Patent ID: 8919167

Claim:
A method of manufacturing threaded rebar comprising: providing a lead pass bar comprising a body extending along a longitudinal axis, wherein at least one portion of the body has a cross-section defining a plane that intersects the longitudinal axis, wherein a first part of the plane has a first width, a second part of the plane has a second width, and a third part of the plane has a third width, wherein the first width is less than the second width and the third width, wherein the first part of the plane is located adjacent to the longitudinal axis, and the second part of the plane and third part of the plane are located distal from the longitudinal axis on opposite ends of the first part of the plane, wherein the lead pass bar has a X-axis through the first part of the plane, the second part of the plane and the third part of the plane, and a Y-axis through only the first part of the plane, and wherein the lead pass bar is formed in a first orientation along the longitudinal axis of the lead pass bar in one or more lead pass bar roll sets in which the X-axis is substantially perpendicular to and the Y-axis is substantially parallel to lead pass rolls of the one or more lead pass bar roll sets; and forming a threaded rebar having substantially continuous threads from the lead pass bar by hot rolling the lead pass bar in one or more threaded rebar roll sets, wherein forming the threaded rebar comprises forming the threaded rebar from the lead pass bar in a second orientation along the longitudinal axis that is different from the first orientation in which the X-axis is substantially perpendicular to and the Y-axis is substantially parallel to threaded rolls of the one or more threaded rebar roll sets, and wherein the threaded rebar is formed without having to remove longitudinal ribs along at least a portion of the body.