bartek systems coupler catalog - ozone...

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

Index

Introduction -Product

Description

-Reinforcement Bar Coupler

-Coupler Splicing Sytem

-Feature

Page 3-4

Bartek “P” Parallel

direct rolling system

Page 5

Threading Types Page 7-8

Special Coupler

Types

Page 6

Standard readymade

systems &

Accessories

Page 9

Couplers Method of

Statement

Page 10-12

Bartek “P” Method of

Statement

Page 13

Hydraulic Press

Method of Statement

Page 12-15

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 8110-1: 1997, section 3, chapter 3.12.8.

The Association Francaise de Normalisation

(AFNOR), in its standard NF A 35-020 (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 1912.

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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.

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.

BARTEK SYSTEMS ® COUPLER SPLICING SYSTEM

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.

R e i n f o r c e m e n t B a r C o u p l e r

STEEL REBAR CONGESTION IN

CONCRETE WITH COUPLERS STEEL REBAR CONGESTION IN

CONCRETE WITHOUT COUPLERS

FE A TU RE S

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BARTEK SYSTEMS ® COUPLER DIMENSIONS

- Other sizes are available upon request

Product Codes

Bar Dia. (mm)

Coupler External Dia.

(mm)

Coupler Internal Dia.

(mm)

Coupler Length (mm)

Thread Size

(mm)

Thread Pitch (mm)

CCBK12160M 12 20.0 11.9 30.0 M14 2.0

CCBK16200M 16 26.0 17.4 40.0 M20 2.5

CCBK20240M 20 32.0 20.9 48.0 M24 3.0

CCBK25300M 25 40.0 26.3 60.0 M30 3.5

CCBK28330M 28 44.5 29.3 66.0 M33 3.5

CCBK32360M 32 50.0 31.8 72.0 M36 4.0

CCBK36420M 36 56.0 34.8 80.0 M39 4.0

CCBK40450M 40 62.0 40.3 90.0 M45 4.0

Table 1.0

BARTEK SYSTEMS ® COUPLER SPLICING SYSTEM

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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.

Bartek “P” Parallel direct rolling system

Steel Bar

Diameter

(mm)

16

18

20

22

25

28

32

36

40

Outer

Diameter

of Coupler

(mm)

25

28

30

32

38

42

48

54

59

Length of

Coupler

(mm)

45

50

55

60

65

70

80

90

95

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

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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.

Large Rebar Small Rebar

Reducer

Adding length with nuts

Adding Length without nuts

Bartek Systems ® “H” Hydraulic Pressed Couplers

ADVANTAGES:

Standard Parameter for BARTEK “H” Hydraulic Pressed Couplers

Anchor Plate Linking

Bar Terminator

Weldable Couplers

Bartek Systems Special ® Coupler Types

Table 1.2

Steel Bar

Diameter

(mm)

16

18

20

22

25

28

32

36

40

Outer

Diameter

of

Coupler

(mm)

25

28

30

32

38

42

48

54

59

Length of

Coupler

(mm)

45

50

55

60

65

70

80

90

95

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Bartek Systems ® Threading - Types

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)

(3)

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.

Screw the coupler to the rear of the thread on the

continuation bar.

(1)

(2)

(3)

Position the continuation bar with the coupler against

the end of the first bar.

Rotate the coupler from the continuation bar to

engage against the rear of the tread on the opposing

bar and lock tight.

Bartek Systems ® Type-A

Bartek Systems ® Type-B

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.

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.

t

t

2t

2t

2t

t

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(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.

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.

Position the continuation bar with the coupler against the end

of the first bar.

(2)

(3)

Rotate the coupler from the continuation bar to engage

against the rear of the thread on the opposing bar and lock

tight.

Rotate the locknut along the continuation bar.

(4)

(5)

Hold the rebar in its required orientation and with a

wrench tighten the locknut against the coupler.

Bartek Systems ® Type-C

2t

2 ⅔t

t

⅔t

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Coupler – threaded steel coupler system is a

natural extension to our rebendable Stabox

rebar connection system for rebars 12mm

The rebar connection system with the 100%

load transmission – suitable for both static

and dynamic load.

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.

2nd concrete pour -additional bar

1st concrete pour Bar

1st concrete pour 2nd concrete pour

Bar+ socket incl. coupler cap

Rebar Connection System

Standard Readymade Systems & Accessories

2nd Bar thread protection cap

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BARTEK SYSTEMS ® COUPLERS

M e t h o d o f S t a t e m e n t

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.

Table 1.3

COLD FORGED BAR

THREADED FORGED BAR

Steel Bar

Diameter

(mm)

16

18

20

22

25

28

32

36

40

Outer

Diameter

of Coupler

(mm)

25

28

30

32

38

42

48

54

59

Length of

Coupler

(mm)

45

50

55

60

65

70

80

90

95

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.

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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

(mm)

12

14

16

18

20

22

25

28

32

36

40

Size

(m)

14 x

2

16 x

2

20 x

2.5

22 x

2.5

24 x

3

27 x

3

30 x

3.5

33 x

3.5

36 x

4

39 x

4

45 x

4

Length

(mm)

14

16

20

22

24

27

30

33

36

39

45

Teeth

Height

(H)

1.083

1.083

1.353

1.353

1.624

1.624

1.895

1.895

2.165

2.165

2.165

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

Ø

Dia

.

Length +2

-2

Table 1.4


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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.

1st concrete pour (steel bar 1) 2nd concrete pour (steel bar 2)


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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.


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.

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.)

Ø

Dia

.

Length +2

-2


1st concrete pour (steel bar 1) 2nd concrete pour (steel bar 2)

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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.


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.

HYDRAULIC PRESSED COUPLERS


(steel bar 1)

PRESSED

PRESSED

BARTEK COUPLER No. 2 :

(steel bar 1) (steel bar 2)

BARTEK COUPLER (TO

BE PRESSED)

(steel bar 2)

No. 1 :

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(steel bar 2)

No. 3 :

(steel bar 1)

PRESSED

PRESSED

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

How to check and identify your Bartek Coupler

For Middle East INQUIRIES:

BARTEK SYSTEMS FZC

P.O.Box: 121260 Sharjah, U.A.E.

Tel : +971 6 552 8744

INGPRO GMBH Sterngasse 3 ;1010 Vienna – Austria TEL: +43 15320180-203 FAX: +43 15320180-603 e-mail: [email protected]

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bartek systems coupler catalog - ozone...

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