ML20076C470

Design Review of Dayton Bar-Grip Reinforcing Bar Splice Sys, Technical Evaluation Rept

ML20076C470
Person / Time
Site:	Seabrook
Issue date:	02/28/1983
From:	SCIENCE APPLICATIONS INTERNATIONAL CORP. (FORMERLY
To:	NRC
Shared Package
ML20076C474	List: ML20076C470 ML20076C475
References
CON-NRC-03-82-096, CON-NRC-3-82-96 SAI-1-186-03-61, SAI-1-186-3-61, SAI-1-186-3-610-3, NUDOCS 8303080182
Download: ML20076C470 (60)

Text

Report No. SAI-1-186-03-610-3 DESIGE RETIEN OF THE DAIT05 BA M RIP REIEFORCIEG BAR SPLICE SYSTEN TitCHNICAL ETALUATION REPORT Prepared By:

Science Applications, Inc.

1710 Goodridge Drive McLean, VA 22102 Prepared For:

U.S. Nuclear Regulatory Commission Washington, D. C. 20555 i

February 28, 1983 i

NRC Contract NRC-03-82-096, Assignment 7

,e-Mease Send Copy of xg g,99g gMOBM&

i NOTICE i

This report was prepared as an account of wcrk sponsored by ]

an agency of the United States Govenment. Neither the J United States Government nor any agency thereof, or any of their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for any third party's use, or the results of such use, of any

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information, apparatus product or process disclosed in this report, or represents that its use by such third party would not infringe privately owned rights. ]

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4 l EIECUTITE 3INGIARY 1

l This Technical Evaluation Report (TER) has been prepared by Science Applica-2 tions, Inc. (SAI), under contract from the U. S. Nuclear Regulatory Commission i (NRC) staff, to document an engineering evaluation of the Dayton Bar-Grip

! Reinforcing Bar Splice System. Neither the NRC nor its staff has, as yet, 4

epproved this TER for use in any licensing action. This splice system is used to positively connect steel reinforcing bars (i.e., rebars) in such a manner 4 na to develop the minimum ultimate tensile strength of the concrete rein-forcing steel on which they are used. The coupler design concept consists of.

I using an hydraulic press to cold-press a steel sleeve around the ends of the

! deformed reinforcing bars.

4 l Steel for tension elements in reinforced concrete requires direct, positive

! coupling of adjoining elements in conformance with standards defined by the i American Concrete Institute (ACI) and the American Society of Mechanical Engi-neers ( ASME). Currently, the only splice system approved by the NRC for general use in nuclear power plant construction applications is the CADWELD System. The Public Service Company of New Hampshire has proposed the use of the Dayton Bar-Grip System, which is manufactured by Dayton Barsplice, Inc.

(DBI), of Mianisburg, Ohio, in constructing their Seabrook Nuclear Power Plant. This TER has been prepared to support an NRC staff evaluation of the Dayton Bar-Grip splice system.

The information presented in this TER is based on a review of data obtained from DBI, a number of users of the couplers, and applicable codes and regula-tions. The report includes a description of coupler design features, the process used to manufacture the couplers, installation procedures and quality assurance / inspection procedures. An engineering analysis discussion and a-summary of performance tests performed by DBI to substantiate their coupler design are also included in this TER.

The Dayton Bar-Grip coupler is furnished in two types (i.e., the plain Coupler and the threaded Coupler) and several sizes to accommodate No. 5 through No.

l. 18 rebars. Only the plain coupler is evaluated in this TER.

The couplers have been successfully used on a wide variety of construction

( projects both in the United States and in several foreign countries. The l I couplers used on most of these projects had to be designed to satisfy require-ments that were similar to those imposed on projects regulated by the NRC. ,

b Performance tests have been run on all of the coupler sizes that are manufac-  !

tured by DBI. . Although these testa generally conform to the requirements of ,

the applicable codes and standards, several apparent nonconformances were noted. These nonconformances included . strains in excess of 0 3 percent, lack of total elongation at failure . data and reduction in strength af ter some .

cyclic tests. It is recommended that DBI be asked-to either justify such

, -cpparent nonconformances or to run appropriate additional tests before the NRC accepts the Bar-Grip plain coupler for general use in nuclear plant construc-

tion.

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i l It is suggested that DBI be encouraged to develop a generic Quality Assurance

{ Manual and related Quality Control Procedures rather than relying on each l

! customer to develop his own such documentation for each specific project.

i Although it has been recommended that DBI be asked to provide certain addi-q tional data / documentation prior to the granting of NRC approval for the gen-

eral use of the Dayton Bar-Grip Splice System on nuclear power plant projects, j it is concluded that this system can be used in specific applications provided that such applications are reviewed and approved on a case-by-case basis,

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l j Consequently, the pending application for the use of this splice system at the j Seabrook Nuclear Power Plant should not be delayed pending the gathering of additional data according to recommendations contained in this TER. None of j the recommendations presented should preclude the use of the Dayton Bar-Grip Splice System at the Seabrook Nuclear Power Plant.

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BELE OF Cam!MS 1

Section Egg EXECUTIVE SMERY iii

' LIST OF FIGURES 'vi Vi

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LIST OF TABLES .

1.0 IN 2000CTION 1-1 l

2.0 GENERAL DISGSSION 2-1 2.1 Background 2-1 2.2 Applicable Codes and Regulations 2-1

, 2.3 Applicable Specifications and Procedures 2-4 2.4 Bibliogra@y 2-5

3.0 SYSTEM DESCRIFfION 3-1 3.1 Design Features 3-1

. 3.2 Manufacturing Process 3-4

3.3 Quality Assurance 3-4 34 Installation Procedures 3-5 4.0 ENGINEERING ANALYSIS 4-1 l 5.0 TEST RESULTS 5-1 5.1 Installation Tests 5-1 5.2 Performance Tests 5-2 i

i 5.2.1 Code Requirements 5-2

5.2.2 Unspliced Rebar Tests 5-3 5.2.3 Static Tensile Tests 5-3

! 5.2.4 Cyclic Load R sts 5-11 l 6.0 SAI EVALUATION .6-1 6.1 General Discussion 6-1 6.2 Current Users of Splice System 6-2 6.3 Conclusions and Reccanendations 6-2 4

REFERENCES 7-1 APPENDIX - Brochure Describing the Dayton Bar-Grip Splice Systen A-1 V

I LISE T FIGItES Ficure h Eg;;g 3.1 Dayton Bar-Grip Plain Coupler Configuration 3-2 3.2 Minimla Setting Out Dimensions for Bar-Grip Couplers 3 l

3.3 Installation of Dayton Bar-Grip Couplers 3 4.1 Schematic Representation of Tensile Load Transfer 4-2 4.2 Schematic Representation of Cmpressive Load Trasfer 4-3 LIST T ' DEES Table ' lit;lg Eg;;g 2.1 Caparative Splice System Code' Requirements 2-2 5.1 Rebar Manufacturers and Deformation Patterns 5-4 5.2 Sumary of Unspliced Rebar Tensile Tests 5-5 5.3 Sumary of Plain Coupler Static Tensile Tests 5-6 5.4 Sumary of Plain Coupler Cyclic '1%nsile Tests 5-12 6.1 Power Plant Projects that have used Bar-Grip Couplers 6-3 6.2 References Supplied by Dayton Barsplice, Inc. 6-4 4

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i i 1.0 INTRODUCTIOR i

Steel for tension elements in reinforced concrete requires direct, positive

i. coupling of adjoining elements in conformance with a variety of standards j defined by the American Concrete Institute (ACI), the Americcn Society of Mechanical Engineers (ASME) and the Nuclear Regulatory Commission (NRC).'

Currently, the only splice system approved by the NRC for general use in i- nuclear power plant construction applications is the CADWELD system. The i Public Service Company of New Hampshire has proposed the use of .the Dayton

? Bar-Grip Reinforcing Bar Splice System for work at its Seabrook Nuclear Power i

i Plant [1]l. This Technical Evaluation Report (TER) has been prepared by Science Applications, Inc. (SAI), under contract from the NRC staff, to docu-IIent an engineering evaluation of the Bar-Grip splice system. l l' The objective of chis work assignment was to review and evaluate conformance of the Bar-Grip splice system with the requirements of ACI Standard 349-80

} [2], the ASME Code Section III, Division 2 [3,4], in 1uding Code Case N-185 l

[5], and NRC Regulatory Guide 1.136 [6] and to make an independent assessment of the acceptability of the splice system for use in nuclear power plant i construction applications.

The information presented in this TER in based on a review of documents and 7

literature obtained from Dayton Barsplice, Inc. (DBI), who is the manufacturer of the couplers used in the splice system and applicable codes and regula-l tions.

1 A background discussion describing the events which led up to the need for this report is presented in Section 2.0 together with a list of applicable codes, regulations and specifications. Section 3 0 contains a description of j the splice system. Included is a description of significant design features l as well as descriptions of the process used to manufacture the couplers, quality assurance procedures and installation procedures.

A discussion is presented in Section 4.0 in which the behavior of the splice i system is described from an engineering analysis point of view. Section 5.0 j contains a summary of some of the more significant test results which were j cbtained by DBI to substantiate their coupler design.

f Section 6.0 contains data resulting from SAI's review of the Bar-Crip splice system design. Included is a general discussion regarding the adequocy of the coupler design, a summary of current users of the splice system, and a number j -of conclusions and/or recommendations ~regarding the acceptability of the system for use in nuclear plant construction.

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I References are denoted by "[1]* throughout this TER. 'A complete . list of i references is given on - Page 7-1.

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2.0 GBERAL DISCUSSIGE I This section contains a general background discussion to establish the need for the evaluation documented in this report. Also included are summaries of codes, regulations, specifications and correspondence that relate to the -

$ Dayton Bar-Grip Splice System design and the request to the NRC for the B approval of its use in nuclear power plant construction.

2.1 BACKGROUND

Steel for tension elements in reinforced concrete requires, in certain situa- t tions, direct, positive coupling of adjoining elements in conformance with  !

I standards such as those defined in ACI Standard 349-80 [2], the ASME Code Section III-Division 2 [3,4], ASME Code Case N-185 [5], NRC Regulatory Guide I 1.136 [6], the Uniform Building Code [7] and ACI 318-77 [8]. Currently, the only splice system approved by the NRC for general use in nuclear power plant construction applicaticns is the CADWELD system.

The Public Service Company of New Hampshire has proposed the use of the Dayton  ;

Bar-Grip Reinforcing Bar Splice System manufactured by Dayton Barsplice, Inc.

(IBI) of Miamisburg. Ohio in performing work on their Seabrook Nuclear Power Plant. This request, which has been initiated through appropriate NRC channels with the assistance of United Engineers and Constructors, who are the Architect / Engineers for the Seabrook project, is officially documented in [1].

DBI was formed in 1979 as a joint venture of the Dayton Sure-Grip and Shore Company of Dayton, Ohio and CCL Systems Ltd. (CCL) of London and Leeds, '

England. Dayton Sure-Grip has been making accessories and chemicals for concrete construction for over 57 years. CCL Systems has been making engi- '

neered systems for prestressing and placing concrete for over 47 years.

I DBI has provided considerable product description and performance test data

[9,10] to support the evaluation documented in this report and the request for approval to use the Bar-Grip splice system in nuclear plant construction.

These data, which are summarized in Sections 2.3 and 2.4, includes DBI bro-  !

I chures and procedure manuals [11,12], reports on tests performed both directly for DBI or CCL [13-18] and for potential users of the system [19-21] and documents approving the use of the splice system in particular applications ,

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2.2 APPLICABLE CODES AND REGULATIONS

'Ihis section contains a brief description of the various codes and regulatiens which are referenced in this TER. Included is a short summary of the sections

I of each document that pertain to the use of a swaged mechanical splice like the Dayton Bar-Grip splice evaluated herein. Also included as Table 2.1 is a comparative listing of significant splice system code requirements between the latest revision of the principal codes referenced on nuclear power plant i construction projects.

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.t Table 2.1. Canparative Splice System Code Requirements.

i Stamary cf Code Requirenent i Item t

4 ACI 318-77 ACI 349-80 ACI 359-80 (with 80 Sunner Addenda)

Design Requirements Must develop Must develop See a plicable ,

125% of bar 125% of bar performance test 4

yield strength . yield strength requirements.  !

Performance Test i Requirements:

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Static Tensile Test Required No Yes, 6 specimens. Yes, 6 specimens. l '

Cyclic Test No Yes, 100 cycles Yes, 100 cycles  !

Required of 5-90% of of 5-90% of minimum yield, 3 specimens. p3specimens.

yield, l Test Acceptance WA 125% of specified 125% of specified Criteria yield, no loss of yield, 100% of strength after specified  ;

cyclic test, ultimate, and 90% i of actual I. ultimate.

l Strain Criteria None Connections Load-strain curve.  !

staggered if required up to strain at 0.9 f 2% strain, Total i exceeds 0.3%an[I elongation at  !

design load fallure must be:  :

exceeds 50% of recorded. ,

yield.

l Unspliced Rebar None None Average strength Test Requirements not less than  !

90% of. actual i strength of any- l bar.

l Note: 1. For swaged splices - 3.of each patt arn in each size.

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1. " Code Requirements for. Nuclear Safety Related Concrete Struct-1 uree," ACI 349-80, American Concrete Institute, Detroit, Michi-gan, April-1981 [2].

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!- his code covers the proper design and construction of concrete i structures which form part of a nuclear power plant and which i have safety related functions, but does not cover concrete react-or vessels and concrete containment structures as defined in l~

[3,4].- he code'is an extension of [8]-and, as such, permits the i use of mechanical reinforcing bar connections.. The additional requirements specified in this code include either the need'for l static tensile strength and cyclic performance tests or an ex-i tremely conservative design; visual inspection by a qualified i inspector; and, in some cases,' a requirement to stagger connec-tions between adjacent bars.-

j Qualification tests must be performed under -this code to verify l 1

that the splice system develops 125 percent of the specified yield strength of the bar during both the static tensile and low cycle (i.e.,100 cycle) tensile tests. If the splice system does 3 not satisfy these qualification test requirements, this code then j requires that adjacent splices be staggered at least-24 inches so as to develop at least twice the calculated tensile force at each cross-section. %e code also requires that tha splices be stag-gered if the unit strain of the splice at 90 percent yield ex-

ceeds 0.003 in. per in and if the maximum computed design stress of the splice equals or exceeds 50 percent of the yield strength of the bar.

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2. ASME Boiler and Pressure Vessel Code, Section III-Division 2,

! " Code for concrete Reactor vessels and containments," the Ameri-can Society of Mechanical Engineers, 1980 Edition [3].-

' %e only mechanical splice system permitted by this edition of i the ASME code, which is also identified as ACI 359-80, is a i filler metal splice system (i.e., the CADWELD splice system).

L his code specifies that the splicer must be subjected to initial qualification tests prior to splicing, continuing splice perform-

! ance tests to insure that production splices meet the tensile

! requirements, and certain quality assurance and inspection-j: criteria.

l l 3. ASME Boiler and Pressure Vessel Code, Section III-Division 2, i " Code for Concrete Reactor Vessels and Containments," the Ameri-l can Society of Mechanical Engineers,1980 Edition with Summer.

j 1980 Addenda [4].-

This addition of the code, which is also identified as JACI Standard 359-80 (with Summer Addenda), permits, for the first time, the use of several different types of mechanical splice systems for splicing of reinforcing bars - (e.g., sleeve with--

ferrous filler metal-splices,' taper threaded-splices, swaged :

. splices and threaded splices ~in thread deformed; reinforcing : ~

bars). Earlier editions of the code only permitted the use.of 2-3 h

mechanical splices made using a ferrous filler metal concept.

This code specifies that all splice systems must be subjected to splice performance tests, splicer qualification tests, and continuing splice performance . tests as well as well documented quality assurance and inspection criteria.

4. "ASME Code Case N-185, Requirements for Materials, and Qualifica-tion and Performance Testing of Swaged Reinforcing Bar Splices Splices", Section .III, Division 2, Concrete Reactor Vessels add containment. Approved by Council, 8/29/77, Approved by ACI, 10/17/77 [5].

The approval of this Code Case by the ACI and ASME resulted in

the acceptance of a swaged mechanical splice system for use in Category I nuclear plant construction a7 stated in [4].

5. " Regulatory Guide 1.136, Material for Concrete Containments," U.

S. Nuclear Regulatory Commission, Revision 2, June 1981 [6]. ,

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This guide describes some bases acceptable to the NRC staff for implementing certain Quality Standards and Quality Assurance Criteria specified in 10 CFR Part 50 with regard to material for concrete. containments. This revision of the guide endorses those j articles of Part CC of the 1980 Edition of the ASME Code [3]

which relate to the use of mechanical splicing of reinforcing bars. This edition of the guide did not permit the use of any mechanical splice system except for those using a ferrous filler metal and, consequently, does not permit the use of a swaged splice system such as is described in this TER.'

6. IbifGIm Building Code,1979 Edition, International Conference of Building Officials, Whittier, California, 1979 [7].

2 This code, in Section 2607 (f) 2, permits the use of either l welded splices. or other positive connections in reinforced con-crete building construction.

This code further states that full positive connections shall develop in tension or compression, as  !

required, at least 125 percent of the specified yield strength of  % ,

the bar. 1 l

7. " Building Code Requirements for Reinforced Concrete," ACI 318-77, American Concrete Institute, Detroit, Michigan,1977 [8].

This code, in Section 12.15.3, permits the use of mechanibal' ~

connections provided that the connection deve. lops in tension or -

compression, as, required, at least 125 percent of the specified.

. yield strength of the bar.

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2.3 APPLICABLE SPECIFICATIONS AND PROCEDURES a  ;

The following documents contain specifications for the Bar-Grip Reinfdtcing Bar Splice System.: Also included in this list of documents are documents that i. .

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i contain quality assurance and inspection procedures.

1. " Brochure - Bar-Grip Systems," Dayton Barsplice, Inc., Miamis-i burg, Ohio, 7/81 [11].

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his brochure contains a summary of the design and performance i characteristics of the Bar-Grip splice system. This brochure has

)- been included as Appendix A of this TER.

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2. " Operating Manual - Bar-Grip Mechanical Splicing Systems for

Reinforcing Bars with Hydraulic Press Equipment," Dayton Bar-l splice, Inc., Miamisburg, Ohio, 12/80 (12].

his manual contains. detailed operating instructions for the use 1 of the three types of presses which can be used to install Bar-Grip splices. Se Bar-Grip Draw Press described in this manual

! is no longer in use per information received from DBI [9]. The i Bar-Grip Side Press and the Bar-Grip Bench Press continue to be

{ used.

1 i 3. " Report on Performance Testing of No. 5 through No.18 Bar-Grip 1 Sleeves for Dayton Barsplice, Inc.," WJE No. 820300Q,-Wiss, 4

{ Janney, Elstner and Associates, Inc., Northbrook, Illinois,

! 5/7/82 (13].

] Appendix 2 to this test report contains a procedures manual for >

the performance testing of spliced reinforcing bars as manufac-

[ tured by DBI.

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j 2.4 BIBLIOGRAPHY s .

! %e h_= ants summarized below support the request 'from the Public Service

j. Company of New Hampshire for NRC approval of the use of the Bar-Grip splice j system in nuclear power plant construction.

! 1. Letter from J. DeVincentis,' Project Manager, Yankee Atomic Elec-j- tric Company /Public Service Company of New Hampshire, to Mr.

i George W. Knighton, Chief, Licensing Branch No. 3, Division of l Licensing, NRC, Subject. " Request for Authorization to Utilize

} the Dayton Bar Grip System at Seabrook -Station," 12/28/82 [1].

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$ j%is letter was the initial request for NRC a proval for the use

! of the Dayton Bar-Grip System at the Seabrook Nuclear Power.

[, ' Plant.

2. " Report on Mechanical Splicing and Non-Destructive Examination of Reinforcing Bars Spliced by Swage Method for NRC Approval,"

Prepared for Public Service Company of New Hampshire - Seabrook Station by United Engineers and Constructors, Inc., -Philadelphia, Pennsylvania,. November, 1982 [24].

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1 L his report was submitted as an attachment to [1] and contained

several h= ants which supported the request for permission to -

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use the Dayton Bar-Grip Systcm at the Seabrook Nuclear Power Plant. -

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3.0 SHEEEN nemenwru3i This section contains a description of the Dayton Bar-Grip Reinforcing Bar.

y Splice System. Included is a description of significant design features, the L process used to manufacture the couplers, quality assurance procedures and installation procedures.

%e Dayton Bar-Grip Splice System ~ was designed to connect steel reinforcing

{- bars in such a manner as to develop the minimum ultimate tensile strength of bars of the specification and grade of reinforcing steel on which it is used, r  % e coupler design concept adopts a portable hydraulic press to cold-press the sleeve to the ends of deformed reinforcing bars [11].

The Bar-Grip splice system is furnished in two types, the Bar-Grip plain coupler and the Bar-Grip threaded coupler. The Bar-Grip plain coupler, as shown in Fig. 3.1, is used in straight line applications to join two rein-forcing bars.- The Bar-Grip threaded coupler is used for special situations like those calling for the elimination of starter bars, slip forming, dia-phragm walls, access openings and potential or planned additions [11]. Only the Bar-Grip plain coupler will be evaluated in this report since this is the only design for which NRC approval has been requested.

3.1 DESIGN FEATURES Dayton Barsplice, Inc. (DBI) states in [11] that their Bar-Grip coupler was y designed to provide the construction industry with a compact, easy-to-install,'

and fast system for use in splicing rebars. EBI further states- [12] that most

{- Bar-Grip coupler configurations can be installed in less than three minutes by operators with simple training.

h DBI has sought to achieve their design requirements by a swaging process to mechanically splice two reinforcing bars together. DBI states in (11] that their Bar-Grip couplers are capable of mechanically splicing high yield,

[ ribbed reinforcing bars, sizes No. 5 through No.18, without special end-preparation. The design concept of the Bar-Grip plain coupler system, as described in a- report published by the International Conference' of Building Officials (publishers of the Uniform Building Code) [19),. basically employs a

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steel sleeve which has an inner diameter slightly larger than the reinforcing bars which are to be spliced. %e ends of the reinforcing' bars are inserted an equal' distance into the sleeve. %e sleeve is then spliced onto the bars,

(- by a swaging procedure, using a hydraulic side or bench press and swaging the sleeves onto the bar by a series of overlapping pressings.'

Enough room must be left on the job site to insert the Bar-Grip press between

{ adjacent rows of reinforcing bars. The minimum " setting out" dimensions-required for this purpose are given in [11) and shown in Fig. ' 3.2.. If such-is-

/ not the case, then Bar-Grip Couplers can_ be-" half-spliced" in the fabricating L- shop. 'For this latter case, the second half of the splice is completed on the-L

-job site. Wreaded couplers can also be used, if necessary, c

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Figure 3 1. Dayton Bar-Grip Plain Coupler Configuration.

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Minimum Setting Cut Cimensions (accompanying tables fer Bar-Grip Couplers)

H = height for bar above ccncrete FU '

S = centersof bars

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! T = centerof rows of bars

[ X = height of one row above ancther

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'~:H

. T lm l l U = distance of row frem structure

~ t ~ L L  : Note: These measurements assume

:  : : .  : L i the cuter die is remcVed clear of

_ the coupler. Rear bars are S T completely spliced !!rst.

Singte Rcw Ccuble Row Weights and Access Measurements for Bar-Grip' Couplers Casaler Lasqtas Retar Bar Gris Press Nominal Average Cavaler Minimum Settlag Out Otmersions SL's To Se uses lattial Final Westat M 3 7 X U

.n.!mmt in. (nm) lb. tag) in. imm) in.imm) in it-mt in. imm) in. f mmt 5 Ece P*ess SG750 3" i%) 3%iE6) 0.48 (0.2 1 4%i120) 2% iTC) 4W 8115) 5% v15S 5 % i150) 5 3 ce ? ess SG750 3% e 95) 4#102) 0.35 +0.39) 5(125 3 e7S 4%i120) 7t150) U% 4160) 7 Sice P ess dG750 4*,.4110) 4 % 117) 1.24 0.56) 15:125) 3175) 5:12 S  !:2001 i 'a t t SS I Sce sess 9G750 5:1271 5%et:51 1.31,0.52) 5:150) 3% # 30) 5%d'306 5 % i220: 5 % i '55) 3 SicesessSG1140 51:27) 5 % 41351 1.31 0.32) SWt165) 4W i105) 5 ti!S ava i240) 1H:2:51 9 Sice cress SG1140 5 m 140) 5(152) 2.43 (1. 01 7 ;17 S 4% 105) 5 % 150) 0 % i250) IN 2 S to 5ce sess 5G1140 $=,.it$0) 5 % 4172) 3.481.53) TN i190) 4W it:01 55:155) 11:27 S 3% i2001 11 5ce Press SGt140 5%1TS 7% t118) 4.4212.31) 5 % i205) 4%i120) 5 % i170) 12: CC) ine220) to Ece ?*ess 3G1140 3"'.. 220) 3h:223) 1.23 3.73) 3% i2:0) 446120) 7 '75) 14 255) 3*22 S tS 5de 7ms SG1157 11 % 238) 12 % .324) 19 5013.39) 12(;001 SY 1135) 912 5) t 5% .465) 11 ,250)

Figure 3 2. Minimum Setting Out Dimensions for Bar-Grip Couplers.

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3.2 MANJFAC11

RING PROCESS I l The Bar-Grip sleeves are manufactured from seamless steel tubing that conforms to the requirements specified in ASTM A-519. The sleeves are available in j sizes compatible with tio. 5 through No.18 reinforcing bars.

As discussed in [11] and Appendix A, DBI supplies a series of Bar-Grip Side and Bench Presses for use in the installation of the Bar-Grip splice system.

The Side Press is available in three models and can be used to install splices for all sizes of rebars. Two Bench Press models are available. One of these models is used to install No.14 splices and the other is used to install J j No. 18 splices.

I The special dies used i' the various presses described above are supplied by j DBI to suit a particular size of sleeve and are stamped with a number corres-pending to the rebar size and press.

In addition to providing the coupler sleeves and presses, DBI will supply all l necessary hydraulic pumps and auxiliary equipment, including spring load j balancers to provide fingertip control of the positioning of the press over u the sleeves and around the bars on the construction site. These balancers can {

be suspended from the rebar to be spliced or from suitable scaffold equignent 3 l

which may be in use for other functions on the job site. g l

3.3 CUALITY ASSUPRXI DBI states that their Bar-Grip System has met the following industry specifi- l cations [11]: ASME Section III, Division 2 (ACI 359-80 with Summer 1980 g Addenda) [4]; ACI 349-80 Nuclear Design Code [2]; U.S. Army Corps of Engineers 3 i Typical Specification; ACI 318-77 Building Code [8]; Canadian Standards Asso-ciation Nuclear Cede, CSA N287.3. ]

4 No specific quality control manual or set of quality control procedures on either the manufacturing or installation of the splice system has been pro-vided for use in preparing this report. DBI has indicated that they do not i normally write such manuals / procedures although they would if they were asked to. Such a manual wculd be a useful tool for providing a uniformly installed and verifiable product. Rather than write such manuals, DBI identifies the guidelines to be followed when installing their splice system in design brochures [11] and operating manuals [12] and subsequently expect the con- 1 struction project manager to develop specific documentation.

Quality assurance of the connection involves: .

i

1. Confirming that a minimum pressure of 10,000 psi has been reached by the hydraulic press during installation,

2. Measuring the initial and final nominal average coupler lengths,

3. Determining the number of bites indented on the sleeve, and

! 4. Determining the insertion length of the rebar into the coupler i

sleeve.

I 3-4 i

The Bar-Grip sleeves are identified by a stamp on the sleeve indicating the size of bar for which the coupling is intended, the heat lot number, and a Bar-Grip identification code. The sleeves are packaged in containers that are labeled with company name and address, product name, item, quantity, bar size and identification mark.

An operating manual for the Bar-Grip hydraulic press has been written by DSI

[12] to govern the use of the various hydraulic presses and to specify proce-dures for installing the splice system. Dies are supplied in different sizes to suit different sizes of sleeve. Each die is stamped with a number for identification so as to ensure that the correct die has been used for a particular size of sleeve.

DBI has specified that the minimum design pressure exerted by the hydraulic press to make a good connection in the coupler is 9,700 psi. They recommend that the pressure be set to 10,000 psi and to have a 300 psi permissible fluctuation during pressing. DBI describes that an oval shape, rather than an octagon shape, would be formed on the coupler if the swaging pressure was inadequate. Conformance to specified pressure requirements can, therefore, easily be assured by visual inspection.

DBI further states that, if inadequate pressing is found, the coupler can be re-pressed to acquire the desired 10,000 psi swaging pressure. This will avoid the need for cutting the rebar due to incorrect pressing pressure.

EBI recommends that a trial run be performed using off-cuts of rebar. During the trial, the pressure gauge on the hydraulic pump should be checked to assure that it registers up to 10,000 psi at full load. The frequency of performing this test has not been stated.

Finally, DBI statas that no special requiremet.hs must be adhered to when installing the Dayton Bar-Grip Splice System under adverse environmental conditions (e.g., moisture, temperature, dirt, etc.) beyond those which would normally be maintained on a construction site. For example, although there would be no requirement to wire brush the coupler to remove rust before installation, there might be a requirement to wipe the coupler off with a

, cloth or brush to remove loose material as a matter of good " housekeeping" practice.

3.4 INSTALIATION PROCEDURES Ease of installation is one of the principal advantages claimed for the Bar-Grip plain coupler. DBI states in theic brochure [11] that a worker could be trained to install these couplers in less than one hour. DBI also states that the installation of their plain coupler requires no heat and no bar end preparation, and that it can be applied in any weather condition, even under water.

Although DBI supplies two types of coupler, the Bar-Grip plain coupler and the Ear-Grip Threaded Coupler, only the plain coupler is evaluated in this report.

The Bar-Grip plain coupler is used to join two high yield, ribbed reinforcing bars. Since the coupler utilizes a swaging process rather than a thread or other positive interlock mechanism, the two bars to be connected can be 3-5

completely free to rotate, if required, immediately prior to installation.

The Bar-Grip sleeve installation process uses an hydraulic press which is calibrated to the force required to swage the sleeve onto the two bars to be joined. Each bar size has a particular sleeve that varies in inside diameter and length in accordance with the size of the bar to be joined. End prepara-tion of the bars is generally not necessary beyond cursory hand wiping or brushing as noted above.

There are currently two types of Bar-Grip press available (A third type of press, the Bar-Grip Draw Press, was formerly used, but is no longer, due to a recent redesign of the Bar-Grip press.) [9]:

1. The Bar-Grip Side Press, which is designed for bars up to size

1. 18, swages the coupler sleeve to the end of the bar in a series of side--action squeezes; and

2. The Bar-Grip Bench Press, which can handle rebars in sizes #5 to

1. 18, is used primarily in the fabrication shop to half splice couplers so bars are ready for final coupling when they reach the job site.

i Following installation, outside inspection personnel can visually examine the coupler by measuring the length of rebars being pressed, the number of inden-I tation marks on the coupler and the shape of the coupler after pressing.

! When pressing the sleeve on-site, the press should be supported by a chain fall or cable, which can be suspended from scaffolding or other convenient support. This supports the weight of the press, leaving the hands free to locate the die accurately.

, The following steps are performed when properly installing the coupler:

a

! 1. Pittino Solice or Counler Off Site i

i (a) Place a chalk mark or wire tie on the bar at a location equal to half of the length of the sleeve as shown in

, Fig. 3.3 (a) . (Note - This is most importanti)

(b) Coat the inner and outer pressing dies with Release Agent to prevent the sleeve sticking to the die after the splicing operation.

(c) With the press supported on a bench or by a chain fall, the bar is inserted between the dies and a sleeve is placed over i

the end of the bar to the mark or wire. The sleeve should

, be positioned in the press so that the right end of the die jaws will make the first swage at or slightly to the left of

! the center of the sleeve as shown in Fig. 3.3 (b). This swage is shown in Fig. 3.3 (c). The remaining swages on the l first rebar can be completed on the site when the second rebar is coupled. Measure accurately for the first rebar swage. The sleeve should not be swaged beyond the end of the bar in the sleeve, since this will prevent the second j

3-6 q l

I I l Chalk Mark cr Wire ~le to i + t inc of Sleeve il l' i N i 3;g, NScuate cut Fecar

(a) i my e

~ __- . _- w

Sice Arm ci, Side Arm

/ l L N\ \_ \ \ \ \ \ \\\ \ \ \\\\ NN kW__J- V L . - ,L gbilium, C

! l N\\ \ \\ \\ \\ \ \ \\\\ \ M

_1 Aetnforcing ,;, s\ev, t

Sar P V ,_ g -

i

]

(b) i Bar Being Swaged

_ v\ *-First Swage Position 1

x \/

n , - ; ... - _

+- ~ n a

- ,- ,- , - g i 2 r, , ,,,

Unswaged Bar f t_

(c)

Figure 3 3 Installation or Osyton Sar-cri; Ccuplers.

3-7

/

Last Swage Positfen l

[ ]

Cie Pressed Sleeve 1 \, ,

@rJ_b){J89'

.. _. ... .~ ,= - .

- s. ... % -~~n.s -

bif5 _u h[k-%&*Ja@N!~

'- _ A_

1 hZ l'"d~ - -

.T 3/32 - 3/16 In. (2-5 mm) Overnang Recar (d) t Canter First Site ',

i

'r l

- _ L. :' --..,-- m q ~- - m.x' !_ - _ .4@,w

_3

• i a a . . ~-

Y,Y ,

7,

/ - Y-~ .ht;$ .k t

~

l I - -

'1 xW.m.% . _^-j_ & 2W&s&f- _

aw l i

i (e)  ;

i l

l 1

1 l

l l

l Figure 3 3 Installation of Dayton Bar-Grip Couplers (Cont'd).

1 3-8

l

-t rebar' from butting to the first; and, the second rebar will

j. have a shorter swage length.

(d) Activate the pump. . Activate the press with the hand or foot switch. The inner die is pushed forward by the hydraulic

ram until:it reaches the sleeve. The dies then compress the

! sleeve until the maximum operating pressure of 10,000 psi  ;

l -(700 bars) is reached. The hydraulic pump will automati-

cally release at 10,000 pai. . The pump switch _ should then be-released. If, at any time before full pressure is reached,

the operator sees that the bar or sleeve have slipped out of i alignment; or, if anything becomes trapped in the press, the i switch should be released and the ram will react immediate-f 1Y+

e

2. Fr==lation of na1r m11e. an sie.

4 i (a) Coat the inner and outer pressing dies with Release Agent to i prevent the sleeve sticking to the die af ter the splicing

operation.

}

} (b) If the reinforcement is vertical, the bar with the half.

1 swaged sleeve is located above it and lowered until the j fixed reinforcing bar butts'up to the bar inside the sleeve.  ;

j. The weight of the new bar will ensure that the ends of the'-

+

bats will. remain in contact'until the swaging is started.'

l (c) If the reinforcement is horizontal, there is a possibility

! that the ends of the bars may not be in contact when press-4 ing is started. As a guide, place a chalk mark on the j second rebar the same distance as on the first bar (equal to

one half sleeve length).

j (d) The first bite should be made in the center of the sleeve.

j Bites should then be made progressively out to both ends of i the sleeve with 3/32 to 3/16 in. (2 to 5 mm) die overhang -

! beyond the end of the sleeve as shown in Fig. 3.3 : (d). All l bites must overlap,

j. 3. 21(cina Both Rarn At m e % a-1 i (a) Coat the inner and outer pressing dies with Release Agent to -

j prevent the sleeve sticking to the die af ter the' splicing j operation. ,

! (b) On-site splicing of both bars at one time can be done if desired. Wire tie the lower bar for vertical splicing to -

hold the sleeve as previously explained. Chalk marks can be F -used on the bars for' horizontal splicing. Start in the i middle of the sleeve.and work out to one end. .Then come i back and work from the middle toward the other end as shown f

in' Fig. 3.3 - (e). -

1-3-9

l-f l

' Itis page is intentionally blank.

}

O 3-10

i 4.0'>m +r JamLYSIs a

This section includes a discussion of the process through which loads are r transferred between the spliced reinforcing bars.through the Bar-Grip splice j syatem.

t Since no specific engineering analysis was provided by mI for use in perform-

! . ing this evaluadon, the following discussion reflects SAI's'. understanding of I

the behavior of the Bar-Grip splice system. It should be noted that such an analysis is not required by any of the reinforced concrete design codes dis-p cussed in this TER.

l As previously discussed, the Bar-Grip splice system uses a concept in which a j steel sleeve is swaged around the rebars to be spliced. This swaging process

forces the sleeve around the deformations in the rebar thus locking the sleeve

! to the rebars. Because of this, the loads to be transferred between the

! rebars are transferred primarily as normal loads between the deformations in

! one of the rebars and the splice sleeve, through the splice sleeve, and i finally as normal loads between the deformations in thec other rebar and the j splice sleeve. These loads are shown schematically. in Figs. 4.1 and 4.2 as

[ the force notation F. Figure 4._1 illustrates the transfer of tensile loads

[ and Fig. 4.2 illustrates the transfer of compressive loads.'

1

! An alternate load path would be for the loads to transfer'between'the rebars

{ and' splice sleeve through friction along their contact surface. This load path, which is also shown schematically in Fig. 4.1 by the forces P and Pf ,

~

j would only be effective if the residual radial pressing forces, P, -were -large 1 enough to develop a significant friction force, F .f Since the magnitude of '

l this residual pressing force would probably be difficult to predict with any >

degree of accuracy, it would probably be best not to assume that this load l- path exists when determining the load carrying capability of the-splice..

p i

i l

\

t e

i 2

4_1

= = _ _ _ - _ _ _ _ _ _ _ _ . . -. - . .- ... - - . - .- .-_ . . - -

T RADIAL PREl oAD -

p CUE To PRESSIMe r 9 sr 4 7 Tr Tp 'T FCSSISLE FiticTlert FoKcaS (NELECT) 1 N' I- O B//A v4% //4WA+

L 3 Figure 4.1.. Schematic Representation of Tensile Load Transfer.

u2 <

i I  !

I  ;

cce m esmme (RADIAL PRELcAD i ,,e < 1, rossists wxicTioH FOAC55 (NEqLECT) y .f r

I w e l _h((/RE9^R) A y((t on , R EBA K, 2 s  !

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i

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I 4-3 o

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S This page is intentionally blank.

4 4-4

i 5.0 TEST RP5lIW5E Engineering structures are rarely loaded to levels that cause material failures. For this reason, the fact that a particular new material or product j is being used in such a structure is not necessarily a good measure of a system or material's capability. Testing of full-size specimens or simula-tions of actual components has, therefore, become a generally accepted method of evaluating new materials and products. The Dayton Bar-Grip splice system has been evaluated using such an approach.

These evaluation tests have been performed both directly for Dayton Barsplice, Inc. (DBI) or their parent company, CCL [13-18], and under the auspices of potential users of the splice system [20-22]. Many of these tests have been performed for DBI by the independent testing laboratory of Wiss, Janney, Elstner and Associates, Inc. (WJE) of Northbrook, Illinois. A portion of the tests performed by WJE to demonstrate conformance of the splice system to applicable codes are summarized in this section together with a description of a series of installation tests performed to simulate the preparation of splices under adverse conditions that might occur at a construction site.

It should be noted that each of the tests described in this section were witnessed by representatives of United Engineers and Constructors (UE&C), who

) are responsible for the design and construction of the Seabrook Nuclear Power Plant.

5.1 INSTALLATIN 'ITETS

[ Each of the tests performed by WJE used bars which were spliced, under adverse conditions, by DBI. These adverse conditions were selected to simulate condi-tions which might occur at a typical construction site. It should be noted that these conditions would, generally, not occur under a vigorous inspection and quality assurance program.

The following procedures were carried out during the preparation of test bar splices to simulate adverse conditions:

1. 'Ibe bar ends were immersed in water prior to being inserted into the sleeve.

2. Bars No. 5 through No.14 were deliberately mis-inserted by one-half bar diameter each.

3. No.18 bars were deliberately mis-inserted by one inch.

4. Pressing was done at the lowest' permissible hydraulic pressure specified by DBI in their installation procedures (i.e., 9,700 psi) .

5-1

/- .

5.2 . PERPORMANCE TESTS i As previously mentioned, DBI has conducted a series of performance tests of tensile splices at WJE [13-15]. These tests were performed to evaluate the Bar-Grip plain coupler for conformance with the ASME Section III, Division 2 (ACI 359-80 with Summer 1980 Addenda), ACI 318-77 and ACI 349-80 Codes as well i

as typical splice requirements of the U.S. Army Corps of Engineers. These tests, which are summarized in the following subsections, were performed on

splices that had been installed under adverse conditions as described in the previous section to simulate conditions that might occur at a typical con-struction site. It should be noted that, although all WJE test data provided

, to SAI by EBI has been reviewed, only the data from the most recent WJE test t

report [13] has been summarized in the various tables included with this

, Section of the TER.

It was concluded that, unless specifically noted otherwise, the performance '

tests described.in this section are sufficiently complete so as to be an acceptable demonstration of the quality of the Dayton Bar-Grip plain coupler for use on the Seabrook Nuclear Power Plant. This conclusion is discussed -

mere completely in Section 6.3.

}

5.2.1 Code Requirements ,

i As previously discussed, tests have been performed on the Bar-Grip splice l system to evaluate its conformance to several codes. Two of these codes, the  :

i ASME Section III, Division 2 (ACI 359-80 with Summer Addenda) [4] and the ACI  !

, 349-80 [2] codes, relate directly to nuclear power plant construction. The l discussion in the remainder of this section will be restricted to an I

, evaluation of the conformance of the Bar-Grip system to these latter two i codes.

The ACI 349-80 Code [2] specifies that the splices must develop in tension or -

) compression, as required, at least 125 percent of the specified yield strength j l of the bar. 'Ihis code further specifies that mechanical connections shall be'  !

l qualified for use on the basis of a series of performance tests. 'Ibese' tests  ?

j must include a minimum of six static tensilo tests and three cyclic tensile .

i tests. During the cyclic tests, the bar-to-bar connection specimens for each  ;

reinforcing bar size and grade being evaluated must be subjected to 100 cycles  !

of tensile stress variations from 5 percent to 90 percent of the specified minimum yield strength of the reinforcing bar. Furthermore, the specimen i shall be tested statically to failure following the cyclic tests to demon- l strate that no loss of static tensile strength occurs when compared with like i specimens from static tensile strength tests.

• As discussed in Section 2.2, the ACI 349-80 Code also requires that mechanical 'f connections must be staggered relative to connections of adjacent bars if both j the unit strain over the full length of the splice at 90 percent of the yield i strength of the bar exceeds 0.003 in.- per in. (i.e., 0.3 percent) and the '

maximum computed design load stress at the connection equals or exceeds 50 '

percent of the yield strength of the bar. -

l 'Ihe 1980 Summer Addenda to the ASME Code [4] contains a number of performance I test requirements that must be satisfied to qualify mechanical splice systems  ;

5-2

l 4

j for use in the construction of nuclear power plant components. %ese perfor-3 mance test requirements include both static tensile tests and cyclic tensile i tests. This edition of the ASME Code is the first edition of this code that

permits the use of mechanical reinforcing bar splices of the type evaluated in this report. This permission was granted _ through the incorporating of Code

} Case N-185 [5] into the code.

1

! The ASME Code specifies that each of these tensile and cyclic tests must be performed on specimens of each bar size and splice type to be used in con-struction. Six splice specimens for each bar size and splice type must be i tensile tested to failure and three specimens for each bar size and splice

! tyg must be subjected to the low cycle tensile test. For swaged splices, the 6

ASME Code further specifies that three different deformation patterns shall be used for each bar size tested. Table 5.1 lists the reinforcing bar manufac-

turers and their respective deformation patterns for each size of splice used j to run the performance tests described in this report.

] he ASME Code also specifies that the average tensile strength of all of the i splices tested shall not be less than 90% of the actual tensile strength of j the reinforcing bar being tested nor less than 100% of the specified minimum j tensile strength of the bar, and that the tensile strength of an individual

splice specimen shall not be less than 125% of the specified minimum yield j strength of the spliced bar.

%e specified minimum strength values for the ASTM 615, Grade 60 reinforcing

bar material which was used for all of the performance tests is

i 4

Minimum Yield Strength, fy = 60 ksi

) 125% of Minimum Yield Strength, 1.25fy = 75 ksi 1

Minimum Tensile (i.e., Ultimate) Strength = 90 ksi l

j te ASME Code further states that each individual test report on the spliced

! and unspliced specimens shall include, as a minimum, information on the ten-i sile strength of the material, the total elongation at failure, and a load-1 strain curve up to a minimum of 2% strain. Implicit in this statement is a i requirement that the total elongation at failure be measured and recorded to j be at least 2%.

l 5.2.2 Unspliced Rebar Tests l A series of tensile tests were run on samples of unspliced rebar to determine l tensile strength, elongation, and load versus strain data for bars that would l subsequently be used for coupler performance tests. This data was required to i support the performance tests since the ASME Code [4] and Code Case N-185 [5]

j require that the average tensile strength of splice specimens shall not be less than 90% of the actual tensile strength of the reinforcing bar being j tested. The data resulting from this series of tests is summarized in j Table 5.2.

l 4

t i 5-3 1

-Table 5.1. Rebar Manufacturers and Deformation Patterns.

Rebar Size Rebar Manufacturer Deformation Pattern 5,6,7,10,11 Armco Crescent Bethlehen Diagonal

~ North Star Slant 8 Armco Cross Hatch Bethlehen Diagonal North Star Slant 14 Armco Cross Hatch Bethlehen Diagonal Marathon Horizontal 18 Armco Cross Hatch Bethlehem Diagonal Marathon Slant

\

j 5-4 s

.~

4

[

Table 5.2. Stmaary of Unspliced Rebar Tensile Tests.

90% of Strain Number Ultimate Ultimate at Elongation Bar of Tests Deformation Stress Stress 0.9 fy at Failure

( Size Performed Pattern (ksi) (ksi) (Percent) (Percent) t 5 1 Diagonal 105.8 95.2- 0.238 13.9 1 Crescent 103.2 92.9 0.236 12.7 1 Slant 105.5 95.0 0.215 14.6 6 1 Diagonal 113.4 102.1 0.186 14.2 1 Crescent 112.5 101.3 0.165 14.1 1 1 Slant 108.0 97.2 0.184 15.8 7 1 Diagonal 110.3 99.3 0.205 14.3 1 Crescent 105.7 95.1 0.205 15.8 1 Slant 113.0 101.7 0.197 13.9 8 1 Diagonal 105.7 95.1 0.201 12.6  ;

1 Cross Hatch 105.9 95.3 0.194 14.9 1 Slant 101.1 91.0 0.203 16.0 9 1 Diagonal 109.3 98.4 0.191 13.3 1 Crescent 106.5 95.9 0.196 15.8 1 Slant 103.8 93.4 0.199 12.6 10 1 Diagonal 105.1 94.6 0.190 11.6 1 Crescent 106.9 96.2 0.185 15.7 1 Slant { 110.5 99.5 0.197 13.8 i

11 1 Diagonal i 103.7 93.3 0.204 11.3 1 Crescent l 105.4 94.9 0.193 15.0 1 Slant 111.4 100.3 , 0.197 13.0 14 1 Diagonal 105.3 94.8 0.173 15.6 1 Crescent 108.9 98.0 0.201 11.0 1 Horizontal 99.8 89.8 0.197 11.9 18 1 Diagonal 105.8 95.2 0.190 12.2 1 Crescent 102.5 92.3 0.181- 11.9 q 1 Slant 110.4 99.4 0.180 11.9 i

l 5-5

5.2.3 Static 'Nnsile Tests As seen from Table 5.3, static tensile tests have been performed using No. 5 -

through No.18 rebar and for a variety of deformation patterns. Most of the results cbtained during these tests demonstrate the conformance of the coupler design to code requirements. However, several a@arent abnormal tests were -

observed. i Two relatively low ultimate strength values were documented in these test _

results. One occurred with a No.10 rebar which had a diagonal deformation -

pattern. This rebar pulled out of the coupler at an ultimate strength of 87 -

ksi. The other low ultimate strength value involved a No.14 rebar which had a horizcntal deformation pattern. This rebar p211ed out of the coupler at an  ;

ultimate strength of 86 ksi. Although both of these low strength values -

indicated that the specimen ultimate strength was less than 90% of the actual tensile strength of the unspliced rebar being tested, the average ultimate _

r strength of both of the specimens being tested for each particular size and type of reinforcing bar being tested did exceed appropriate code requirements and thus these low values did not constitute a code nonconformance. Further- -

more, both of these low strength values exceeded 75 ksi and, consequently, were more than 125 percent of the specified minimum yield strength of the spliced bar.

Several strain-related nonconformances were documented in these test results.

Six of the specimens exhibited a total strain at 90 percent of tha specified yield strength of the unspliced bar that was greater than 0.3 percent. These -

six specimens involved No. 5,7, 9 and 14 splices. Only one of these noncon-formances exceed requirements by more than 10%. This latter case involved the same No.14 test specimen with horizontal deformations and failed in pull-out mode discussed above that had a low ultimate stress. -_

'Ihe ASME Code specifies that the individual test report for each splice speci-men test must contain the total elongation at failure. This data has not been -

provided for more than 25% of the specimens (15 specimens out of a total of 54 specimens). The apparent reason for the failure of WJE to provide this data is that the specimens in question failed in bar pull-out mode. It would be difficult, if not impossible, to accurately determine total elongation for such a failure since it might not be possible to put the failed specimen "back together" temporarily for purposes of measuring total change in length in such a case. However, it is suggested that an estimate of total elongation could i be made for such pull-out cases and, as such, it is recommended that DBI be asked to provide further data regarding total elongation for the specimens in question. One way to make such an estimate would be to saw cut the splice longitudinally after failure and measure the elongated length of the recon-structed samplc between previously established marks.

Another nonconformance was that the load-extension curve for approximately one-half of the samples tested had not been carried out to a minimum of 2%

strain as required by the ASME Code [4). WJE states in (13] that this was done to avoid possible damage to the extensometer that was used to record the load-strain data. Again, this could be estimated by other means. It is recommended that DBI be asked to furnish data confirming that the 2% strain requirement specified by the code has been satisfied prior to permitting the '

use of the Dayton Bar-Grip Splice System in nuclear power plant construcM.on.

5-6

l Table 5.3. Sumary of Plain Coupler Static Tensile Tests..

Splice -Strain Number Ultimate at. Elongation Bar of Deformation Stress .0.9 fy at Failure Failure Size Tests Pattern (ksi) (Percent) '(Percent)- Mode 5 2 Diagonal Min. 109.4 0.156 4.6 Bar Break Max 109.7 0.187 4.3 Bar Break Avg 109.6 2 Crescent Min 102.9 0.332 2' 7.3 Bar Break Max 105.5 0.270 5.0 Bar Break Avg 104.2 2 Slant- Min 105.8 0.228 6.7 Bar Break Max 106.1 0.273 5.6 Bar Break-Avg 106.0 6 2 Diagonal Min 110.9 0.151- 4.1 Bar Break Max 112.5 0.168 (4) Pull Out Avg 111.7 2 Crescent Min 104.5 0.164 (5) Bar Break Max 113.2 0.153 5.6 Bar Break Avg 109.0 2 Slant Min 107.7 0.196 5.3 Bar Break Max 108.4 0.176 5.0 Bar Break Avg 108.1 7 j 2 Diagonal Min 109.8- 0.155 4.1 Bar Break-l Max 110.7 0.192 3.7 Bar Break Avg 110.3 2 Crescent Min 101.7 0.3302 (4) Pull Out

{- Max 106.3 0.3022 5.3 Bar Break I . Avg 104.0' 2 Slant Min 106.3 0.209 (4) Pull Out Max 110.2 0.240 (4) Pull Out Avg. 108.3 1

5-7

Table 5.3. Sumary of Plain Coupler Static Tensile Tests (Cont'd).

Splice Strain Number Ultimate at Elongation Bar of Deformation Stress 0.9 fy at Failure Failure Size Tests Pattern (ksi) (Perce6t) (Percent) Mode 8 2 Diagonal Min. 105.9 0.170 4.3 Bar Break Max 106.3 0.141 3.8 Bar Break Avg 106.1 2 Cross Hatch Min 104.6 0.202 (4) Pull Out Max 105.7 0.170 5.0 ' Bar Break Avg 105.2 2 Slant Min 100.8 0.236 4.5 Bar Break Max 102.5 0.214 4.7 Bar Break i Avg 101.7 9 2 Diagonal Min 106.0 0.158 3.9 Bar Break Max 108.0 0.189 4.7 Bar Break .

Avg 107.0 2 Crescent Min 105.5 0.214 (4)  ! Pullout .

Max 106.0 0.3052 (4)  ! Pull Out '

Avg 105.8 i 2 Slant Min 104.0 0.214 (4) Pull Out '

Max 104.5 0.229 (4) i Pull Out Avg 104.3 I l I

! Diagonal 10 2 fMin 86.61 0.298 j (4) Pull Out l Max 106.7 0.197 l 2.6 Bar Break i Avg 96.7 j i  :

2 Crescent Min 106.7 0.187 4.8 Bar Break Max 107.3 0.187 >

5.3 Bar Break Avg 107.0 I I

2 Slant Min 105.7 0.208 3.5 Bar Break Max 109.1 0.211 10.1 CouplerBreakl Avg 107.4 l

l

5-8

L g Table 5.3. Summary of Plain Coupler Static Tensile Tests (Cont'd).

L Splice Strain Numbet Ultimate at Elongation f

L Bar Size Tests of Deformation Pattern Stress (ksi) 0.9 fy (Perceht) at Failure (Percent)

Failure Mode r

L 11 2 Diagonal Min 104.7 0.187 5.3 Bar Break Max 104.7 0.213 4.9 Bar Break Avg 104.7 k 2 Crescent Min 97.4 0.253 (4) Pull Out Max 102.9 0.268 (4) Pull Out F Avg 100.2 L

l 2 Slant Min 102.4 0.231 3.9 Coupler Break

! Max 106.3 0.263 (4) Pull Out Avg 104.4 1

14 2 Diagonal Min 104.4 0.199 6.0 Coupler Break Max 104.4 0.202 5.9 Coupler Ereak Avg 104.4 2 Crescent Min 105.3 0.255 6.1 Coupler Break Max 107.8 0.220 6.8 Coupler Break Avg 106.6 2 Horizontal Min 85.61 0.426 2 (4) Pull Out Max 97.1 0.3202 (4) Pull Out Avg 91.4 l 18 3 2 Diagonal Min 102.6 0.180 2.8 Bar Break

( Lx 104.4 0.170 5.5 Coupler Break Avg 103.5 2 Crescent Min 103.0 0.166 4.2 Bar Break Max 104.9 0.210 3.6 Coupler Break Avg 104.0 2 Slant Min 107.1 0.155 5.2 Coupler Break Max 107.4 0.150 4.8 Coupler Break l

Avg 107.3 5-9

Table 5.3. Stenary of Plain Coupler Static Tensile Tests (Cont'd). l Splice Strain Number Ultinate 'at Elongation Bar of Deformation Stress. 0.9 at Failure Failure

, Size Tests Pattern (ksi) (Per t) (Percent) Mode i

Notes: 1. Splice tensile strength less than 90% ' of actual tensile strength of rebar being tested.

2. Strain is greater than 0.3 percent.

l 3. The No.18 splices were made with a special 14 inch long sleeve

that was designed specifically for nuclear applications.

l 4. Elongation not measured due to bar pull-out.

l

5. Reason not given for not measuring elongation.

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5-1.0

I k

l c 5.2.4 Cyclic Load Tests Three cyclic tests were run on bar-to-bar splices in order to satisfy the code requirements discussed in Section 5.2.1. Results from these tests are summar-I ized in Table 5.4.

The ASME Code [4] requires that three specimens of the bar-to-bar splice for r each reinforcing bar size and grade splice type to be used in construction be L subjected to a low cycle tensile test. For swaged splices, the code also requires that three different deforma: ion patterns be used for each bar size

/ tested. Each specimen murt withstand 100 cycles of stress variation from 5%

( to 90% of the specified minimum yield strength of the reinforcing bar. One cycle is defined as an increase from the lower load to the higher load and return. 'Ite only failure criteria specified in this code is that the specimen must " withstand" the applied cyclic load.

{

The ACI 349-80 Code [2] is similar to the ASME Code. However, the ACI 349-80 Code is more specific in its requirements in that it specifies that the

[ specimen must be tested statically to failure after completion of the cyclic tests and that each specimen should show no loss of static tensile strength capacity when compared with like specimens used in the static tensile strength

( tests.

As seen from Table 5.4, each specimen withstood 100 cycles of stress variation and, therefore, satisfied the applicable ASME Code [4] cyclic load test re-

[ quirements. However, almost half of the specimens failed to satisfy the ACI 349-80 Code [2] in that the specimen static tensile strength capacities after e cyclic tests were shown to be lower than the values for like specimens in

( static tensile strength tests as previously given in Table 5.3. Considering only those specimens showing strength reduction after cyclic tests, it is found that the strength reduction was an average of 1.9 ksi (minimum 0.1 ksi,

[ maximum 7.3 ksi). Since these strength reductions were quite small and since none of these strength reductions resulted in, ultimate strengths below those permitted by the applicable codes for static tensile tests, it is recommended that this code nonconformance should not be used as a basis for rejecting the

[ use of the Dayton Bar-Grip coupler on nuclear plant construction projects.

(

5-11 l l

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Table 5.4. Strrnary of Plain Coupler Cyclic 'Ibnsile Tests.

l l

Number Ultimate Stress 1 Bar Ceforr:ation of Stress Variation Size Pattern Tests (ksi) (ksi) Failure Pzxles l

5 Diagonal 1 108.1 2 -1.5 Bar Break Crescent 1 106.1 1.9 Bar Break l Slant 1 105.82 -0.2 Bar Break 6 Diagonal 1 110.0 2 -1.7 Bar Break Crescent 1 113.2 4.2 Bar Break Slant 1 108.6 0.5 Bar Break 7 Diagonal 1 110.0 2 -0.3 Bar Break Crescent 1 104.5 0.5 Bar Break Slant 1 113.2 4.7 Bar Break 8 Diagonal 1 106.2 0.1 Bar Break Cross Hatch 1 105.6 0.4 Pull Out Slant 1 101.4 2 -0.3 Bar Break 9 Diagonal 1 106.5 2 -0.5 Bar Break Crescent 1 101.0 2 -4.8 Pull out Slant 1 105.3 1.0 Bar Break 10 Diagonal 1 107.5 10.8 Bar Break Crescent 1 108.3 1.3 Bar Break Slant 1 103.5 2 -3.9 Pull Out 11 Diagonal 1 105.8 1.1 Bar Break Crescent 1 99.0 2 -1.2 Pull Out s Slant 1 107.1 2.7 Coupler Break 14 Diagonal 1 104.4 0.0 Coupler Break Crescent 1 99.3 2 -7.3 Pull Out Horizontal 1 97.3 5.9 Pull Out 18 Diagonal 1 104.8 1.3 Coupler Break Crescent 1 103.7 2 -0.3 Bar Break Slant 1 106.22 -1.1 Coupler Break Notes: 1. Stress variation values were obtained by subtracting the s average ultimate stress of like specimens in static tensile i tests from the ultimate stress in cyclic tensile tests.

2. These ultimate stresses were lower than the ultimate stresses measured in like specimens in static tensile tests.

i 5-12

s h

e 60 DESIQi REVIDi This section summarizes data obtained during SAI's review and evaluation of the Dayton Bar-Grip Rebar Splice System design. Included is a general discus-sion regarding the adequacy of_the coupler design, a cummary list of current

' users of the splice system together with comments obtained from some of the users, and a number of conclusions. and recommendations regarding the accept-

. ability of the design for use in nuclear power plant construction applica-tions.

6.1 GENERAL DISCUSSION This design review was ' conducted by SAI at the request of the NRC. As back-ground information, SAI was provided with a number of documents by the NRC staff for use in this review. It was further suggested by the NRC staff that SAI contact DBI with a request for additional, more recent data. This request was made and Mr. Steven Holdsworth of DBI sent SAI a number of documents [9]

which were used extensively during the review.

Another valuable source of information used during this review was a presenta-tion made by Mr. Anthony Cave, President, DBI and Mr. Steven Holdsworth, Operations Manager, DBI [10]. This presentation included a general discussion regarding the design and use of the Bar-Grip splice system as well as the actual pr.eparation of a splice. DBI had made a similar presentation to members of the NRC staff in 1981 [25].

Several advantages and disad&antages of the Bar-Grip coupler design which were identified during this design review and which directly concern the safe use of the couplers are summarized in the following paragraphs.

A primary advantage claimed for the Bar-Grip splice system is the speed by which the couplers can be installed ir. the field by relatively unskilled labor. DBI claims that any construction worker can be trained to install a Bar-Grip splice in less than one hour. - The speed of installation claimed by the manufacturer of the coupler appears to be valid. The claim that the coupler installation procedure. can be taught quickly to any construction worker is also probably valid provided that appropriate inspection procedures are followed after installation.

Another advantage claimed for the Bar-Grip splice system is that the couplers can be installed under a variety of adverse conditions including bad weather (e.g., rain, snow, etc.), low hydraulic pressure, and non-square bar end cuts.

This advantage also appears to be valid as based on the splice installations witnessed by SAI.

One potential disadvantage of the Bar-Grip splice system is that a relatively bulky hydraulic press must be used to install the splice. The press used to install large splices (e.g., No.14 and No.18 splices) is particularly large.

This disadvantage would be most pronounced during the installation of splices at construction locations which are far above ground or which involve the 6-1 2..mi .

uw i

i l

l installation of splices in close proximity to adjacent rebars.

'Ibe Dayton Bar-Grip splice system has been reviewed by several potential users 3 for use on construction projects. Data generated under the direction of some -

of these potential users is included in [20-22]. A Research Report written by j the International Conference of Building Officials [19], who are the pub-lishers of the Uniform Building Code, states that the Dayton Barsplice Bar-Grip Systems for joining reinforcing steel bars are an alternate method of construction to that specified in the 1979 Uniform Building Code [7] provided }

that several conditions are satisfied concerning location, cover and inspec- {

tion. In [23] the City of Los Angeles has given its approval to the use'of the Bar-Grip system subject to conditions similar to those proposed by the International Conference of Building Officials.

l f i

6.2 CURRDTP USERS OF SPLICE SYSTDI

~

Bar-Grip couplers have been used for several years on a large number of construction projects, including several power plant projects both in the

United States and in other countries. DBI provided the representative list of such projects given in Table 6.1.

DBI also provided the list of references given in Table 6.2 of persons who have used the Dayton Bar-Grip Splice System. These persons have been involved with the evaluatim, testing, quality assurance, an4/or installation of Bar-

' Grip couplers and can be contacted for further information concerning the use

. of this splice system.

I 6.3 CCNCLUSIONS AND RECOMMDIDATIONS  !

i }

i It is concluded by SAI that the Dayton Bar-Grip Rebar Splice System is a l

. suitable system for use in the construction of critical facilities such as j nuclear power plants. Furthermore, it is our opinion that the Bar-Grip splice  ;

j system is at least as good as the other coupler design which is currently  ;

j accepted for use on nuclear plant construction projects. j i  !

Although the coupler design is considered to be acceptable, it is recommended  !

that the manufacturer be asked for further. substantiating data to resolve 1 several apparent code nonconformances that were observed during an evaluation 6 of performance test data before it is approved for general use in nuclear  :

plant construction. 'Ihese apparent nonconformances include:  !

1. Certain No. 7, 9 and 14 splices exhibited strains in excess of j 0.3 percent when loaded to 90 percent of the yield strength of  ;

the bar. Since the ACI 349-80 Code [2] states that splices which  !

exhibit this level of strain at 90 percent of the yield strength  !

of the bar must be staggered relative to connections of adjacent  ;

l bars, it is recommended that such staggering be required until such time as DBI provides an acceptable resolution of this non- ,

conformance for these bar sizes. l l 1

2. The total elongation at failure was not provided for several of l the static tensile test specimens as required by the ASME Code 6-2

. . -. a. - - , - - . - -- -.,--.---- -_____________A

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l Table 6.1. Power Plant Projects that have used Bar-Grip Couplers, l Location Project l Foreion Countries:

United Kingdm Torness Nuclear Pcwer Station l Heysham Nuclear Power Station  :

Windscale Nuclear Power Station '

France Flamanville Nuclear Power Station l Gravelines Nuclear Power Station Catten e Nuclear Power Station I Chinon Nuclear Power Station  :

Belleville Nuclear Power Station La Hague Nuclear Power Station Canada Bruce Power Station Nuclear Plant, Ontario Hydro Brazil Angra 11 Nuclear Power Station Foz de Areia Power Station South Korea Canatcza Nuclear Power Station ,

i Australia Tarong Power Station Erasing Power Station United States:

New Hampshire Seabrook Staticn Nuclear Plant, Outlet Tunnels l r i California Diablo Canyon Nuclear Plant, Retaining Walls  !

! Idaho Idaho Falls IAlclear Waste Disposal Plant t

I Louisiana Cajun Electric Coal Power Plant South Carolina Santee-Cooper Coal Power Plant i Kentucky J. K. Snith Power Plant I D. B. Wilson Power Plant Kansas Sunflower Power Plant E

l B

B e->

t i

i Table 6.2.. References supplied by Dayton Barsplice,' Inc.

k i  :

1. Hans Hasen Phone: (312) 855-7000 l' Harza Ehgineers 150 S. Wacker Drive Chicago, Illinois i

2. Fred Milsovic Phone: (301) 539-7950 -h Project Manager ~!

Kiewit-Raymond-Tidewater I Pt. McHenry Tunnel i Baltimore, Maryland l 4

3. Mr. H. B. McCoy Phone: (816) 523-1000 Massman Construction i Cajun Electric Power Plant t New Roads, Louisiana *

4. Mr. Richard Jarrett Phone: (813) 879-1711 l Greiner Engineering i 5601 Mariner Street Tampa, Florida i i ,

5. Mr. John Arrington Phone: (208) 523-1000 Arrington Construction -[;

Department of Energy  !

Idaho Falls, Idaho f

d t l

?

?

h i

4 5

b 6-4 n_________-___. -. - - , - . .- - . - . .. . .

i l [4]. DBI explained that this data was not available since the i specimens in question failed by bar pull-out and, consequently,

that an .'ccurate measurement of total' change in length could not

, be made since the failed bars could not be reinserted into the i splice. Since the code only requires that the total elongation

! be given at failure and since it does not give.any specific l requirement as to the magnitude of such elongation, it is felt j that DBI could easily have made an approximate measurement of 3

such elongation to c. degree of accuracy which would satisfy the

intent of the code. It is recommended that DBI be asked to i either provide additional data to satisfy this code requirement

or to provide an acceptable explanation regarding the absence of i such data.

i j 3. Several of the cyclic test specimens exhibited an ultimate stress  !

4 that was lower than the ultimate stress measured during static 1 tensile tests of like specimens. The ACI 349-80 Code [2] speci-i fies that there shall be no such reduction in strength after

! cyclic tests. It is recommended that this code nonconformance

! should not be used as a basis for rejecting the use of the Dayton

{' Bar-Grip coupler on nuclear plant construction projects since the i reductions in strength, as presented in.the cyclic test results, did not result in ultimate stresses below those permitted by any of the applicable codes for static tensile tests.

In addition to resolving the apparent code' nonconformances described above, it 1 is suggested that DBI be encouraged to develop a generic Quality Assurance

! Manual, together with related Quality Control Procedures, which could be used j by splice system users as a basis for writing appropriate manuals for their ,

specific construction project. DBI has stated that they would write such a

manual if asked to by the users of their splice system but that there has been

no need to do this up to the present time since each specific construction l; project manager writes his own such documents anyway.

j None of the recommendations presented should preclude the use of the Dayton

Bar-Grip Splice System at the Seabrook Nuclear Power Plant as requested by the j Public Service Company of New Hampshire provided that each specific usage be j reviewed and approved on a case-by-case basis. For example, if the specified i- usage is for No. 7, 9 or 14 splice,-it may be necessary to require that the -

i splices be staggered relative to adjacent connections. As another example, it may be necessary to make an especially thorough review of the construction managers Quality Assurance program regarding the use of this splice system pending the receipt of generic quality assurance documentation from IBI. .

}

i 1l f-6-5 4-

. , , 2., _ , _ . , , . . . . , - - . - . , , - ,~ ,, _ , ,,,,,-a, , . . , . ,

This page iS intentionally blank 6-6 .

. mm ices

l. Letter from J. DeVincentis, Project Manager, Yankee Atomic Electric Company /Public Service Company of New Hampshire, 'co Mr. George W.

l Knighton, Chief, Licensing Branch No. 3, Division of Licensing, .NRC, '

Subject:

" Request for Authorization to Utilize the Dayton Bar-Grip System at Seabrook Station," 12/28/82.

2. " Code Requirements for Nuclear Safety Related Concrete Structures,"

ACI 349-80, American Concrete Institute, Detroit, Michigan, April, 1981.

3. ASE Boiler add Pressure Vessel EQgb. Section M = Division L " Code for Concrete Reactor Vessels and Containments," the American Society of Mechanical Engineers,1980 Edition.

i 4. ASE Boiler add Pressure Vessel Cosb. Sestian m : Division L " Code for

, Concrete Reactor Vessels and Containments," the American Society of Mechanical Engineers,1980 Edition with Summer 1980 Addenda.

!. 5. "ASME Code Case N-185, Requirements for Materials, and Qualification and j Performance Testing of Swaged Reinforcing Bar Splices", Section EL.

l Division L Concrete Reactor Vessels and Containment. Approved by

Council, 8/29/77, Approved by ACI, 10/17/77.

6. " Regulatory Guide 1.136, Material for Concrete Containments," U. S.

! Nuclear Regulatory Commission, October,1978 (Revision 1).

i

! 7. Uniform Buildina CQde,1979 Edition, International Conference of Building I Officials, Whittier, California, 1979.

8. " Building Code Requirements for Reinforced Concrete," ACI 318-77, Ameri-

! can Concrete Institute, Detroit, Michigan, 1977.

9. Letter from Steve Holdsworth, Operetions Manager, Dayton Barsplice, Inc.,

Miamisburg, Ohio, to Neil E. Johnson, Science Applications, Inc., Oak -

Ridge, Tennessee,

Subject:

" Transmittal of Information on Dayton Bar-Grip

! Splice Systems," 7/13/82.

10. Letter from Neil E. Johnson, Science Applications, Inc., to Owen Rothberg, NRC Division of Digineering,

Subject:

" Dayton Bar-Grip Splice System Presentation to the NRC on 10/1/82," 2/28/83.

11. " Brochure - Bar-Grip Systems," Dayton Barsplice, Inc., Miamisburg, Ohio, 7/81.

12. " Operating Manual - Bar-Grip Mechanical Splicing Systems for Reinforcing Bars with Hydraulic Press Equipment," Dayton Barsplice, Inc., Miamisburg, Ohio, 12/80.

13. " Report on Performance Testing of No. 5'through No.18 Bar-Grip Sleeves for Dayton Barsplice, Inc.," WJE No. 8203000, Wiss, Janney, Elstrer and 7-1

i L

i Associates, Inc., Northbrook, Illinois, 5/7/82.

l

14. " Interim Report - Camtak and Bar-Grip Sleeve Testing for Dayton Bar-splice, Inc.," WJE No. 786490, Wiss, Janney, Elstner and Ase,aciates, j

{ Inc., Northbrook, Illinois, 9/18/79. I

15. "Bar-Grip Systems Test Report - Summary of Test Results Dr Bar-Grip i

Plain Couplers," Dayton Barsplice, Inc., Undated (Note - This is a re-issued version of " Report on Bar-Grip Plain Coupler Testing for Dayton ,

Barsplice, Inc.," WJE Nos. 786490 and 815300, Wiss, Janney Elstner and l j Associates, Inc., Northbrook, Illinois, Undated, j s

16. Roger G. Slutter, " Tests of Grade 60 Reinforcing Bars Spliced Using CCL

!' Camtak System," Report No. 200.79.674.1., Prepared by Fritz Engineering {

i Laboratory, Department. of Civil Engineering, Lehiah -University, Bethle- i hem, Pennsylvania for the Dayton Sure-Grip and Shore Company, June,1979.  !

17. E. W. Bennett, " Tests of CG Standard Splices on 32 mm Grade 380 Deformed [

Bar," Report No. CCL 8, Prepared by University of Leeds, Department of  ;[

Civil Engineering for CCL Systems Ltd, Surrey, England, January 1980.  !

i

18. E. W. Bennett, " Fatigue Tests of Spliced Reinforcement in Concrete  !

Beams," Paper presented at the American Concrete Institute Convention,  !

1 Puerto Rico, September 1980.  !

i i

19. "Research Report - Bar-Grip Systems for Splicing of Reinforcing Steel f Bars," Report No. 3848, International Conference of Building Officials, Whittier, California, October, 1981. {

h

20. " Report of Tests of Mechanical Butt Splices on Reinforcing Steel Bar," i Arkansas State Highway and Transportation Department, Division of Materials and Tests, Little Rock, Arkansas, 10/23-24/79. I

(

21. " Report on Reinforcing Steel Mechanical Splice Tests," Pacific Testing i Laboratories, 11/29/79. '

22. " Report on Tests of 47 CCL Bar-Grip Side Action Press Splice and #14 CCl l Camtak Extrusion Type Press Splice," State of Ohio, Department of Trans-  !

portation, Division of Highways Testing Laboratory, Columbus, Ohio,  !

1/25/80.

j!

23. " General Approval - Dayton Barsplice, Inc. Bar-Grip Systems for Splicing l

}

Reinforcing Bars," Research Report No. -RR 24374, Department of Building i and Safety, City of Los Angeles, California, 1/1/82, i

24. " Report on Mechanical' Splicing and Non-Destructive Examination of Rein- .

forcing Bars Spliced by Swage Method for NRC Approval," Prepared for Public S&vice Company of New Hampshire Seabrook Station by United '

i Engineers and Constructors, Inc., Philadelphia, Pennsylvania, November, .

1982.

25. Memorandum from H. L. Graves, ' Mechanical / Structural Engineering Branch, NRC. Division of Engineering Technology to Distribution, subject: " Meeting' with Representatives of Dayton Barsplice, Inc.,"L4/22/81.

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BEIONER DEEGIBING 'IEE DAMQI BAINIRIP SELIG SYIMIM i )

This appendix contains a brochure published by Dayton Barsplice, Inc. which describes the characteristics of the Dayton Bar-Grip Rebar Splice System.

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l 4f 1 d. M. J . #f Bar Grtp' splice. i gr ' . ].

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" t-

• Behave like continuous bars. The results of tensile tests and f" Practical tests on concrete compression tests camed out by independentlaboratoriesin the beams reinforced by continuous I

Threaded- ba,s and ey ea,s spiiced ihe Bar-Grip way show that the u.S.end eercad repeaieeiy show that reinforcement barsjoined the

Couplers spiicea bars perform equivaient Bar Gripwaymeetaiispecifica-to the continuous bars at service, tions of the appropriate agencies.

The pressing on of our supplied Time and again, test results confirm yield, and ultimate loads.

[ pre-threaded couplers can take that Bar-Gnp splices achieve both

( plice at the fabrication shop or

• Require less transverse reinforcement because the oh i dan oc t e tdjacent to the jobsite. The rebars ars coupled by turning our pre- bursting forces produced by the counter-action of lapped bars strengthof thebar, threaded steel stud into the

( threaded couplers. has been elim;nated by elimi.

nation of the overlap itself.

Our systems have been satis-factorily tested for normal and Consider theSe si'=i" ' 'a " d ' < a "'

steel at the overlap splice L'E'iatfai"n* attn"affs"e'ecies

( * * * * " ' ' ' " * ' ' * ' ' " "***

throughout the world, including WR U S splices with Bar-Grip couplings.

the Public Works Commission in New Zealand, the Department of r o Easy-to-install.The Bar-Grip

• Can cut on-site labor costs in Transport. United Kingdom; the System of mechanical rebar half because they can be applied Building Commission in Hong l

splicing requires very little half in the fabrication shop and Kong; the CSIR in South Africa; specialized labor. Your own then supplied to the construction the TechnicalInstitute in Sao workers can be trained in less site for finat installation. Paolo, Brazil; and in accordance than an hour, with design codes used in

• Require no heat, powders, or mortars. Applied cold to the {. h - u g Australia Holland, France, Spain, the Middle East, and Central and Dars, couplers are pressed int ngid, permanent splices. In effect. P' SS WNU J td S"'"^***-

In the past few years, our they form one continuous bar. All Bar-Gnp Systems meet the systems have met or exceeded o Can be applied in any weather following industry spec.ifications: standards in tests by the conditions. There are no ACI-359-ASME Nuclear; ACl-349 University of Illinois. Lehigh powders to ignite no hot metals Nuclear Design Code; U.S. Army University, Pittsburgh Testing to protect from the rain, mist, or Corps of Engineers Typical Laboratories, New York City i I

campness, and no pre-heating Specification; ACI-318 Building Board of Appeals. the Corps of of bars or splices. Code; Canadian Standards Associ. Engineers, various federal, state.

ation Nuclear Code, CSA N237.3. and local authorities. They are

• Require no bar-end preparation, recognized by the CRSlin the so ends can be shear cut or flame-cut. No threading of rebar @ jlC fJ current handbook.

Bar-Gnp Systemshavebeen

( or purchase of specially ribbcd bars is necessary.

T g--

.  ! used successfully by many contractors,,ncluding i Massman

• Join standardlengths of steel to i Construction. Turner Construction, provide extra long bars; join L 1 George Hyman Construction, cut-offs to provide required  ; [b ,

g f 9 I '15 f Bellows Construction, Southem lengths of steel. Can be done in the fabncating shop or on-site. py )- C#! E'

,, States Steel. Texas Cold Finished Steel. F. M. Russe!I Construction, b *

• 1 Haywood Construction. and i .

J. A. Jones Construction.

c

, 2 A

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A-5 l

J Bar-Grip Couplers-strong,

"*"'"S Bar-Grip' 7 : ' A.' N

. "":l" s ',_"a'"

oup ers .-

s h> M For mechanically joining high $

yield ribbed reinforcing bars, sizes 4 j ,; p <

• 5 through 18, w;thout overiapping l w s

or special end preparation, you '

=- - =-

want Bar-Grip Couplers- I

• 4 A seamless steel sleeves applied I.

M, t y  ;

over rebars on-site with a hand controlled hydraulic press-or h,g. j on,eas tengm cecouper 7 -E-

" half-spliced" in the fabncating shop. Once complete, this Bar-L j j, v A

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Grip splice achieves the specified ultimate tensile strength as well 1

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as the yield strength of the bars l 4

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themselves, as required by various design codes ir' t*1e i a l

rs.:ami A=12

• United States. as well as sai-Grip' Coupler s si2 inews throughout the world. z Bar-Gnp Couplers eliminate the Minimum Setting Out Dimensions p cations s b s s abs, (accompanying tables for Bar-Grip Couplers) columns and retaining walls. As a , H = height for bar above concrete result, t) ey cut down significantly U

! S = centers of bars on the time required for design I !

detailing. Special octagonal dies T = center of rows of bars iX; X = height of one row above another increase pressing speed by - _a_ '

allowing single line pressing. , ~ L .

U = distance of row from structure Better-swaging steel formulations

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Note 7 These measurements assume improve strength and rigidity. The ,? I ' '

the outer dieis removed clear of result: easy-to-tnstall. reliable _ the coupler. Rear Dars are splices at very reasonable cost. S T completely spliced first.

Single Row Double Row Weights and Access Measurements for Bar-Grip' Couplers Counter Lengths Renat Bar Grip Press Nominal Average coupler Minimum Setting Out Dimensions Size To Be Used laittal Final Weight H 3 T X U in. immt in tmmt b.Ing) in. (mm) in (mmt in. (mm) in (mmt in. f mmi 5 Sce Press BG750 3's180) 3% t 86) 0.4640.21) 4%(120) 2%I70) 4t115) a 64 ,165 6% t160) 6 See Press 8G750 34i95) 41102) 0 8510.396 51125) 3175: 4 % (1201 7(1801 6%1160) 7 Sice Press BG750 4' .(1101 4 % I117) 1.2440 56) 5's(135: 3175) 5(*256 81200) 6 5 i165) 8 S.co Press SG750 5:127) 5%(136) 1.81 to 82) 64150, 3% iBO) 5'.I130) 84(220) 61(165 8 5 ce Press BG1140 5(127) 5%1136) 1.81 to 82) 64(165) 44t105) 6 11551 941240) 8' s215) 9 Sde Press BG1140 54 t140 6 (152) 2.43 i t .10) 7 (175) 4%(1056 6% (160) 10 % 4250) 6's #215) 10 See Press SG1140 6',.i160) 64(172' 3.48(1.55) 7's (190) 4 5 (110) 69 (165) 11r275: 8 4 1220)

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J 11 See Press BG1140 6 4 8175) 7%(188) 4 4212.01) 8 % (205: 44(120) 64q170) 12i3001 84a2206 14 S ce press 8G1140 8 "s.(220) 9%(239) 8 33(3.78) 9 % (230) 44(120) 7(175: 14 a 3556 912251 18 S ce Pmss BG1157 11%(298) 12 % (3241 19 60 (3.89) 124300) 54i135) 91225) IS% s465) 11 #230) 4 j A-6 1

i

c Bar-Gri;iSystems Presses speed

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All Bar-Grip Presses are compact, easy-to-operate, and designed to y

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'n e U yg 3w speed up the jointing process. This press is used to attach all bar-Grip splices.

. whether they're used on-site or in Compact, easy-to-operate, and fast. it can apply a the fabricating plant. coupler or threaded coupler in approximately Dayton Barsplice can supply all 3 minutes.

necessary hydraulic pumps and The Bar-Grip Side Press swages the coupler to the auxiliary equipment, including end of the reinforcing bar by means of a series of spring load balancers to provide side-action " bites." Application speed increases as

{ fingertip control of the positioning bar diameters decrease, because smaller diameters of the press over the sleeves and require shorter sleeves, hence fewer squeezes.

around the bars. . Naturally, then, the smaller bar sizes require the

( These balancers can be suspended from the rebar to be smaller, lighter hydraulic press. The Bar-Grip Side Press requires a load balancer or block and-tackle.

spliced or from suitable scatfold equipment which may be in use for ,, g mmens

[ othe? ' unctions on the jobsite.

Either eiectric or gasoline

,imm>

8.7.6.5 ceuoter ano in aga m. immi n<mmi BG750 115 (52) 24 f 600) 8(205) hydraulic power sources are (25-16) nreaced counter available-220 volt single phase 14.11.10 9.8 counter and BG1140 207(94) 29(735) 9(222) or 220-440 volt three phase-or (43-25) nreaces couoer regular gasoline, whichever is best Coumer BGH57 230005) 34(825) 0225)

$7; suited to site ';cnditions.

Bar-Grip' Side Press

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. Bar-Grip' Bench Press 1j ]

Generally. the Bar-Grip Bench Press is used in the fabrication shop to swage on threaded couplers and

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I j to half-splice Bar-Grip Coupiers so that bars are

[. ,3 y ~ ll l-i j ready for final coupling when they reach the job-site. .-

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The Bar-Gnp Bench Press can also be used 4-l ad 7 o .f . maq g

l on-site-where fabricating shop conditions can be g3 .. , .' i I h (1

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1, j provided-to speed up the jointing process. Either gi;2 P J

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way, this press helps you install steel more quickly and to pour concrete sooner.

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• • " W "*****

kr"[$ e Coucier M, $$ $5 ll%

(  !) 1785) ( ) (2 0) 1 3.mni'bk 4

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1 Uefcoupler ( ) (1 5) (19h0) (1 80) 'i Uncuers cumoin case of pressi hs>.; , a i i

! I l Bar Grip

• Bench Press

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! We're Dayton Barsplice, Inc. l l -ready to put generations l of concrete construction l experience to workforyou I

We have the best of two worlds.

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As a new company founded in ,

{ 1979, we have the forward-looking y J

exuberance of youth. At the same

time, however, we enjoy the know-how that comes from the l generations of experience shared j by the companies who pooled I

their resources and expertise to -  !

J form us-The Dayton Sure-Gnp and Shore Company of Dayton, Ohio, U.S.A., and CCL Systems i

- Ltd. of London and Leeds. England.

l Dayton Sure-Grip has been l

making accessories and chemicals for concrete construction for F over 57 years. CCL Systems has been making engineered systems -

for prestressing and placing g- - - - - - - - - -- -

g[

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{ concrete for 47 years. ' L. Id ~d,;f (,, , . ,

We've got everything you'll l

need to put Bar-Grip Systems to 3

1 work on your next contract-the MD W.ZEC engineenng and technical staff to help and advise during the design -

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stage, and the couplers, presses, 7. -

{ and auxiliary equipment for installation.

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Best of all, with Bar-Gnp ..; ,

i Systems you get everything you y- f i need for one low price. There are l no hidden costs of any kind. For

~_ -

i further information or a quote on -*

I your next job, call our Engineering Sales Department, collect..:t j'

l 1513-8591263 Telex: 288 249

~'

y DAYTON Engineered systems BARSPLICE,INC. for concrete reinforcing steel P.O. Box 366 Miamisburg, Ohio 45342 (513) 859-1263 1

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