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Cold-forged couplers are mechanical splicing devices used to connect two reinforcing bars (rebar) in construction. Unlike threaded, welded, or swaged couplers, cold-forged couplers rely on a cold-forging process to enlarge (upset) the ends of the rebars before threading and joining them with a coupler sleeve.

What Are Cold-Forged Couplers?
Cold-forged (or upset-forged) couplers are mechanical rebar splicing systems in which the rebar ends are enlarged mechanically at room temperature and then threaded to allow a coupler to screw on.
This method keeps the full strength of the bar and creates a direct, full-contact mechanical joint.

How the Cold-Forging Process Works?

Bar End Upsetting
The end of each rebar is inserted into a cold-forging machine that applies high axial pressure to upset (expand) the bar end, increasing its diameter.

Threading
After upsetting, the enlarged section is cut with parallel threads, which match the coupler sleeve.

Coupler Installation
The coupler is screwed onto the threaded ends of both rebars, forming a full-strength mechanical splice.

Key Advantages

✔️ Full Strength / Higher Performance

Upsetting ensures the threaded portion has equal or greater cross-section compared to the parent bar.

Joints often meet or exceed Grade 500 / 600 rebar requirements.

✔️ Ideal for Congested Reinforcement

No need to overlap bars; reduces rebar congestion and concrete usage.

✔️ Consistent, Factory-Controlled Process

Cold forging is done using hydraulic equipment, producing uniform results.

✔️ Suitable for Large-diameter Reb ar

Typically used for 16mm to 50mm diameters.

✔️ Effective in Seismic Zones

Many systems are certified to ISO 15835 / ACI 318 requirements for seismic applications.

Applications

High-rise buildings
Bridges & flyovers
Metro & rail infrastructure
Water retaining structures
Nuclear and power plants
Precast concrete elements

🛠️ Installation Requirements
Correct upset diameter
Proper thread quality
Clean threads and couplers
Torque key / wrench tightening
Proper alignment of bars
Improper upsetting or threading is the main cause of failure.