Mechanical RebarSplicing Systems

Introduction

Lap splices depend onconcrete for strength,and therefore lack structural integrity andcontinuity in concreteconstruction.

Mechanical splicing provides the assuranceof maintaining load path continuity of thestructural reinforcement,independent of the condition or existence of the concrete.

ERICO mechanical rebar splices are tested and proven.They offer the most effective method of joining rein-forcing bars and meet the codes of national and inter-national regulatory organizations.

Our products are:

• LENTON® Taper Threaded Splices• LENTON® FORM SAVER• LENTON® INTERLOK• LENTON® SPEED-SLEEVE• LENTON® QUICK-WEDGE• LENTON® TERMINATOR• CADWELD® Rebar Splices

ERICO® is the worldwide leader in design and manufac-turing of advanced mechanical rebar splicing systems.With more than 40 years experience, the “Rebar SplicingSpecialists” at ERICO understand the concrete construc-tion business and inherent rebar splicing problems. Ourengineering capabilities, broad experience and extensivetesting base combined with our multiple splicing andanchorage systems, allow us to provide engineers andcontractors with product solutions to rebar splicing chal-lenges – today and into the future.

Ease of use, reliability, structural integrity, and minimalcongestion are the benefits of using ERICO products. Oursystems will handle your needs in tension, compression,cyclic and stress reversal applications.

Benefits of Mechanical Splicing

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• Mechanical systems are more reliable than lap systems because they don't depend on the concrete for load transfer.

• Mechanical connections offer greater structural integrity. Mechanical splices offer strength and toughness during man-made, seismic or other natural events.

• Codes require that mechanical splices deliver higher performance than typical design lengths for lap splices. This is typically 125% to 150% greater capacity* provided by the mechanical splice versus the lap splice.

• Lap splicing increases rebar congestion at the lap zone and is one of the major causes for forming rock pockets and voids in the concrete. Mechanical splices eliminate these congestion problems and willmake the overall job more cost effective through minimized job site problems.

• Building codes stipulate a steel ratio of under 8% and this makes it nearly impossible to achieve a balanced design with lap splicing. Mechanical splicesallow the designer to achieve an ideal balance of steel and concrete by eliminating the additional rebar in the lap zone.

BEAM REINFORCINGLAP BAR

COLUMN REINFORCING

LAP SPLICES

PLAN VIEW

COLUMN REINFORCING

MECHANICAL COUPLER

BEAM REINFORCING

MECHANICAL SPLICES

PLAN VIEW

• Working with “small” diameter reinforcing bars mayrequire the use of larger column dimensions to accommodate a greater quantity of bars. Using mechanical splices allows the option of larger diameterrebar in a smaller column while minimizing congestion.This reduced column size results in a more efficient design and an optimum use of floor space.

• Mechanical splices eliminate tedious lap calculations.

• Mechanical splices are fast and easy to install and require no specialized skilled labor.

• Mechanical splices are cost effective by reducing labor costs and accelerating job schedules.

• Dowel bar substitutes reduce labor on site, form- work costs and increase job site safety.

• Bar terminators eliminate congestion and simplify bar placing.

• Repair splices eliminate the cost of breaking away massive amounts of concrete

* Depending on reinforcing bar standard

More and more engineers are specifying mechanicalrebar connections over lap splices. They've found thatmechanical connections afford a reliability and consis-tency that can't be found with lap splicing.

STRAIN (in. per in.)

ST

RE

SS

(ks

i)

MECHANICAL SPLICE

LAP SPLICE DESIGN VALUE

0.002 0.004 0.006 0.008 0.010 0.012 0.014 0.016 0.018

80

60

40

20

100

00.020

InternationalCodes & StandardsERICO mechanical splices meet the requirements of major international codes and standards:

AustraliaAS3600

AustriaOnorm B4700

BrazilABNT – NBR 8548 – AGO/84

CanadaCAN3-N287.2CAN3-N287.3

ChileNCH 204

ChinaGB 1499-91

FranceNF A 35-020-1

GermanyDIN 1045

JapanJIS G3112

MalaysiaMS146

NetherlandsBRL 0504

NorwayNS 3437

United KingdomBS 8110

United StatesAASHTO; ACI 318-2002; ACI 349; ACI 359/ASME-III div 2, BOCA, CABO, ICBO, NRC, SBCC1, UBC 1997; U.S. Army Corps ofEngineers, ICC

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The LENTON Rebar Splicing Family

LENTON® TAPERTHREADED SPLICESLENTON splices are theslimmest couplers availableand their tapered threadmakes them the most reliable,easy to install and cost effec-tive system. The LENTONtaper threaded range consistof standard and transitioncouplers as well as positionalcouplers to join bars of anyshape, size and diameter. Alsoweldable and bolt couplersare available for joiningstructural steel to reinforcedconcrete.

LENTON®

FORM SAVERLENTON FORM SAVER is ideal for eliminatingprotruding dowel barsin segmental pour appli-cations and temporaryopenings. It is uniquelydesigned with theLENTON tapered thread,factory installed threadprotector and nailingplate for easy attach-ment to the form.

CADWELD®

CADWELD rebar splices areused where strength andtoughness are critical. CADWELD - the world’s premier mechanical splicingsystem - offers consistencyas well as versatility andflexibility. CADWELD rebar splicing system is the mostused system in nuclear construction worldwide.

CADWELD is also used forno bar end preparationapplications where new reinforcement is connectedto existing reinforcement.

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ERICO, Inc. manufactures a complete line of rebar splicing systems. Each system is designed to meet different splicing requirements. ERICO has the staff, experience and resources to help select the systemthat's right for any application. The following is a list of the most popular splicing systems availablefrom ERICO – The rebar splicing specialists.

LENTON®

INTERLOKLENTON INTERLOK is a pre-cast joining system, designedto provide structural integrityfor joining rebar in precastconstruction. The LENTONINTERLOK system allowsmaximum efficiency in precastconstruction as blockoutsand concrete patching areeliminated providing archi-tectually appealing results.

LENTON®

QUICK-WEDGELENTON QUICK-WEDGE isdesigned for retrofit applica-tions and is fast and easy toinstall. Because it utilizesshort dowels, LENTONQUICK-WEDGE reduces costlyand potentially damagingconcrete removal. It is anextremely cost effective system to use for bridgewidening, seismic upgrades,closure pours and pile extensions.

LENTON®

SPEED-SLEEVELENTON SPEED-SLEEVE isthe first choice of contrac-tors for compression onlyapplications. LENTONSPEED-SLEEVE is uniquelydesigned for fast, one-maninstallation and easyinspection. Using squaresaw cut ends, LENTONSPEED-SLEEVE meetsinternational coderequirements for compression only splicing.

LENTON®

TERMINATORLENTON TERMINATOR is ataper-threaded anchorage,which is secured to the endof a length of reinforcingsteel bar and is capable ofcreating a more effectiveanchorage than the tradi-tional hooked rebar. Thisapproach greatly simplifiesrebar placement, reducescongestion and improvesstructural integrity.

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LENTON is the most widely used mechanical splicingsystem in the world today. The LENTON system isdesigned to connect two pieces of rebar together inthe field quickly and easily.

LENTON taper threaded splices utilize the time-tested,field proven taper thread for assurance of strength,consistency and reliability while simplifying installation. Designed for use with worldwide grades of rebar,LENTON develops the full tension splice strengthrequirement per numerous international design stan-dards. The LENTON system is available in several stylesto meet virtually any application. The applicationsinclude standard bar-to-bar connections, precagingapplications, hooked bar applications, closure pours,precast connections, rebar terminations and anchor-ages, transition splices, segmental construction andconnections to structural steel.

For compression only connections the LENTON SPEED-SLEEVE is ideal. SPEED-SLEEVE installs quickly in aneasy one man operation.

The CADWELD rebar splicing system is the most widelyused mechanical splice in nuclear construction. The

CADWELD metal filled splice is also ideal for repairapplications.

The LENTON INTERLOK precast joining system isdesigned to provide structural integrity for joining rebarin precast construction. The system allows maximumefficiency in precast construction as blockouts andconcrete patching are eliminated - providing architec-turally appealing results.

LENTON TERMINATOR is a replacement for hookedrebar in beam/column, roof/column, piles and pile cap,footings, and just about anywhere a typical hookedbar would be utilized for anchorage in traditional cast-in-place precast construction. The LENTON TERMINATORis simply an oversized coupling secured to the end of a length of rebar, creating anchorage within the con-crete. Pioneered by ERICO in the 1970s, mechanicalrebar anchors effectively eliminate the rebar hook,minimize embedment lengths, simplify concrete place-ment, reduce construction costs and allow greaterflexibility in design and construction. In addition toproviding an alternative to hooked rebar, it can also beutilized as a stop nut for bar passing through a pileplank or structural steel element.

Applications

MECHANICAL SPLICING AND ANCHORINGLENTON Taper Threaded Splices • LENTON SPEED-SLEEVE • CADWELD

LENTON INTERLOK • LENTON TERMINATOR

LENTON “A2/A12”Bar-to-bar connection, whereat least one bar is free to rotate.Full tension capacity.

LENTON TERMINATORReplacement for bent bars in foundations, pile caps andcolumn footers.

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LENTON Weldable “C3J/C2/C12” Coupler designed to be arc- welded to structural plates and shapes.

LENTON COUPLERSIdeal for shear wall applications.Mechanical splices reduce overallcongestion.

LENTON TERMINATORReplacement for a bent section of reinforcing steel.

BENT BAR APPLICATIONS

LENTON POSITION COUPLERFor bar-to-bar connections where neitherbar can be rotated and where one bar isfree to move in its axial direction.

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LENTON FORM SAVER is ideal for segmental pours byeliminating protruding dowels. It is uniquely designedwith our LENTON taper thread, factory installed threadprotector and keyed mounting holes for easy attachmentto the form. LENTON Form Saver eliminates drillingexpensive formwork and the need for bend/rebend of

rebar. FORM SAVER is ideal for slip form, jump form,segmental pour, stairwell applications, bridge andhighway construction and precast applications. LENTONFORM SAVER is available in sizes #4 through #11(12mm - 36mm).

Applications

DOWEL BAR REPLACEMENTLENTON FORM SAVER

LENTON FORM SAVERInstalled into the precast wall panels. Once the panel is positioned at the jobsite, the matching external threaded rebar is screwed into the coupler to maintain continuity between the cast-in-place and precast sections.

Equipment and Crane Openings

Stairwell

Floor Slab,Highway or Bridge Slabs

1st Pour

2nd Pour

7

ERICO offers a wide range of products to splice rebarin the field or to repair or extend column or beambars that are in a structure. Sometimes rebar may beaccidentally cut in the field or a structure may get anaddition and the reinforcement must be extended. For these applications, ERICO offers several productsincluding the CADWELD rebar splicing system and theQUICK-WEDGE mechanical rebar splice. The CADWELDsplice is the original mechanical splice pioneered byERICO in the 1950s and is suitable for connecting twopieces of rebar in-situ with no bar end preparationrequired. This system is the premier rebar splice in the

world, and as a result, it is the primary splicingmethod used for nuclear and blast resistant structures.In addition, the QUICK-WEDGE splice is ideal forrepairing or extending small rebars in sizes #4 - #6(12mm - 20mm). This quick and easy to use system isflexible, reliable and economical. Installation is madein seconds by over-lapping rebar in the steel sleeveand driving a wedge pin between the bars with aportable hydraulic hand tool. Splices can be madewith as little as 3" (76mm) of exposed dowel. This sys-tem is also ideal for adding confinement steel (stirrups)in seismic upgrade applications.

Applications

REPAIR/RETROFIT APPLICATIONSLENTON QUICK-WEDGE • CADWELD Rebar Splicing System

CADWELDMetal-filled rebar connectiondesigned with an over-sized interior to allow for radius bars.

CADWELDMetal-filled rebar connection usedto splice to existing reinforcementbars. No bar end preparation isrequired.

QUICK-WEDGERemove sections of deterioratedroad slabs or bridge decks. Expose a minimal length of rebar by chip-ping out additional concrete. Newreinforcing steel is joined by an ovalshaped coupler. A hydraulic handtool is used to install a wedge pinbetween new and old rebar.

QUICK-WEDGEStirrups are joined at two locations around an existing column. The column is encased with additional concrete pour.

CADWELDMetal-filled rebar connectionused to splice to existing rein-forcement bars.

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LENTON Taper Threaded Splicing Systems

LENTON COUPLER

LENTONTAPEREDTHREAD

®

®

LENTON is the most widely used mechanical splicing system in theworld today. And why not? LENTON is unique because it uses a taperthread for assurance of strength, consistency and reliability while simplifying installation.

Designed for use on worldwide stan-dard grades of rebar, LENTON developsthe ACI full tension splice strengthrequirement as per many internationalstandards. No “special” high strength,enlarged thread section, or increasedrebar size are necessary, allowing thesupply of rebar from multiple sourcesfor maximum cost savings.

• Fastest system to install – acceleratingconstruction schedules.

• Threading at the fabrication shop eliminates installation equipment “problems” at the job site.

• Excellent for future extensionapplications.

• Contractor can save valuable crane time while gaining flexibility on mechanical splicing schedules.

• Electrostatically epoxy coated couplers are available to maximize corrosion protection.

• Taper thread design eliminates crossthreading problems.

• Available in sizes #3 - #18 (10mm - 57mm)

LENTON Offers a Coupler for Every Application:A Type – Standard bar-to-bar applicationP Type – For bent bar applicationsC Type – For connecting reinforcing bar to structural steelS Type – For joining reinforcing bar to standard metric boltD Type – An alternative to hooked bar or as an anchorR Type – A Type transition coupler

Luxor Casino – Las Vegas, USA

9

LENTON FORM SAVER

LENTON FORM SAVER solves the age old problem of joining rebar through aconcrete form. As an extension of theLENTON product line, FORM SAVER offersthe LENTON advantages with additionalfeatures. All couplers are supplied pre-assembled to the rebar with built ininternal coupler thread protection toeliminate concrete paste contamination.The plate designed to mount the couplerassembly is pre-attached and featureskeyed holes to ease attachment to the form.

• Ideal for slip form, jump form, segmen-tal pour and stairwell applications, to name a few.

• Provides job site safety by eliminating protruding dowels.

• Exceeds International Building Code Requirements.

• Quality assurance tensile testing during production runs.

• Available in sizes #4 - #11 (12mm - 36mm)

The system eliminates:– The need to cut holes in expensive

form work;– Questionable condition of "bent

and rebent" rebar;– Bars breaking during straightening;– Specifying Grade 40 rebar for

the application.

LENTON TAPERED THREAD

FORM SAVER �COUPLER

¤

COUPLER THREAD PROTECTOR REMOVED

Nationale Nederlanden – Netherlands

10

CADWELD

CADWELD®

FILLERMATERIAL

CADWELD®

FILLERMATERIAL

CADWELD®

SLEEVE

For the most demanding applications,CADWELD rebar splicing system hasearned its reputation as the strongestsplice. The primary usage for CADWELDis related to critical structures requiringhigh safety margins such as blast resist-ant facilities, pressure vessel applica-tions, or seismic resistance.

CADWELD is a mechanical splice, not aweldment. The system utilizes an inter-nally grooved sleeve working in con-junction with the rebar deformations.Load is transferred from the rebar tothe sleeve via CADWELD filler material.The finished connection developsstrength and consistency – there is noequal in the industry.

Due to its popularity in critical struc-tures, CADWELD is the world’s mosttested mechanical splice. Its recordincludes over 25,000 actual field madetensile tests.

• Consistently develops minimum ultimate strength of the rebar.

• Excellent for joining circumferential bars.

• Simplifies acceleration of splicing schedules.

• Retrofit and repair with short dowels and requires no bar end preparation.

• Available in sizes #4 - #18 (12mm - 57mm)

CADWELD rebar splices have been used in over 200 nuclear

power plants worldwide.

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LENTON QUICK-WEDGE

The QUICK-WEDGE splicing system is designed to deliver a quick and simple method of splicing #4 - #6(12mm - 20mm) bar. Installation ismade in seconds by over-lappingrebar in the steel sleeve and drivingthe wedge pin between the barswith a portable hydraulic hand tool.

QUICK-WEDGE offers fast installa-tion by allowing rebar to be cut tothe approximate size that spansbetween the rebar being joined,doing away with custom cuttingand fitting as in butt splicing.Splices can be made with as little as 3" (76mm) of exposed dowel.

• Minimal dowel lengths eliminate excessive and expensive concrete chipping in retrofit installations.

• “Lapped bar” capability and minimal exposed bar ends make the QUICK-WEDGE system a natural for road/ bridge repair and closure pours.

• The ideal splice system for addingconfinement steel (stirrups) in seismic upgrade applications.

• Exceeds characteristic strength requirements in the code

• Can make up to 100 splices per hour.

QUICK-WEDGEProtruding bars from the precast wall are joined using anoval shape coupler. The bars areoverlapped and assembled usinga hydraulic hand tool. Cast-in-place concrete is poured afterthe connections are completed.

QUICK-WEDGEA minimal amount of concrete isremoved from the existing road way orbridge deck. An oval shaped mechanicallap splice coupler is assembled using aportable hydraulic hand tool.

CityLink – Melbourne, Australia

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LENTON INTERLOK

U.S. Patent No. 5,468,524U.S. Patent No. 5,366,672

For precast construction, ERICO offers the LENTONINTERLOK rebar splicing system. Splices are designed to maintain structural integrity between load bearing pre-cast members such as columns, beams and shear walls.The completed connection exceeds the ACI BuildingCode Requirement.

LENTON INTERLOK utilizes the LENTON taper threadedsystem on one end, which has been recognized world-wide for nearly two decades. The opposite end of thesleeve is filled at the jobsite with a specially formulatedcementitious filler (grout). A quality connection isassured since both the coupler and filler are supplied byERICO as a system.

Unlike embedded connections, tensile loads are trans-ferred through the rebar, and are not dependent on thecompressive strength of the concrete.

• Maintains structural integrity through precast sections.The reinforcing steel acts as one continuous bar well above 125 percent of yield.

• Unlike embedded connections, tensile loads are transferred through the rebar, and are not dependent on the compressive strength of the concrete.

• The connection is not detrimental to surrounding concrete, since no heat is produced, as in arc-welding.

• No more unsightly and costly patchwork required, creating an aesthetically appealing finish.

• Designed for all rebar sizes from #6 - #18 (20mm - 57mm).

FILLER MATERIAL

LENTONINTERLOKSLEEVELENTON TAPERED THREAD¤

¤

Turner Field – Atlanta, Georgia – USA

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LENTON SPEED-SLEEVE

For compression only applications, SPEED-SLEEVE is the splice ofchoice. The system is designed to allow compressive loads to betransferred by aligning square cut rebar to bear on one another.SPEED-SLEEVE is desirable because it can be installed on rebardowels without the upper bar in place. This feature allows one-man installation and is conducive to prefabricated cage assembly.

The Pentagon – Washington DC, USA

• Installation is a one-man operation keeping labor costs down.

• Transition splices can be made withthe use of simple adaptor inserts.

• Install with an air or electricallydriven impact wrench.

• Fast installation keeps construction on or ahead of schedule.

• Designed for sizes #6 - #18 (20mm - 57mm).

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LENTON TERMINATORRecent code changes have significantlyincreased the amount of rebar required,while at the same time, designers are strivingfor more compact structural elements. Thisresults in rebar congestion and placementproblems. Built on the extensive testing conducted for headed anchors, the LENTONTERMINATOR answers these challenges byeliminating the majority of rebar embedmentlengths required, while reducing job-siteman-hours and related labor costs.

Utilizing the principles of the Shear ConeTheory on which ACI-355 is based, theLENTON TERMINATOR is designed for use on all rebar grades sizes #4 - #18 (12mm -57mm). The LENTON Terminator incorporates the time-tested, field-provenLENTON tapered thread and is suppliedthrough a network of local rebar fabricators.

ACI-355 is based onthe principles of the

Shear Cone Theory

• 60% less rebar congestion by eliminating the need for hooked rebar embedments.

• Complies with major codes and standards while minimizing embedment lengths to reduce congestion.

• Simplifies concrete placement forbetter concrete consolidation.

• Offers more embedment options, while allowing greater design flexibility.

• Faster installation lowers the in-place cost.

• Standard product dimensions require minimal detailing.

• Simplifies expansion while allowing for future extensions.

Malampaya Offshore Platform –The Phillippines

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Put the ERICO Advantage to Work for You

The Rebar Splicing Specialists MEMBER

Celebrating its 100th year, ERICO is a diversified globalmanufacturer with a network of offices and manufacturingfacilities in over 24 countries and with more than 1400employees. Headquartered in Solon, Ohio, USA, ERICOhas two businesses: the Fixing and Fastening Business selling Electrical and Mechanical Fixings and Fasteners and Concrete Reinforcement products; and the ElectricalBusiness offering Facility Electrical Protection, Panelboardand Rail and Industrial Electrical products. Well-knownbrand names include: CADDY® fixings and fasteners;CADWELD® welded electrical connections; CRITEC® surgeprotection devices; ERIFLEX® low-voltage components featuring FLEXIBAR® busbar; ERITECH® lightning protectionand grounding; and, LENTON® mechanical rebar splices.Visit ERICO online at www.erico.com.

LENTON® Taper Threaded Splices

LENTON® FORM SAVER

CADWELD®

LENTON® INTERLOK

LENTON® QUICK-WEDGE

LENTON® SPEED-SLEEVE

LENTON® TERMINATOR

The LENTON Rebar Splicing Family

Projects

16

KPN, Rotterdam – Netherlands

Panoramic Tower – Lisbon

Storebaelt West Bridge – Denmark

Sizewell B – UK

Fernmeldeturm – Hannover

Messeturm – Frankfurt

Petronas Towers– Malaysia

Skydome– Toronto, Canada

17

Nationale Nederlanden – Rotterdam

F3 - Platform NAM – Rotterdam

Trianon– Frankfurt

La Défence– Paris, France

Bank Swiss Union

Control tower,Schipol Airport

– Amsterdam

RSB C456LT02 0210M3

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CANADA34600 Solon RaodSolon, Ohio 44139U.S.A.Tel. 1-800-677-9089Fax 1-800-677-8131

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SWITZERLANDPra Pury 7d3280 MurtenSwitzerlandTel. 41-26-672-9999Fax 41-26-672-9998

THAILANDLevel 23, M. Thai Tower, All Seasons Place87 Wireless RoadPathumwan, Bangkok 10330ThailandTel. 66-2-627-9037Fax 66-2-627-9168

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Copyright ©2003 ERICO International Corporation. All rights reserved.CADDY, CADWELD, CRITEC, ERICO, ERITECH, ERIFLEX, and LENTON are registered trademarks of ERICO International Corporation.