This paper describes the loads experienced by solid expandable tubulars during down hole expansion. These loads are compared to the loads experienced by tubulars when expanded using current laboratory techniques. The paper demonstrates that the current practices for expanding test samples do not necessarily represent all of the loads that can be experienced in situ. The loads that are excluded in making expanded thread connection test samples may have significant impact on the performance of the threaded connections. Newly developed testing methods and equipment that have been used to replicate the actual down hole loads that are generated when casing is expanded will be described, and data generated from the testing of samples made with the new equipment presented.