install on the upper (the new) rebar half section of the sleeve. With the specific mold fixed on the hydraulic press, apply three consecutive presses on the half section of the sleeve, now the sleeve is fixed on the side of the new rebar. Join the new rebar with the open sleeve side to connect it with the existing rebar. Apply again three presses with the hydraulic on the other side of the sleeve to ensure full splice. No. 1 : BARTEK COUPLER (TO BE PRESSED) (steel bar 1) (steel bar 2) No. 2 : PRESSED BARTEK COUPLER (steel bar 1) PRESSED (steel bar 2) 14

15 No. 3 : PRESSED BARTEK COUPLER (steel bar 1) (steel bar 2) PRESSED How to check and identify your Bartek Coupler BATCH No. CODE SIZE OF THE COUPLER BARTEK COUPLER TYPES Bartek No Marking standard Bartek Coupler Bartek S Super Coupler Bartek P Rib Peeling Coupler Bartek H Hydraulic Coupler 15

16 For Middle East INQUIRIES: BARTEK SYSTEMS FZC P.O.Box: Sharjah, U.A.E. Tel : INGPRO GMBH Sterngasse 3 ;1010 Vienna Austria TEL: FAX:

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