In-Place Stainless Steel Swaged Couplers

IN‐PLACE STAINLESS STEEL SWAGED COUPLERS

Content

INCON’s Stationary Swaging Machine 1

INCON’s Portable Swaging Machine 2

Why INCON’s Cold-Swaged Couplers? 3

ICP/CS-S – Stainless Steel Cold Swaged Position Coupler 5

Main Features and Applications 7

INCON Quality Assurance 8

INCON Memberships 8

BRINGS YOU THE COMPLETE SOLUTION

INCON’S STATIONARY SWAGING MACHINE

At INCON, we developed our high‐tech third generation swaging machine which accelerates the workflow while enhancing the quality of the product. Simplicity and outstanding performance are key features of our swaging machines. They provide an immense 1000 T pressing force that reduces the swaging time of a 40 mm bar coupler to less than 15 seconds. The fully digital controlled system, touch screen, flexible die changing and laser metering technique make the construction process fast and accurate. It can operate efficiently under all weather conditions either on site or in workshops. The swaging mechanism does not require special preparation of the steel bars and does not alter their original mechanical properties. Using INCON swaging machine at site is the optimum way for our clients to overcome construction obstacles effectively, eliminate undesired labor and material costs, and enhance the integrity and performance of the structural system.

EFFICIENT INSTALLATION PROCESS Swaging is a cold working manufacturing process that involves exerting a considerably large compressive force around the object’s circumference to alter its geometry. The process is performed by compressing the coupler around the profile of the steel bar to create a secured and strong mechanical interlock.

Half section view of a typical swaged coupler showing the embedded steel bar. The marks left by the deformed steel bar are clearly visible on the internal surface of the vacant side.

INCON’S PORTABLE SWAGING MACHINE

Cold‐swaged mechanical splices are performed by deforming the coupling sleeves around the ends of the spliced bars using INCON’s portable swaging machine. Swaging is performed in‐place without the need to carry out special preparations on the reinforcing bars.

IN‐PLACE INSTALLATION PROCEDURE

Step 1: Ensure that the reinforcing bars are Step 2: Insert INCON coupling sleeve into the clean from any dirt or grease before reinforcing steel bar with the guidance of the proceeding. Then, place a mark on each bar to placed mark. indicate the required insertion length based on the technical data.

Step 3: Using INCON’s portable swaging Step 4: Ensure the coupling sleeve is crimped machine, exert pressure on the coupling over the entire bar embedment length in sleeve according to the recommended values order to develop the required mechanical detailed in the technical data. interlock.

WHY INCON’S COLD‐SWAGED COUPLERS?

INCON Cold‐Swaged Couplers integrate durability; structural performance and cost effectiveness to provide our valuable clients with state‐of‐the‐art products and services that satisfy all their needs during the construction of new structures or rehabilitation of existing ones.

STRUCTURAL PERFORMANCE  Full strength of the reinforcing bars is maintained up to 100% of their tensile strength.  Alteration in the bars’ cross‐sectional areas and mechanical properties are avoided.  Ductile behavior in the structural members is maintained.  Structural performance is independent of concrete type and strength.  Slip is completely eliminated between couplers and the embedded steel bars.  Bars are concentrically aligned resulting in direct force transfer between the two bars.

CONSTRUCTION SIMPLICITY  The coupling sleeve is compatible with all deformed steel bars.  No special preparation is required for connecting any deformed bar type or size.  Installation of the mechanical splice requires only INCON’s swaging machines.  Congestion of steel reinforcement is significantly reduced.  Formwork damage is avoided during construction of wall‐slab connections.  Substantial reduction in the number of laborers needed for cut and bend works.

COST EFFECTIVENESS  Remarkable saving in material and labor cost.  Savings in stainless steel cost and welding material, especially for long splices.  Reduction in time required for preparing detailed drawings and calculation sheets for lap splices.  Reduction in inspection time for lap splices and bent bars during the construction phase.  The need for operating heavy pieces of equipment is not required on site.

QUALITY CONTROL  INCON Cold‐Swaged couplers are manufactured in accordance with the strictest Canadian standards in ISO certified and UKAS accredited facilities.  Both experimental and analytical investigations are performed on our products to ensure outstanding structural performance that exceeds the requirements provided in major building codes and standards.  In addition to our research and development program, INCON has been working in collaboration with Western University in Canada to continuously develop the quality of our mechanical splicing devices.

ENVIRONMENT  INCON splicing devices are recyclable and can be manufactured of recycled materials.  Reinforcement waste associated with lap splices is significantly reduced.  Noise pollution associated with threading of steel bars on site is significantly reduced.  No welding or heating required in production process or site applications.

INCON products are key for the success of every construction project. 4

ICP/CS‐S –Stainless Steel Cold Swaged Position Coupler

INSTALLATION 1‐ Install the short coupler sleeve on the existing bar using INCON’s portable swaging machine according to the technical data.

2‐ Install the extended coupler sleeve on the second bar using INCON’s stationary swaging machine according to the technical data.

3‐ Insert the threaded rod with the attached lock nuts into the extended coupler sleeve.

4‐ Align the second bar with the existing one without exceeding the allowable gap between them.

5‐ Rotate the threaded rod until it completely accommodates the threads on the existing bar. Secure the connection by tightening the lock nuts.

CONFIGURATION ICP/CS‐S stainless steel coupler is composed of two sleeves that differ in their lengths but share the same diameter and thread size. The internal surfaces of both sleeves are threaded up to a certain length and smooth for the remaining length. The unthreaded part of the short sleeve is crimped on the existing bar using INCON’s portable swaging machine; whereas the unthreaded part of the extended sleeve is crimped on the second bar using INCON’s stationary swaging machine. A threaded rod and two lock nuts are used to connect the two sleeves together and secure the mechanical splice.

MAIN APPLICATIONS ICP/CS‐S stainless steel coupler is widely used for either new construction or repair applications where the mechanical splices of two stainless steel cages or individual stainless steel bars are to be installed in‐place.

General Short Coupler Sleeve Extended Coupler Sleeve Threaded Rod and Lock Nuts Allowable Coupler Outer Inner Thread Thread Bar Insertion Threaded Sleeve Bar Insertion Threaded Sleeve Threaded Lock Nut Gap Bar Size Code Diameter Diameter Size Pitch Length Length Length Length Length Length Rod Length Thickness DdMTPp1e1L1p2e2L2LsT G ICP/CS-S10M 10M 20.0 14.0 14.0 1.5 32.0 18.0 52.0 28.0 41.0 71.0 65.0 5.0 5.0 ICP/CS-S15M 15M 28.0 19.0 20.0 2.5 53.0 22.0 78.0 37.0 49.0 89.0 87.0 8.0 5.0 ICP/CS-S20M 20M 35.0 24.0 24.0 3.0 60.0 27.0 90.0 44.0 59.0 106.0 103.0 10.0 5.0 CANADA ICP/CS-S25M 25M 43.0 30.0 30.0 3.5 79.0 34.0 116.0 56.0 76.0 135.0 132.0 13.0 8.0 ICP/CS-S30M 30M 50.0 34.0 36.0 4.0 87.0 38.0 129.0 65.0 84.0 153.0 148.0 14.0 8.0 ICP/CS-S35M 35M 60.0 41.0 40.0 3.0 102.0 43.0 149.0 77.0 96.0 177.0 163.0 15.0 10.0 ICP/CS-S45M 45M 74.0 50.0 48.0 4.0 127.0 48.0 180.0 93.0 106.0 204.0 180.0 16.0 10.0 Note: All units are in (millimeters).

General Short Coupler Sleeve Extended Coupler Sleeve Threaded Rod and Lock Nuts Allowable Coupler Outer Inner Thread Threads Per Bar Insertion Threaded Sleeve Bar Insertion Threaded Sleeve Threaded Lock Nut Gap Bar Size Code Diameter Diameter Size Inch Length Length Length Length Length Length Rod Length Thickness D d M TPI p1 e1 L1 p2 e2 L2 Ls T G ICP/CS-S#4 #4 0.9 0.6 0.6 13 1.5 0.7 2.4 1.2 1.7 3.0 2.8 0.2 0.2 ICP/CS-S#5 #5 1.1 0.7 0.8 11 2.1 0.9 3.1 1.5 1.9 3.5 3.4 0.3 0.2 ICP/CS-S#6 #6 1.3 0.9 0.9 9 2.3 1.0 3.5 1.7 2.2 4.1 4.0 0.4 0.2

USA ICP/CS-S#7 #7 1.5 1.1 1.1 9 2.7 1.2 4.0 2.0 2.6 4.6 4.6 0.4 0.2 ICP/CS-S#8 #8 1.7 1.2 1.2 9 3.1 1.3 4.6 2.2 3.0 5.3 5.2 0.5 0.3 ICP/CS-S#9 #9 1.9 1.3 1.3 9 3.3 1.5 5.0 2.5 3.2 5.9 5.7 0.5 0.3 ICP/CS-S#10 #10 2.1 1.5 1.4 7 3.6 1.6 5.4 2.8 3.6 6.5 6.1 0.6 0.4 ICP/CS-S#11 #11 2.4 1.6 1.6 9 4.0 1.7 5.9 3.0 3.8 7.0 6.5 0.6 0.4 ICP/CS-S#14 #14 2.9 1.9 1.9 7 4.9 1.9 7.0 3.6 4.1 7.9 7.0 0.6 0.4 Note: All units are in (inches).

Europe ICP/CS-S32 32 53.0 36.0 36.0 4.0 90.0 40.0 134.0 69.0 87.0 160.0 155.0 14.0 10.0 ICP/CS-S40 40 67.0 45.0 45.0 4.5 115.0 45.0 165.0 85.0 97.0 187.0 172.0 15.0 10.0 Note: All units are in (millimeters).

Note: Dimensions are subject to change without prior notice.

MAIN FEATURES AND APPLICATIONS

NEW CONSTRUCTION OR REPAIR The cold‐swaged splicing method is suitable for a wide variety of applications including new construction, on‐site repair work or strengthening of existing structures. The simplicity and robustness associated with this method makes it suitable for all construction projects.

STEEL BAR PROPERTIES ARE MAINTAINED The mechanical characteristics and geometrical properties of the stainless steel bars are maintained intact throughout the installation process without the need to expose the bars to heat or to perform unnecessary cutting or threading operations.

SPECIAL PREPARATIONS ARE NOT REQUIRED The swaging process is conducted in‐place without the need to rotate the bars or to perform any other preparation prior to the installation of the couplers.

OUTSTANDING PERFORMANCE LEVELS INCON’s cold swaged couplers can be used in all applications where Type 2 couplers are required. Bar strength and splice integrity are maintained under both static and dynamic loads until bar break limit is reached.

INCON QUALITY ASSURANCE

INCON ensures consistent production and delivery of superior quality products based on a stringent quality management system in accordance with ISO 9001 certification. Our products are designed and manufactured to comply with the relevant codes and standards such as ACI 318, CSA A23.3, Eurocode 2, BS 8110, DIN 1045, IBC, AASHTO and ASME Sec 3 Div 2. INCON developed its quality assurance program by defining ongoing iterative monitoring at each manufacturing stage to comprehensively assess the products until reaching their intended destination. The evaluation practices are fully traceable and encompass all production phases such as planning, designing, manufacturing, packaging, shipping and customer service. To date, INCON has achieved a high level of customer satisfaction through providing them with zero‐defect innovative products that efficiently fulfill their requirements and applications.

INCON MEMBERSHIPS

INCON is proudly an active member in the most prestigious organizations and committees throughout Canada and the United States.