METHOD STATEMENT FOR

FORGING COUPLER

Project Name : TCS Building at Siruseri

ISSUED TO NAME:
CONTROLLED COPY NO: 1
ISSUED BY: JAYANTHI R DATE: 30.01.2023

OWNER :

PMC :

SPECIALIST SUB CONTRACTOR: UNITED CONSTRUCTION SYSTEMS PRIVATE LTD.

Checked By:
Approved By:

N.SIVARAMMAN AAR.MAHINDREN
Benefits :
 Practical and economical alternative to laps
 Simple Process
 Fast Cycle time less than 30 seconds per threads
 Easy installation no torque wrench required
 Shortens Construction cycle times
 Full traceability of material origin and production batch
 Continuity of reinforcing bars, no reduction of the bars cross section
area
 Wastage of steel material reduced
 Staggering of bars not required
 Tensile failure/bar break occurs only outside the joint
 No Slipping problem
 Allows full ductile elongation of bar
Work Method
of Statement
The methodology of threading on RE-BAR at the site for use of
mechanical couplers , the following steps are adopted for
threading .

a) The set of machine that is used for threading of the Re-Bar are placed to
close proximity of the bar cutting & bending contractor for easy movement
of the cut to length of the Re-Bar to be brought near to the set of machine
used for threading of bars. (Bringing the re-bar next to our machine is in
your scope)

b) The first operation is to saw cut the ends of the bar to 90* straight cut, this
means proper care will be taken by our machine operator to cut the bar at
a place which is straight & does not have any bend

c) After cutting the Re-Bar a visual inspection of the Re-Bar is done by the
site in charge to find out if the Re-Bar is of proper diameter or not, the bar
is also checked for deformity such as square, oblong or egg shaped. We also
check for any cracks along the horizontal ribs or holes or fracture on the
cross section of the sawed bar. If any such factor comes to our light , we
inform the site engineer from the clients side before proceeding further.

d) The 90* saw cut bars are placed on to a M.S. C-CHANNEL FABRICATED
STAND of 5mts.in length x 4mts in width for re-bar length up to 8 mts. (
to be provided by you ) not in our scope.

e) The saw cut bar is fed to the upsetting machine in order to cold forge the
bar e.g. the 32mm dia. Rebar to 34mm dia max. for only to the extent of
 threading length only. The upsetting of 2mm more, of the parent bar does
not cause any fracture at the cross section of the Re-Bar.

f) The cold forged rebar is then shifted on the M.S C-CHANNEL stand to the
threading machine ( thread cutting machine) for threading of the rebar.

g) The threaded Re-Bar is checked for quality of threads & we use GO- NO-GO
gauge to determine the compatibility of threaded bar to the coupler. The
threaded re-bar ( both sides ) we fix the coupler on to one side ( if
requested) & the other side is capped with a plastic cap for protecting the
thread from damages while transporting.

h) The threaded Re-Bar will be stacked according to the size next to our
threading machine. The threaded Re-Bar is to be taken away by your
labour for installation, as the same does not fall under our scope nor the
fixing of the bar on to the column.
 UPSETTING TECHNOLOGY

CUTTING

The end of reinforcing bar is sawn square.

COLD FORGING

The sawn end of the reinforcing bar is then enlarged by a cold

forging process. The diameter of the bar is increased to a pre determined
diameter, ensuring non reduction of the nominal cross section area of the
parent bar

Cold forging : The core diameter of the bar is increased to a pre-

determined diameter.

Before cold forging process

After cold forging process

Turning : The rib of forged bar is removed by turning process for even
surface.
 Run the couple to the end of the thread on the fixed bar.

 Position and rotate the continuation bar in the coupler.

 Tighten the joint using a wrench on the continuation bar.

 No torque wrenching required.

STANDARD SPLICES :

Standard UNICON splices are accomplished by use of a standard female

coupler matching the thread size made on the bars.
Rebar threads drawings:

Type A threads are used with standard splices:

Type B:

Type B threads are used with standard splices

Type C:

The type C threads have an extended length to fit the full length of a
coupler:

GENERIC FEATURES

 No reduction of the ductility of the reinforcing bar.

 Tensile failure guaranteed to occur away from the joint.

 No reduction of the nominal cross sectional area of the parent bar.

 Easy visually traceably.

 Raw-Material test report.

 On site service.
POSITION SPLICE

The Unicon splicing creates a full-strength connection of grade 500

reinforcing bars with a minimum guaranteed tensile strength of both
125% of the nominal yield strength of the bar and 100% of the nominal
tensile strength of the bar.

It does so by not reducing the cross-section area of the bar.

Forging Machine With Power back
Forging Threading Machine
Dimensions of couplers
Dimensions of Forging Threaded Couplers :

Rebar Dia Type O.D.*L(mm) Nominal Dia. of Pitch(mm)

Coupler Thread(mm)
(mm) Forging Forging

coupler

Φ40 DZG40A Φ60*90 M42 3.0

Φ36 DZG36A Φ60*80 M38 3.0

Φ32 DZG32A Φ50*72 M34 3.0

Φ28 DZG28A Φ45*66 M30 3.0

Φ25 DZG25A Φ40*60 M27 3.0

Φ20 DZG20A Φ32*48 M22 3.0

Φ16 DZG16A Φ28*40 M18 2.5

Chemical Composition of Coupler(%) EN-8D STEEL MAX. LIMIT

C Si Mn S P

0.46 0.25 0.65 0.029 0.022

Chemical Composition stated above is maximum permissible limit.

Dimensions of forging Reducer Couplers

Rebar Dia Type O.D.*L(mm) Nominal Dia. of Pitch(mm)

Coupler Thread(mm)
(mm) Forging Forging

coupler

Φ40 DZG 40/32 Φ60*81 M42/M34 3.0/3.0

DZG 40/25 Φ60*75 M42/M27 3.0/3.0

DZG 40/20 Φ60*69 M42/M22 3.0/3.0

Φ32 DZG32/25 Φ50*66 M34/M27 3.0/3.0

DZG32/20 Φ50*60 M34/M22 3.0/3.0

DZG32/16 Φ50*56 M34/M18 3.0/2.5

Φ25 DZG25/20 Φ40*54 M27/M22 3.0/3.0

DZG25/16 Φ40*50 M27/M18 3.0/2.5

Φ20 DZG20/16 Φ32*44 M22/M18 3.0/2.5

T
Plastic Cap fiting:

Once the bar ends have been threaded, couplers must be screwed
onto them with their plastic cap on the outer end.
 Forging Machine
Pressure Details

Extent of threading Length

Sl No Dia of Rod Pressure Kg
(mm)

1 16 mm Rod 220 to 240 18 mm

2 20 mm Rod 240 to 260 22 mm

3 25 mm Rod 270 to 290 27 mm

4 32 mm Rod 340 to 360 34 mm

5 40 mm Rod 360 to 380 42 mm

Length (mm)
Sl No Dia of Rod No of threading
Half thread

1 16 mm Rod 20 mm 8 Nos

2 20 mm Rod 24 mm 8 Nos

3 25 mm Rod 30 mm 10 Nos

4 32 mm Rod 36 mm 12 Nos

5 40 mm Rod 45 mm 15 Nos

Length (mm)
Sl No Dia of Rod No of threading
Full Thread

1 16 mm Rod 40 mm 16 Nos

2 20 mm Rod 48 mm 16 Nos

3 25 mm Rod 60 mm 20 Nos

4 32 mm Rod 72 mm 24 Nos

5 40 mm Rod 90 mm 30 Nos
 METHOD STATEMENT FOR
FORGING COUPLER

Project Name : NEW LIFE ASSEMBLY OF GOD COMMUNITY

(NLAG) CHURCH