Finite Element Analysis and Experimental Validation of a Swaged Rebar Coupler System for Robotic Reinforcement Splicing

Abstract Rebar couplers play a critical role in ensuring the quality and efficiency of construction processes. However, conventional coupling methods are often labor-intensive and prone to inconsistent quality due to human error, highlighting the need for automation and enhanced precision. In this study, a swaged rebar coupler system, specifically optimized for robotic reinforcement splicing in construction environments, was developed and evaluated. Conventional swaging tools require manual assembly of the swaging mold onto the coupler; by contrast, the proposed swaging tool can automatically open and close its swaging mold and apply it to the coupler. The proposed coupler system was designed using a new material and an automated swaging tool. To enhance the efficiency of the swaged coupler system development, a finite element analysis (FEA) framework incorporating both swaging and tensile strength test processes was established. Through finite element analysis (FEA) and experimental validation, the proposed system demonstrated tensile strengths exceeding 600 MPa with no slip occurrences, meeting the requirements of KS D 0249. These findings confirm the reliability and practical applicability of the proposed swaged coupler system, presenting a viable solution for automated rebar connections in robotic construction environments.