Why Rebar Cold Forging Machines Are a Contractor’s Secret Weapon

In the fast-paced world of construction, efficiency, durability, and cost-effectiveness are non-negotiable. Enter the rebar cold forging machine—a game-changing tool that’s quietly revolutionizing how contractors handle reinforced steel. Here’s why this unassuming piece of equipment is a contractor’s ultimate ally.

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1. Unmatched Strength and Precision in Rebar Joints

Rebar cold forging machines specialize in creating bulged ends on TMT bars, preparing them for threading and coupling. Unlike traditional welding or lap splicing, cold forging preserves the structural integrity of the steel by aligning the grain flow and eliminating heat-induced weaknesses. This results in joints that are 30–50% stronger than conventional methods, ensuring compliance with high-tension requirements in skyscrapers, bridges, and seismic zones 15.

Key features driving this strength include:

• Hydraulic systems with capacities up to 220 tons, ensuring uniform pressure distribution 

• EN 31/D2-grade dies and punches, which withstand wear and maintain precision even under heavy use 

• Polyhedron valves and Yuken hydraulic systems, optimizing performance for rebar sizes up to 40 mm 

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2. Speed That Beats Project Deadlines

Time is money, and cold forging machines deliver both. With the ability to process 70 rods per hour (for 32–40 mm bars), contractors can splice rebar at lightning speed. This is critical for large-scale projects like highways or high-rises, where delays cascade into budget overruns 

Why contractors love the efficiency:

• Semi-automatic operation: Reduces manual labor and human error.

• Quick mold changes: Switch between rebar diameters (12–40 mm) in minutes 

• Portability: Mounted on trucks or trailers, these machines can be deployed across multiple sites in a single day 

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3. Cost Savings That Add Up

While the upfront cost of a rebar cold forging machine (₹1.8–₹2.9 lakh) might seem steep, the long-term savings are undeniable:

• Reduced material waste: Cold forging uses 100% of the rebar, unlike welding, which burns through rods 

• Lower labor costs: One operator can handle what previously required a team.

• Minimal maintenance: With no heat involved, components like dies and hydraulic pumps last longer 

For example, a single machine can replace 10–15 workers manually threading rebars, slashing labor expenses by 60–70% 

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4. Versatility Across Applications

From high-rises to industrial plants, these machines adapt to diverse needs:

• Construction sites: Forge rebar ends for mechanical couplers, ensuring seismic-resistant connections 

• Roadwork: Stabilize infrastructure by reinforcing concrete slabs and pillars.

• Automotive and mining: Create custom components like axle shafts or drill rods 

Manufacturers like Surya Engineering and Vruddhi Couplers even offer customizable dies for niche projects, making the machines indispensable for specialized contractors 

5. Sustainability Meets Compliance

With stricter environmental regulations, cold forging stands out as an eco-friendly alternative:

• Zero emissions: No heat or fumes, unlike welding 

• Recyclability: Forged rebar joints are fully reusable, aligning with circular economy goals 

Rebar cold forging machines are no longer a luxury—they’re a necessity for contractors aiming to stay competitive. By merging strength, speed, and savings, these tools ensure projects are completed on time, within budget, and to the highest safety standards. As one Mumbai-based contractor put it, “Once you go cold forging, you never look back.”

Choosing the Right Anti Smog Gun / Dust Suppression System: A Buyer’s Guide

 

Choosing the Right Anti Smog Gun / Dust Suppression System: A Buyer’s Guide :

Surya Engineering is one of the leading Manufacturer and Exporter of anti smog  gun,  mist cannon,  dust suppression systems,  etc. The Anti-Smog Gun (also known as a Dust Suppression Cannon or Mist Cannon) is an advanced air pollution control device designed to reduce airborne particulate matter (PM2.5/PM10), dust, and smog in urban, industrial, and construction environments. It atomizes water into ultra-fine mist to bind and settle pollutants, improving air quality and compliance with environmental regulations.

Key Features

1. High-Efficiency Misting

• Nozzle System: Stainless steel rotary nozzles produce 20–150 micron droplets for optimal dust capture.
• Coverage: Effective range of 40–50 meters (depending on model).
• Flow Rate: Adjustable water flow (30–250 liters/minute).

1. Mobility & Flexibility
   • Mounting Options: Truck/trailer-mounted, stationary, or portable trolley designs.
   • Rotation Angle: 0°–320° horizontal and -15°–45° vertical oscillation for 360° coverage.
2. Eco-Friendly Design
   • Water Conservation: Uses 70–90% less water than traditional sprinklers.
   • Optional Additives: Compatible with biodegradable dust suppressants (e.g., magnesium chloride).
3. Durability
   • Construction: Heavy-duty stainless steel or corrosion-resistant aluminum body.
   • Weatherproof: IP65-rated components for harsh outdoor conditions.
4. Smart Operation
   • Remote Control: Bluetooth/Wi-Fi-enabled models for remote activation.
   • Automated Timers: Pre-programmed spraying schedules.

Technical Specifications

Parameter	Details
Tank Capacity	1,000–2000 liters (customizable)
Spray Height	Up to 60–100 meters (vertical/horizontal)
Nozzle Count	8–16 rotary nozzles (stainless steel)
Weight	500–2,500 kg (depending on model)

Applications
Construction Sites: Controls dust during excavation, demolition, and material handling.

• Mining & Quarries: Reduces silica dust during drilling, blasting, and transport.
• Urban Areas: Mitigates smog and PM2.5 in traffic-heavy zones or during stubble burning.
• Waste Management: Suppresses odor and dust at landfills and recycling plants.
• Events & Public Spaces: Used in stadiums, festivals, and parks for cleaner air.

Compliance & Certifications

• EPA Standards: Meets guidelines for reduction
• ISO 9001: Quality-manufactured components.

Models

Model	Capacity	Coverage
SE-30	1,000 liters	35-40 meters
SE-50	2,000 liters	40–50 meters

Why Choose This Anti-Smog Gun?

• Proven Efficiency: Reduces airborne dust by 80–95% in target zones.
• Low Maintenance: Self-cleaning nozzles and easy-access service panels.
• ROI: Avoids regulatory fines and improves worker health/safety.

Warranty & Support
Warranty: 1 years on mechanical parts.
Training: On-site installation and operator training included.

For more detail visit web site : www.suryaengineering.com

WHAT KIND OF TESTING IS PERFORMED ON REBAR COUPLERS?

What kind of testing is performed on rebar couplers?

 

 

Rebar coupler testing and solutions are a significant and integral part of providing the best materials on varied construction sites in India. Keeping in touch with the codes and compliances to reduce bar congestion can improve the efficiency and quality of the project. It also gets completed on time.

We need to conduct all the tests to help in the high performance of our rebars. With various testing expertise, you can be assured that we will handle your next prestigious project with our key coupler products.

 

Conducting primary tests

 

v  Static Tensile Test (UTS, bar break, elongation)

1.      Slip Test

2.      Cyclic Tensile Test (100 cycles)

3.      Low cycle fatigue test

4.      High cycle fatigue test

 

we conduct tensile test and chemical test of round bars. Once the results are satisfactory, the raw material is taken up for production of couplers. Chemical composition test result is provided with each coupler lot. At the start of each project, static tensile test and slip test for spliced sample is carried by us and witnessed by the client. Type tests like Cyclic Tensile Test, Low Cycle Fatigue test have a validity of three years. These type tests have been performed at the prestigious Indian Institute of Technology. These type tests are submitted to client as part of quality approval process.

 

Static Tensile Test (UTS, bar break, elongation) as per IS code 16172

 

All testing equipment are computer controlled with OEM and batches mentioned. The tensile strength of the mechanical splice, when tested by following the details: not less than 600 N/mm2. It should correspond to the minimum tensile strength of the reinforcement bar of Fe 550D grade specified in IS 1786.

 

The minimum percentage elongation at maximum force (is also called uniform elongation). It should measure as per the method given. The reinforcing bar outside the length of the mechanical splice shall be a minimum 3 percent before the failure of the test piece.

 

 

Slip Test

 

The total slip value measured by the test procedure should not exceed 0.10 mm.

 

Cyclic Tensile Test

The mechanical splice is reliable when it can withstand 100 cycles of stress variation. The cycle is from 5 percent to 90 percent of fy (where fy = 550 N/mm2) when tested by standard details. It is to be done without loss of static tensile strength capacity when compared with a similar specimen. The static tensile strength capacity of the sample is determined by testing it statically. It undergoes numerous stress cycles for failure of the required procedure. At the end of the test, the spliced sample shall remain intact.

 

Low cycle fatigue test

 

There are two types of fatigue tests namely low cycle fatigue test and high cycle fatigue test. All reinforcement couplers should be able to satisfy the requirement for low cycle fatigue tests. The mechanical splice should withstand 10 000 cycles of alternating tension and compression load when tested by a standard method.

 

 

High cycle fatigue test

 

High cycle fatigue testing is typically conducted on specimens in load/stress control to develop Stress-Life (S-N) Curves.  An S-N Curve is generated by testing samples at a constant load/stress and recording the number of cycles to failure.  The data is then compiled and a best trend fit is applied.  This establishes a relationship between a particular load/stress level and the fatigue life of the material. 

MBT Couplers & Rebar Bolted couplers

 Rebar Mbt (Mechanical Biological Treatement) Couplers Are Used Only Critical Condition In Construction At The Sites Area. Critical Conditions Like Lack Of  Suitable Rebar Size Into The Concrete Where Not Only Threading Even Lapping Is Also Not Possible.

Here's The Picture Of MBT Rebar Coupler To Joining Two Tmt Bars.   

 The Tmt Bars Join with The Help of Bolts. For Joining Need To Be Drilled In The Tmt Bars. 

Here Fig 1.2 Shown There Are Only 80mm Tmt Length Remaining In Concrete. Then Tha lapping And Threading Process Of Tmt Bars In Not Possible Because for Lapping The Bars Minimum 150mm Length Is Required So There Is Lapping And Threading Is Not Possible For That Conditions The Engineers Design Mbt & Bolted Couplers.

The Material Used In Mbt Coupler Is EN8D .. EN8 Represtnt Series And D Stand For Ductile.

EN8D Material Is Best Material In Mbt Coupler And Also In Others Rebar Coupler.

Sizes Of Mbt Couplers

Basically Mbt Coupler Sizes And Other Rebar Threading Coupler Sizes Are Same But  Mbt Coupler Lengths Is Big As Compare  To Threaded Couplers.The Sizes Available In Mbt Coupler Is Standard From 12mm To 40mm. Like 12mm , 16mm ,20mm..etc

Numbers Of Bolts In MBT Coupler

The Bolts Of Mbt Coupler Is Depends On It Sizes The Minimum Numbers Of Bolts Required is 4

And Other Size And Numbers Of Bolts Chart As Given Below.

 

Coupler Sizes	No. Of Bolts Count
12mm	4 Bolts
16mm	6 Bolts
20mm	8 Bolts
25/32mm	12 Bolts

We are Leading Manufacturer Of Rebar Threaded And Forged Couplers And Also Providing Threading And Coupler Installation Services In All Over India.. And We Also Have Dealers In Other Metro States Like Mumbai, Delhi, Bangalore , Hydrabad , Lucknow , Ahmedbad, Chennai Kolkata,And Others States. And Also We Work With Top Infras and Government Projects Companies. Like L&T, ISRO Ind Ltd, Tata Projects Ltd, Dilip Buildcon Ind Ltd Etc.

For Threading Work & Other Information Related Services Call On:- 9223446390

Send Enquiry On Our Gmail:- Surya.Engineers2000@gmail.com

Visit Our Official YouTube Channel :- SuryaEngineering

 

(Thanking You)

                                       

Pvc Diamond Dowel Sleeve And Plate.

 Pvc Diamond Dowel Plate Use In Surface & Floors Where To Pass Heavy Vehicles And  Pass And Carry out Other Heavy Goods. It Provide Strength To Floor Surface To Take Heavy Weight.

Diamond Dowels Transfer The Load Of Surface In Vertical Ways.

Across Minimise The Differential Deflection Between The Slab Panels.

This System Achieve Superior Joint Stability Measurements. And Also Provide Maintenance Free Concrete work. And Reduces Labour Costs Which Can Be  Caused By The Repeatable  Maintenance  Of Floors And Surfaces.

Diamond Dowels Systems Helps To optimise The Time And Amount Of Steel In The Projects .

* Manufacturing Process & Product Information Of Pvc Diamond Dowel Plate .

Diamond Dowel Plates Are Manufactured From Steel Certified To Meet ASTM A36, It Consistent Module Of Diamond Dowel Support And Quality And Performance The Plates Are Manufactured From Grade l0l8 Steels With Cold Finished Steels .And Dowels Moulded From High Density ABS Plastic.

Note- All Steel Is Sawn Full Depth And Debbured Per Industry And IS Guidelines Ensuring Smoothness And l0l8 Steel.

* Sizes Of Pvc Diamod Dowel.

Dowels Are Manufactured In Many Sizes But The Standard Size Of Pvc Diamond Dowel Is 110x110x6mm.

Other Sizes Of Diamond Dowels Are Shows In Below Table.

Slab Depth In (mm)	Dowel Dimensions (In mm)			Dowel Spacing Center To Center (In mm)
	Round	Square	Diamond- Shaped	Round	Square	Diamond Shaped
5 to 6 (130-200)	¾ x 14 (19 x360)	¾ x 14 (19x360)	¼ x 4-1/2 x 4-1/2 (6 x 110 x 110)	12 (300)	14 (360)	18 (460)
7 to 8 (180-200)	1 x 16 (25 x 410)	1 x 16 (25x410)	3/8 x 4-1/2 x 4-1/2 (9 x 110 x110)	12 (300)	14 (360)	18 (460)
9 to 11 (230-280)	1-1/4 x 18 (32 x 460)	1-1/4x18 (32x460)	3/4x 4-1/2 x 4-1/2 (19 x 110 x 110)	12 (300)	14 (360)	18 (460)

 

We Are The On Of The Leading Manufacturer Of Pvc Diamond Dowel At Mumbai & Hydrabad, And Dealing in All Over India And All Metros Cities Like Mumbai, Bangaluru, Hydrabad, New Delhi , Punjab, Chennai , Kolkatta , Lucknow Etc. And Formally work In Governments Projects.,

Etc..

We Also Have us Own Dealers In New Delhi, And Chennai And Others South Ind States.

If u Are Interested to Be With us You Can directly visit on Our Official websites :- Surya Engineering

And Also Send A Mail On- Surya.Engineers2000@gmail.com

Visit Our Official Youtube Channel:-SuryaEngineering

 

Rebar Coupler | Rebar Roll Thread Coupler | Rebar Cold Forged Coupler | Rebar Coupler Overview

Rebar couplers are used in reinforced concrete structures to replace normal rebar lap joints. The couplers are also suitable for use in reinforced concrete columns and walls. Each rebar coupler consists of a piece of rebar equipped with a thread and coupler sleeve at the right end as viewed in the direction of installation. In construction joints, rebar couplers can be used to replace all pieces of rebar going through the formwork.

Each end of the rebar to be joined is cut square and enlarged using a cold forge process. A thread is then formed on the enlarged bar end using a thread rolling machine. The thread is such that the cross-sectional area of the bar ends is not reduced ensuring the strength of the connection matches or exceeds that of the parent bars.

WHY USE REBAR COUPLERS?

The Traditional methods of lapped joints are not always an appropriate means of connecting reinforcing bars. Lapped joints are dependent upon the concrete for load transfer. The use of laps can be time-consuming in terms of design and installation and the increased amount of rebar creates congestion within the concrete.

Couplers are designed to mechanically join two bars together. By creating an end-to-end bar connection, a continuous load path is created from one bar to another that is independent of the condition and quality of the concrete. Mechanical splices are reliable under conditions of cyclic loading into the inelastic range and prove to be advantageous at the locations where inelastic yielding may occur. BENEFITS OF COUPLERS

Spliced rebar performs like continuous reinforcement due to the mechanical joint, unlike lapping which has a complete dependency on concrete.

Steel wastage is reduced significantly. Using couplers save lap-length steel. A 12m rebar can be divided into 3m or 4m as bars as required, which prevents the wastage of end pieces of steel.

Staggering of bars not required.

Bar cross-sectional area is not reduced.

Couplers are used as a replacement for dowel bars which also saves formwork material.

Steel congestion is reduced due to the elimination of laps.

Using couplers provides superior cyclic performance as compared to the lap joint.

Easy to install and no torque wrench required. FEATURES OF COUPLERS EN8D material is used for manufacturing couplers. Reinforcing bar couplers with high carbon contents that have high strength and greater thickness are more sustainable and effective. Reinforcing bar coupler helps to increase the pace of execution and the quality of projects. It can simplify the design and construction of reinforced concrete and reduce the amount of reinforcement required, which is now a valuable national resource. No torque wrench is required for assembling, reinforcing bar couplers. Hand tightening of the bar or coupler is sufficient. Our couplers can be used in power plants, bridges, and all types of R.C.C structures CODE SPECIFICATION In India, the structural consultant is free to define the code to which the couplers have used the project. I. ACI: 318 – 2008:

Type 1 joint required to achieve 1.25Fy as a minimum, e.g: For Fe500 the tensile strength expected is at least 625 N/mm2 (Clause 12.14.3.4).

Type 2 is required to comply with the 1.25Fy requirement and also meet the specified tensile strength of the rebar. E.g: For Fe500 the ultimate stress expected from the same is at At least 700 N/mm2. II. BS 8110 – Part 1, Section 3, 1989:

Specifies tensile testing and slip test for the joint for acceptance of the sample.

Testing the coupler of a precise type, the permanent elongation after loading to 0.6fy should not exceed 0.1mm. E.g: For grade 460 the tensile strength should exceed 497 N/mm2. III. IS 1786 – 2008:

Type 1 – For Fe500 is considered acceptable for use anywhere in the structure if it meets the ultimate strength of 545 N/mm2 which is much lesser than the 1.25Fy. (Clause 8.1 –Table 3).

Type 2 – The condition becomes at least 625 N/mm2 as well. IV. IS 16172 – 2014:

Visit: http://suryaengineer.com/

To Buy Or Any Query Please Contact: 9223446390

Email Us: surya.engineers2000@gmail.com

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