Conventional way of rebar lapping / splicing as per BIS

Photo 1 : Typical rebar exposure/extension for further lapping/splicing

As per BIS456-2000 some guidelines on lapping/splicing are as follows:
Lap splices shall not be used for bars larger than 32 mm. Bars huger than 32
mm shall be welded (based on guidelines of IS9417) or mechanically spliced.
Congestion of reinforcement should be avoided during detailing.
The guideline of lap length / development length of rebar required for lapping /
splicing is as follows:
Grade of RCC M20 M25 M30 M35
Grade of Lap length required in tension as per Cl. 26.2.1 of BIS456-
Rebar 2000:
Fe500 57 x d 50 x d 45 x d 40 x d
Fe600 68 x d 60 x d 55 x d 48 x d
Note: d = nominal diameter of HYSD bar
Some disadvantages of this conventional method of rebar lapping / splicing:
The above table along with photo 1 clearly indicates how much lap length we
need to provide for lapping, conversely how much rebar and binding wires we
might save if we might use mechanical splicing for joining the rebar.

More lapping of rebar causes

congestion, and if vibrator doesnt
percolate through the congestion
and compact the surrounding
concrete around the splice/lap
location, it is likely to create
honeycomb or voids in concrete, as
shown in photo 2. That is one of the
main reasons that although 6%
rebar is permissible in columns as
per Cl. 26.5.3.1 of BIS456-2000, not
 Photo 2

As per Cl. 26.5.3.3 of BIS456-2000, at splice location longitudinal bars in a

column are required to be inclined with the axis of column at a slope not
exceeding 1 in 6, as shown in photo 3. Such profile is difficult to fabricate
accurately without automated bending machine, which incur huge hire charges.
Moreover such fabrication involves a lot of labour dependency and time
engagement.

Photo 3
Now-a-days mechanical splicing system technology is developed where rebar
couplers are designed to join reinforcement bars of dia ranging from 12mm to 40mm
dia. The traditional method of connecting reinforcement bars with lap joints continuity
in reinforced concrete need not be always appropriate. Advantages of simplicity and
economy in lap splicing are limited to smaller diameter bars. Mechanical couplers
offer the solution for splicing when large diameter bars are involved.
The processes and machines involved in rebar coupling process are as follows in
photo 4:

Cutting machine

Cold Forging
machine

Threading machine

Photo 4
The advantages of mechanical splicing system (shown in photo 5) over conventional
rebar lapping system are as follows:
Rebar couplers are manufactured with tensile strength superior than tensile
strength of rebar, for proper compatibility.
Rebar coupler performs like continuous reinforcement. Thus no staggering of
reinforcement bars required for splicing as per BIS456-2000 Cl.26.2.5. Moreover,
the continuity of rebar offers excellent provision for grounding electrical current.
Rebar Couplers reduce rebar congestion and improve concrete flow and
compaction (which is likely to reduce honeycombing or voids as shown in photo
2). Workability with higher steel-to-concrete ratio allows optimum sizing of RCC
structural members.
Since no rebar staggering is necessary, multiple reuses of formworks are
possible.
Rebar coupler increase productivity of work at site because of reduced
installation time and simper quality control requirements.
Rebar coupler leads to savings of cost of rebar to be lapped, binding wires,
wastage of rebar, skilled labour charges savings in bending component involved
in fabrication of rebar. Also automated bending machine involvement not
necessary and rebar threading cycle time is faster in comparison. Thus a lot of
time savings possible and it is economical to use.

Table for Cost Comparison between Rebar Coupler and conventional Lapping
Process for a single lap
Binding Labour Coupler
Bar Average Lap Weight Binding
Rebar Rebar wire for Binding cost for Total Rate +
Dia. length for of wire cost SAVINGS
Cost/Kg Cost lapping wire bending Lapping rebar
d comparison lapping
() () @ 5Kg/T
including
Cost () @ Cost () threading ()
(mm) = 50xd (m) (Kg) tax ()
(Kg) 2/Kg ()

40 2 19.7 35 690.5 0.10 75 3.5 39.5 733.4 270 463

36 1.8 14.4 503.4 0.07 2.5 28.8 534.7 206 329

32 1.6 10.1 353.5 0.05 1.8 20.2 375.5 154 222

25 1.25 4.8 168.6 0.02 0.8 9.6 179.1 110 69

20 1 2.5 86.3 0.01 0.4 4.9 91.7 85 7

16 0.8 1.3 44.2 0.01 0.2 2.5 46.9 60 -13

Rebar couplers are better for connecting precast RCC members with full tension
splice.
Rebar couplers are more reliable than lap splicing as mechanical splices doesnt
depend on concrete for load transfer.

Photo 5 : Mechanical splicing (rebar couplers) used in various projects

Article by: Mr. Sourav Dutta, Manager-Civil, Ion Exchange India Ltd.