E:Hh3 Nov ’05
Macalloy Tensile Structure System: Macalloy 460 Carbon Steel Bar Tendons Macalloy S460 Stainless Steel Bar Tendons Macalloy 460 & S460 Compression Struts
N E W
Macalloy SC460 N E W Stainless Steel Cable Tendons Macalloy Guy Linking Stainless Steel Bar Tendons Macalloy Guy Linking Stainless Steel Cable Tendons Macalloy-Tensoteci Galvanised Cable Tendons
Experience
Innovation
Quality
2
Tensile Structure Systems Since the 1940s Macalloy Ltd has been
concept of Tensile Structures in the early
and exciting opportunities being presented.
leading the way in the design, manufacture
1980s, creating new systems and new
Throughout its history Macalloy Ltd has
and supply of threaded bar systems,
technology that were to change traditional
gained much respect from architects,
consistently serving its various markets with
principles forever.
engineers and contractors and this continues
experience, innovation and quality quality.. Macalloy Ltd developed and introduced the
In recognition of this, the Macalloy portfolio
to be the case today.
of projects continues to expand with new
Olympia Stadion, Berlin A rc rchitect:
GMP
Engine Eng ineer: er:
Schlaich Schlai ch Ber Berger germa mann nn and Partner
Cont Co ntra ract ctor or:: DS DSD D
There are many reasons why specifiers and contractors repeatedly choose the Macalloy system. Here are but a few few,, Macalloy: • Was the first first to develop develop a structur structural al tie system with a yield stress of 460 N/mm2 • Only manufact manufactures ures using using rolled rolled threads threads • Offe Offers rs the most comprehe comprehensiv nsivee range of bar and cable systems in both
carbon and stainless steel • Pione Pioneered ered the art art of stressing stressing tendons tendons (see page 8) • Is the first first to gain gain approv approval al to BS ENV ENV 1993-1 (EC3) • Has German German approval approval for for both its carbon carbon and stainless steel systems • Has a system system prov proven en in fatigue fatigue
• Is a CARES CARES approv approved ed company company • Boasts almost almost 60 years years of experie experience nce in threaded bar systems • Has an experienc experienced ed team of of engineers engineers who offer support and advice from specification to construction stage • Ensur Ensures es all-round all-round sound custome customerr service service Experience, Innovation, Quality
3
Tensile Structure Systems Tensile Structure Range
• Macall Macalloy oy SC460 (stainles (stainlesss steel cable cable system)
The following systems form part of
• Macall Macalloy oy Guy Linkin Linkingg Bar system system
Macalloy’s standard range:
(stainless steel bar system)
• Macall Macalloy oy 460 (carbon (carbon steel bar bar system) system) • Macall Macalloy oy S460 (stainless (stainless steel steel bar system) system)
• Macall Macalloy oy Guy Linking Linking Cable Cable system system
• Macall Macalloy oy Compre Compressio ssion n Struts Struts • Macall Macalloy oy Connecti Connection on Discs Discs • Macall Macalloy oy Bespok Bespokee System Systemss • MacalloyMacalloy-Tensot Tensoteci eci (galvanised steel cable system)
(stainless steel cable system)
Sazka Arena Arch Ar chit itec ect: t:
ATI TIP P, a.s. s.
Steel Structure Design: Excon, a. a.s. Contrac Con tractor: tor: Skan Skanska ska CZ, a.s.
Porto Airport Engineers: Talprojects Contractor: Martifer
4
Macalloy 460 & S460 Bar Systems Table 1: Tendon Capacities for Carbon & Stainless Macalloy 460 Thread
Units
M10
M12
M16
M20
M24
M30
M36
M42
M48
M56
mm
10
11
15
19
22
28
34
39
45 45
52
Min. Yield Load
kN
25
36
69
108
156
249
364
501
6 60 660
Min. Break Load
kN
33
48
91
143
207
330
483
665
kg/m
0.50
0.75
1.40
2.20
3.00
4.80
7.10
9.40
Nominal Bar Dia.
Nominal Bar Weight
M64
M76
M85
M90* M100*
60
72
82
87
97
912
1204
1756 1756
2239
2533
3172
875
1209
1596
2329
2969
3358
4206
12.50 12.50
16.70
22.20
32.00
41.50
46.70
58.00
* Full charpy v notch impact values available upon request only and may be subject to extended lead times
Macalloy 460 & S460 Steel Tendons
M100 are available up to a maximum bar
and are delivered to site with the appropriate
length of 11.950m. Longer lengths may also
packaging in order to ensure minimal
Drawing on the experience, innovation and
be available on request and are subject to
damage during transportation.
quality of Macalloy Ltd, the 460 & S460
longer lead times.
systems have been carefully developed to incorporate fine grain steel with a minimum
Corrosion Protection
Lock Cover Sealing In order to reduce corrosion and ‘bleeding’ in the gap between the bar and the lock cover a sealant can be
yield stress of 460 N/mm . This ensures that
As a means of protecting against corrosion,
the system is approximately 30% stronger
the Macalloy 460 system can be supplied
or a similar proprietary sealant as this can be
than the more common S355 grade steel
with a form of protection to suit your
painted over.
equivalent, enabling smaller diameters to be
specification.
2
1. The joint should be made up and installed
used to take the same load.
Galvanising Hot dip galvanising can be
Macalloy 460 Carbon Bar Macalloy 460 is a carbon steel with an exceptional blend of mechanical properties, combined with rolled threads to provide a material with superior fatigue performance. The carbon Macalloy 460 bar is also a
threading the lock cover back into the bar,
protection coat remains on the threaded
any grease should be removed using Loctite
portion. The threads are are then brushed to
7063 or a similar proprietary cleaner.
remove any excess zinc and are delivered fully assembled (dependent on length) to
current European Standard EN ISO 1461:1999.
carried out using standard techniques and low hydrogen rods. Macalloy 460 bar has the following
460 N/mm
2
Minimu mum m Breaking Str treess
610 N/mm
Minimum Elongation
19%
Minimu Min imum m Charp Charpyy Impact Impact Valu Valuee
27J @-2 @-20˚C 0˚C
Young’s Modulus
205 kN/mm
2
The standard diameter range for this particular system is from M10 to M100. For tendon diameters up to M16 the maximum bar length available is in 6m lengths and for
of the lock cover should be taped over. It is recommended that this is done by using a PTFE tape which is then overlaid with a stiffer tape. The sealant is then injected into the hole in the side of the lock cover, using a “skeleton
protection that is required by the client.
gun”, until the void is completely filled.
Lock Cover
2
2. With the lock cover in place the “open” end
Paint Macalloy can provide any form of paint Painted systems are supplied fully assembled
mechanical properties:
M20 it is 9m. However, However, diameters M24 to
cover should be cleaned and, prior to
By galvanising after the threading process a
galvanising is done in accordance with the
equivalent of 0.55%. Arc welding may be
as normal except that the inside of the lock
applied to the carbon bars after threading.
ensure the components have a good fit. All
weldable steel with a maximum carbon
Minimum Yield Stress
applied. Macalloy recommends Loctite 5068
5
Macalloy 460 & S460 Bar Systems 3. The tape should be removed immediately
Turnbuckles Turnbuc kles give additional adjustment of:
from the end of the lock cover (or shortly
- M1 M10 to to M24 M24::
after applying the sealant).
- M30 M30 to to M100 M100:: +/ +/-- 50m 50mm m
4. Any excess sealant should be removed
+/-- 25m +/ 25mm m
technical department who are willing to offer expert advice and solutions for particular projects. As well as our own machining facility enabling special accessories to be
from the end of the lock cover and around
Fatigue
produced, there is an on-site bar threading
the injection hole, and the sealant tooled to
Threads are rolled on to the bar rather than
facility which means that one-off bar types
produce a fillet.
cut to ensure minimum loss of cross sectional
can be manufactured to individual
area and to give excellent fatigue strength.
specifications. Once production has been
Testing on fatigue has been carried out over
completed, the in-house Test Facility is then
2 million cycles, the results of which are
able to check that components and bars meet
available from the Macalloy technical
the initial design requirements, before finally
Macalloy S460 Stainless Bar
department.
leaving the premises.
Macalloy S460 is an austenitic/duplex*
Approvals
Special projects include:
Generally,, Macalloy 460 should be used in Generally
• Dubai airport airport – a special special 690 690 grade grade of bar
5. The sealant should be left to cure and if necessary any further tidying up can then be carried out.
stainless steel tie bar system, selected from high strength stainless steel to provide the
accordance with the local structural steel
system was developed which included
design codes. The system is the first to be
special high strength connections to take
found to have excellent charpy v notch
designed and tested in accordance with the
the full load of the bar
impact properties adding to the system’s
requirements of the European Code of
appeal.
Practice, BS ENV 1993 (EC3) and BS5950.
optimum balance of strength, ductility and appearance. Austenitic stainless steel is
*Pin set bodies above SPA24 may be in martensitic stainless steel
Macalloy 460 has also been tested and approved for use in Germany under the Zulassung Nr. Z-14.4-427.
numerous glass façade projects • Chang Changii airport airport – 835 grade grade stainless stainless bar with special forks to suit • T5, Heathrow Heathrow – unique unique finish finish to the the thread form and polish for the glass wall
Macalloy S460 bar has the following
Macalloy Bespoke Systems
mechanical properties:
• Uniqu Uniquee machined machined and cast cast components components for
• T5 Rail Intercha Interchange, nge, Heathrow Heathrow – special special
In addition to the standard systems that
T-connection pieces to allow horizontal
610 N/ N/mm2
Macalloy provides, it is also possible for
and vertical bars to be joined in one
Minimum Elongation
15%
special items and systems to be designed
threaded connection.
Young’s Modulus
190 kN/mm2
and produced. Macalloy has an exceptional
Minimum Yield Stress
460 N/mm2
Minimum Br Breaking St Stress
The system comes as standard in diameters M10 to M76. Bars are available in lengths of up to 7.5m in diameters M10 to M56 and lengths of 6m for M64 and M76.
Scottish Parliament.
Stainless Finish All bar and components are finished in a Grit 220 (N3) polished finish, although a whole range of other finishes are available from mirror finish to glass bead. Please discuss your requirements with our Sales team.
Tolerance and Adjustment for Carbon and Stainless Bars The cutting tolerance for bars is +/- 6mm for diameters less than 72mm and +/- 25mm for larger diameters. Adjustment within each fork or spade are: - M10 to M56:
⁄ 2 thread diameter 1
- M64 M64 to M1 M100 00:: +/ +/-- 25mm 25mm.. Photograph courtesy of Press Office
6
Macalloy 460 & S460 Bar Systems Standard Components M460 & S460 Tendons
load in to the bar, especially when used in
Central Connection Plates These are circular
combination with the Macalloy
central discs, commonly used in wind bracing
Macalloy offers a range of standard
TechnoTensioner.
applications where tendons are used to cross each other. Dimensions are given in table 2.
components, including forks, spades, pins,
Bespoke Connection Plates Designed to
are designed and tested to match the tensile
Connection Plate Solutions for Macalloy 460 & S460
capacity of the bar, which is itself based upon
Standard Connection Plates Forks may be
systems, these can be manufactured to suit
the cross sectional area of the thread form.
connected to either carbon steel or stainless
your individual application requirements.
Macalloy offers the same standard range of
steel connection plates, using material with
They are available in both carbon and
components in stainless as it does in carbon
an equivalent strength to BS EN 10025 grade
stainless steel with a choice of finishes, such
steel. With the exception of the lock covers,
S355.
as painted, powder coated, and polished.
all components are dimensionally the same
If carbon steel connection plates are used
Your preferred company logo, lettering
as the standard system.
with stainless forks or vice versa, isolation
and/or designs can be accommodated using
sleeves and washers may be required to
the latest laser cutting, chemical etching, or
Forks are designed to be connected to a BS
prevent bi-metallic corrosion. In such cases,
screen printing techniques. For further
EN 10025 grade S355 plate (Grade 50 to
dimensions according to connection plate B
support and advice, please contact our
BS4360) of the dimensions shown in table 3.
in table 3 should be followed.
technical team.
This will ensure a connection which has a
Coupler Connector Available in all sizes,
yield strength equal to the minimum tendon
these couplers are supplied with a welded
yield strength.
lug to create a hanger connection, removing
Spades are designed to be connected to forks
sag in long span applications, please contact
or between grade 355 plates, simulating a
the Technical Department with your
fork/spade connection.
requirements.
couplers and turnbuckles. These components
Pins connect the fork or spade to the host
complement the Macalloy 460 and S460
Coupler Connector
structure and may be held in place with either circlips or architectural caps.
Lock covers not only help to lock the components in place and hide the remainder of the bar thread form, but they also provide an aesthetic and smooth transition from component to bar. They may be used either side of a turnbuckle or coupler and at the back end of a fork or spade.
Couplers and turnbuckles are a small and unobtrusive way of joining 2 or more bars together when tendons are longer than the maximum bar length. The turnbuckles can further be used to apply a torque or induce a
Table 2: Standard Central Connection Plates Connection Disc
D/10
D/12
D/16
D/20
D/24
D/30
D/36
D42
D/48
D/56
System Size
M10
M12
M16
M20
M24
M30
M36
M42
M48
M56
ØD
130
164
218
248
294
386
444
502
572
694
ØI
96
120
160
180
210
280
320
360
410
500
T
10
10
12
15
20
22
30
35
40
45
11.5
13.
17
21.5
25.5
31.5
37.5
43.5
49.5
57.5
50
70
90
105
115
160
185
205
235
290
ØP ØH (Optional)
7
Macalloy 460 and S460 Bar Systems Table 3: Component Dimensions - Macalloy 460 and Macalloy S460 Stainless Thread
Units
Fork Ref.
M10
M12
M16 M16
M20
M24
M30
M36
M42
M48
M56
M64
M76
M85
M90
M100
FA10
FA12
FA16
FA20
FA24 FA24
FA30
FA36
FA42
FA48
FA56
FA64
FA76
FA85
FA90
FA100
L
mm
63
75
99
122 122
148 148
178 178
204
232
266
314
348
410
4 59
489
555
G (min.)
mm
11
12
15
19
24
26
34
39
44
49
59
76
78
86
91
C Dia.
mm
17
19
25
29
35
44
52
60
69
80
91
108
121
129
143
D Dia
mm
11.5
13
17
21.4
25.5
31.5
37.5
4 3. 5
49.5
57.5
6 5. 5
78.5 78
91.5
96.5 96
111.5
E
mm
18
22
29
34
42
53
61
70
81
97
111
132
153
162
188
Y
mm
20
22
28
37
44
50
64
75
87 87
97 97
115
146
154
169
174
H
mm
30
34 34
45 45
53
64
81
94
109
123
147
169
201
2 36
2 48
28 9
GPA10 GPA12 GPA16 GPA20 GPA24 GPA30 GPA36 GPA42 GPA48 GPA56 GPA64
GPA76
Gusset Plate Ref. A*
GPA85 GPA90 GPA100
T (thickness)
mm
10
10
12
15
20
22
30
35
40 40
45
55
70 70
70
80 80
85
D
mm
11.5
13
17
21.5
25.5
31.5
37.5 37 .5
43.5
49.5
57.5 57 .5
65.5
78.5
91.5
96.5
111.5 11 1.5
E
mm
18
22
29
34
42
53
62
71
81
97
1111 11
132
153
162
189
H (min)
mm
30
34
45
53
63
81
95 95
1099 10
1233 12
147 147
1699 16
2011 20
236 236
248
289
Gusset Plate Ref. B**
GPB10 GPB12 GPB16 GPB20 GPB24 GPB30 GPB36 GPB42 GPB48 GPB56
T (thickness)
mm
8
9
12
15
20
22
30
35
40
45
D
mm
15. 5.55
17
21
25.5 25 .5
30
36
42 42
48
55.5 55 .5
63.5 63 .5
E
mm
20
24
31
36
44
55
64
72
83
99
H (min)
mm
36
40
51
57
67
85
99
113
127
151
SA10
SA12
SA16
SA20
SA24
SA30
SA36
SA42
SA48
SA56
SA64
SA76
SA85
SA90
SA100
Spade Ref. B
mm
78
92
118
147
174
213
2 49
28 4
321
36 4
40 8
471
52 4
5 55
62 5
T (min.)
mm
8
9
12
15
20
22
30
35
40
45
55
70
72
80
85
C Dia.
mm
17
19
25
29
35
43
52
60
68
80
91
108
121
129
143
D Dia
mm
11. 1.55
13
17.5
21.5 21 .5
25.5 25 .5
31. 1.55
37.5
43.5 43 .5
49.5 49 .5
57.5
65.5 65 .5
78. 8.55
91. 1.55
96.55 96.
111. 1.55
E
mm
18
22
29
34
42
53
62
71
81
97
111
132
153
162
189
H
mm
30
34
45
53
63
81
95
109
123
147
169
201
2 36
2 48
28 9
PA10
PA12
PA16
PA20 PA
PA24 PA
PA30 PA
PA36
PA4 2 PA
PA48
PA5 6
PA6 4
PA76
PA85
PA90
PA10 0
Architectural Pin Ref. P Dia.
mm
10.5
12
16
20
24
29
35
41
47
55
63
76
90
93
108
M
mm
22
24
30
39
46
52
66
78
91
100
120
151
155
175
180
PE10
PE12
PE16 PE
P E2 0
PE24
PE30
PE36
PE42
PE48
PE56
PE64
PE76
PE85
PE90
PE100
Engineering Pin Ref. P Dia
mm
10.5
12
16
20
24
29
35
41
47
55
63
76
90
93
108
L
mm
22
24
30
39
46
52
66
78 78
91
100
120
151
155
175
180
TA10
TA12
TA16
TA20
TA24
TA30
TA36
TA42
TA48 TA
TA56
TA64
TA76 TA
TA85
TA90
TA100
Turnbuckle Ref. O/D
mm
17
19
25
29
35
43
52
60
68
80
91
108
121
129
143
Z
mm
50
50
50 50
50
50
100
100
100
100
100
100
100
100
100
100
P
mm
74
78
86
90 90
98 98
160
172
184
196
212
22 8
2 52
270 27
280
30 0
CA10
CA12
CA16
CA20
CA24
CA30
CA36
CA42
C A4 8 CA
CA56
CA64
C A7 A76
CA85
C A9 0 CA
CA100
Coupler Ref. O/D
mm
17
19
25
29
35
43
52
60
68
80
91
108
121
129
143
L
mm
25
29
37
45
53
65
77
89
101
117
133
157
175
185
20 5
Standard Lock Cover Ref. LC10
LC12
LC16
LC20
LC24
LC30
LC36
LC42
LC48
LC56
LC64
LC76
LC85 LC
LC90
LC100
X Dia
mm
16
18
24
28
34
42
51
59
67
79
90
107
120
128
142
N
mm
29
31
37
43
74 74
105
111
117
123
136
144
156
165
170
180
LCS CS116 LCS2 S200 LCS CS24 24 LCS CS30 30 LCS CS36 36 LCS CS42 42
LCS4 S488
LCS CS56 56
Stainless Lock Cover Ref. LCS CS110 LCS CS112 X Dia
mm
16
18
24
28
34
42
51
59
67
79
N
mm
29
31
37
43
65
90
100
100
100
105
Standard and Stainless Lock Covers for Turnbuckles in the range M10 to M2 0 are longer than those shown * Standard S355 plate or equivalent strength ** For use with isolation sleeves and washers
8
Installation & Stres Stressing sing Installation Guidelines 1. The full tendon should be assembled on the ground with all the necessary forks, turnbuckles and couplers in place ensuring a minimum of 1 x thread engagement to provide a full strength joint. The pins should not be in place at this stage, but the length of the overall tendon should be set at the required pin-to-pin dimension. 2. The tendon should then be lifted in to place with the appropriate lifting equipment. 3. Once the fork is located over the structural connection plate the pin should be placed through the fork. 4. When the pins are in place and secured, the tendon is now in a position to be adjusted and tensioned.
Adjustment/Tensioning of Tendon without a Turnbuckle
Macalloy has provided the market with
A tendon with fork ends but no turnbuckle is
It was recognized that there was a need to
configured with a right hand threaded fork to
develop a way of accurately controlling the
one end of the bar and a left hand threaded
amount of load in a tendon for certain
fork to the other end. Tendon length
applications and so the Macalloy
adjustment or tightening can then be
TechnoTensioner, a patented tool, was
achieved by screwing the lock covers back
introduced in the 1990s 1990s..
1. Using a turnbuckle
from the forks and then rotating the bar
M10 – M24 inclusive, +/- 25mm
The hydraulic stressing unit is placed over
relativee to the forks. This can be done by relativ
M30 – M100 inclusive, +/- 50mm
the standard turnbuckle joint and is clamped
gripping the bar directly using a strap
onto the lock covers at either side of the
2. Using left/right hand forks to the ends of
wrench, chain wrench or wrench. The lock
turnbuckle. The live load is then induced into
the bars.
covers must be screwed tightly against the
the tendon through the TechnoTensioner TechnoTensioner and
Each fork will give the following adjustment:
forks in the tendon’s final position. If a small
can be measured with a degree of accuracy
M10 – M56 inclusive, +/- 1 ⁄ 2 thread diameter
amount of known load needs to be induced, a
of +/- 2.5%.
M64 – M100 inclusive, +/- 25mm
torque vs load relationship can be provided.
Length Adjustment/ Tensioning of Tendon without Forks
Adjustment/Tensioning of Tendon with a Turnbuckle A tendon with a turnbuckle can be adjusted
required on site to operate such equipment
If a tendon does not include a fork at one or
in length or tightened by screwing the lock
this can also be provided.
both ends, the easiest way to adjust the
covers back from the turnbuckle body and
tendon length or induce a small amount of
then rotating the turnbuckle. This can be
load is to anchor the tendon via a nut and
achieved using a strap wrench, chain wrench
washer, bearing onto suitable steelwork. The
or wrench. The lock covers must be screwed
nut can then be rotated with a spanner or
tightly against the turnbuckle in the tendon’s
wrench to tighten the tendon or adjust its
final position. If a small amount of known
length. If a small amount of known load
load needs to be induced, a torque vs load
needs to be induced, a torque vs load
relationship can be provided.
For full installation guidelines, please contact a member of the Technical Department.
In Situ Adjustment Macalloy 460 and S460 systems allow a certain amount of adjustment to be achieved:
relationship relationsh ip can be be provided provided.. If a large and/or accurate load needs to be induced, this can be achieved using a calibrated hydraulic jack at the nut end of the bar tendon.
Stressing using the Macalloy TechnoTensioner Since the introduction of its Tension Structures systems in the early 1980s,
original methods for stressing its tendons.
There are several units which cover the full range of diameters available for hire from the Macalloy Site Services department. Similarly,, should specialist sup ervision be Similarly
Further details can be found in our Site Services brochure or can be requested from our Site Services or Tec Technical hnical Departments. Please note that the TechnoTensioner TechnoTensioner should only be used with the Stainless systems under advice from M acalloy acalloy..
Macalloy TechnoTensioner
9
Macalloy 460 & S460 Compression Struts Pin to Pin Length
Compression Struts
508mm and in lengths of up to 14m. For
These utilise standard Macalloy 460 and
contact the Technical department.
information on the stainless range, please
S460 components together with standard circular hollow sections in order to produce a pin ended compression member. Since their introduction, the Macalloy Compressi Compression on
The system contains tapered sections at either end that are designed to suit and connect the fork to the CHS.
Struts have been used on several high profile projects, including 88 Wood Street and Wembleyy Stadium. Wemble
Components Standard Macalloy 460 and S460 fork and pin sets are used together with Grade S275
Hollow Sections Circular Hollow Sections (CHS) are available in carbon and stainless material. The carbon
or Grade S355 CHS. A locking collar may be used at both ends to lock the forks in to position after length adjustment.
range comes in diameters from 26.9mm to
Corrosion Protection The Macalloy Compression Strut system can be provided with corrosion protection if required. This can take the form of galvanising or painting to your preferred specification.
Tolerances and Adjustments The cutting tolerance for CHS is +/-3mm. Adjustment within each fork is: 88 Wood Streeet
M10 – M56 +/- 1 ⁄ 2 thread diameter
Arch Ar chit itec ect: t:
M64 – M100 +/- 25mm
Rich Ri char ardd Roge Rogers rs Partnership
Engineer Engi neers: s: Ove Arup and Par Partner tner
10
Macalloy SC460 Stainless Cable Systems Table 4: Tendon Capacity for the Macalloy SC460 Stainless Cable Systems Cable Dia.
mm
3
4
5
6
7
8
10
12
14
16
19
22
26
Break Load
kN
7.1
12.6
19.6
28.2 28 .2
34.8 34 .8
45.5 45 .5
71. 1.11
102 02.0 .0
139 39.0 .0
182 82.0 .0
212.0
285. 28 5.0
398. 39 8.00
Macalloy SC460 Steel Tendons
between 0.10 and 0.75% of the cable length,
The system is designed to match the
depending on the magnitude and frequency
minimum break load of the 1x19 strand
After the success of the Macalloy 460 and
of loading, and should always be considered
cable. If fittings are required to match the
S460 systems, and also in order to meet the
in the design of the structure.
minimum break load of the compact strand,
ever increasing needs of its customers, the
Macalloy offers three types of cable:
Macalloy SC460 Stainless Cable System has
please seek advice from the Macalloy technical department with regard to
1x19 spiral strand, has moderate initial
been introduced.
component sizes.
stretch properties. All the cable adaptor
This specially designed system incorporates
fittings are designed to match the minimum
cable adaptors, which allow standard
breaking load of the 1x19 cable
imperial threaded swaged cables to be connected to the standard Macalloy S460 range of forks. By using the standard Macalloy S460 forks on the cable ends,
All forks may be connected to either carbon
Compact strand has a higher breaking load
steel or stainless steel connection plates with
along with a lower initial stretch than the
an equivalent strength to BS EN 10025 grade
1x19 strand cable and is available in most
S275 or Grade 316 to BS 970.
diameters
continuity of design remains in projects
Connection Plates
Where carbon steel plates are used, isolation
where standard Macalloy 460 & S460 bar
7x19 strand is the most flexible cable and is
sleeves and washers may be required to
systems have been used alongside the
ideal where this property is paramount.
prevent bi-metallic corrosion, in which case
Macalloy SC460 Stainless Cable Systems.
the dimensions of Gusset Plate Ref B should
Standard Components SC460 Tendons
be used. For more details on other connection plates please see page 7.
The fork and pin components of the system are all made from austenitic/duplex*
Macalloy SC460 Stainless Cable
Finish
stainless steel. The swaged fittings are
All components are finished in a Grit 220
factory swaged to either end of the cable,
(N3) polished finish. Other finishes are
The cable used in the system undergoes both
and the strength of the connection exceeds
available on request, please contact a
a conventional elastic stretch as well as an
the break load of the cable.
member of the Sales team.
initial stretch. This initial stretch can be
*Pin set bodies above SPA24 may be in martensitic stainless steel
Table 5: Component Dimensions – Macalloy SC460 Stainless Cable Systems Cable Dia.
mm
3
4
5
6
7
8
10
12
14
16
19
22
26
M10
M10
M12
M12
M16
M16
M20
M24
M24
M30
M30
M42
M42
L1
90
90
112
122
149
149
201
235
235
288
288
367
383
L2
168.5
168.5
206
233.9
275.7
287.6
378.6
443
461
539
573
689
749.5
17
17
19
19
25
25
29
35
35
44
44
60
60
+
8
8
11
13.7
15
15
22
24.7
24.7
30.7
30.7
37.7
41
–
16
16
22
27.3
30
30
44
49.3
49.3
61.3
61.3
75.3
82
Fork Required
Dia 1 Adjustment
Note:: Note
Design length Design length of tend tendon on taken taken at at zero adjus adjustmen tment.t. Adjustment is per cable adaptor. + Lengthening – Shortening
NOTE: L2 SHOWN AT MANUFACTURED LENGTH
11
Macalloy-Tensoteci Galvanised Cable Tendons As well as the extensive range of bar and
systems. Some of their notable reference
experience in design, manufacture, erection
cable systems in both carbon and stainless
sites are the cable systems of the giant
and stressing of tensile systems. Together
steel, Macalloy Ltd is also able to provide a
London Eye observation wheel in the UK, the
this newly formed partnership can offer the
galvanised cable range to complement its
suspension cables system of the Braga
market a complete and comprehensive
existing tensile systems. Through a close
Stadium in Portugal designed by Souto de
solution for wide span tensile structures
relationship with Tensoteci, a division of the
Moura and the Athens Olympic stadium roof
using steel bars and cables.
Radaelli Tecna Tecna Group of companies, Macalloy
designed by Santiago Calatrava.
offers large diameter galvanised steel cable
Macalloy offers both open spiral strand and
package of bar and cable solutions in both
systems.
full locked coil strand in standard diameters
carbon and stainless steel for Tension
Tensoteci, Tens oteci, Italy’s leading manufacturer of
up to 88mm and 128mm respectively.
Structure applications to architects,
steel wire ropes, cables and accessories,
Standard eye components include fork
engineers and contractors worldwide.
boasts over 100 years of experience. Based in Milan, the company has supplied many
sockets, cylindrical sockets and bridge sockets.
No other company can offer such a complete
Further information on these products can be found in the Macalloy-Tensoteci brochure
prestigious projects throughout the world
The partnership between the two well
or can be requested from the Macalloy
with its large diameter galvanised steel cable
established companies combines years of
Technical Techni cal Department. Department .
Athens Olympic Stadium Archit Arc hitect ect::
Santia San tiago go Ca Calat latra rava va
12
Macalloy Guy Linking Bar & Cable Systems The Macalloy Guy Linking systems systems are a
The bar is available in all diameters up to
range of stainless steel architectural bar and
6m. Longer lengths are available on special
cable systems. Typical applications include:
request but may be subject to increased lead times. Alternatively, Alternatively, couplers provide an
• Mem Membr brane ane struct structure uress
unobtrusive full strength joint.
• Lig Lightwe htweight ight steel steel structur structures es
Components
• Fo Footb otbri ridg dges es • Gl Glas asss Facad Facades es
All components are made from austenitic
• Bal Balus ustr trad adee
stainless steel Grade 316 to BS 970. The
The mechanical and chemical properties of the stainless steel are such that a corrosion protection system is not normally necessary necessary,, eliminating the need for costly paint systems and their inherent long term maintenance.
All forks and pins are designed to match the minimum yield and break load of the bar, as given in table 6, when used with the
Lisbon Expo
dimensions with isolation, please consult our technical team.
Where extra adjustment is required,
turnbuckles can be provided.
Bar
Connection Plates
The Macalloy Guy Linking bar has a 2
minimum yield stress of 315 N/mm for the 2
smaller diameters, falling to 205 N/mm for the larger diameters. Likewise, the minimum 2
breaking stress ranges from 600 N/mm to 510 N/mm2. Minimum elongation is 15%. Whilst the above yield stresses are the standard, Macalloy frequently designs and supplies higher grade systems using cold drawn rod, with bespoke components to
Glyndebourne Opera House, UK
pins, couplers and nuts.
appropriate connection plate.
Macalloy Guy Linking Stainless Bar Tendon
match the load of the bar.
standard component range includes forks,
As with the stainless Macalloy S460 range,
Finish All fittings are provided in an N2 bright polished finish. The bar is finished in a Grit 220 (N3) polished finish.
all forks may be connected to either carbon steel or stainless steel connection plates with an equivalent strength to BS EN 10025 grade S275. Where carbon steel connection plates are used, isolation sleeves and washers are required to prevent bi-metallic corrosion. Dimensions of connection plates, without isolation, are given in table 7. 7. For plate
Adjustment The adjustment within each fork end is +/- 1 thread diameter. The bar is threaded with opposite threads at either end. The system may therefore be adjusted by rotating the bar in situ.
13
Macalloy Guy Linking Bar & Cable Systems Table 6: Tendon Capacities for Macalloy Guy Linking Bar Tendons Thre Th read ad UN UNFF
Unit Un itss
1/44 1/
5/116 5/
3/88 3/
7/1 /166
1/22 1/
5/88 5/
3/44 3/
7/8
1
1 1/ 1/88
1 1/ 1/44
1 3/ 3/88
mm
6.4
8
9.5
11
12.7
16
19
22
25.4
28.6 28
31.8 31
34.9
Min. Yield Load
kN
7.1
11.4
17.3
23.4
31.7
38
59
69
90
100
140
171
Min. Break Load
kN
13.5 13
21.7
33
44.6
60.3 60
92
140 14
164
213
2 26 22
348
427
kg/m
0.25
0.39
0.56
0.76
0.99
1.55
2,24
3.04
3.98
5.03
6.21
7.52
Nominal Bar Dia.
Nominal Bar Weigh Weightt
Oxford House, Hong Kong Architect: Wong & Ouyang HK Façade Engineer: Meinhardt Façade Technology (HK) Façade Sub-Contractor: United Reliance Corporation
Table 7: Component Dimensions - Guy Linking Bar Thread UNF Nominal Bar Dia.
Units
1/4
5/16
3/8
7/16
1/2
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
mm
6.4
8
9.5
11
12.7
16
19 19
22
25.4
28.6
31.8
34.9
FB6
FB8
FB10
FB11
FB12
FB16 FB
FB19
FB22
FB25
FB28 FB
FB32 FB
FB35
Bar Fork Ref L
mm
37
46.5
56 56
63 63
71
87 87
108
117
133
149
170
186
G
mm
7
8.5
10
12
14
17 17
21
24
26.5
30
35 35
36.5
D Dia.
mm
6.9
8.5
9.5
11.8
13.1
16.4
19.5
20.4
26 26
27.6
33.6
36
E
mm
8. 5
11.5
12 12
18
17.5
21
26.5
31.5
36
43
48
52
OD
mm
16
19
22.2
28.6
31.8
38.1
47.5
50.8
57.2
63.5
76.2
82.5
P Dia.
mm
6.4
8
9
11.4
12.5
15.5
18.8
19.8
25.5
27.3 27
32
35.2
PL
mm
21.6
25.3
27.7
34.1
38.3
44.6
56.1
61.4
69.8
76.1
92
98
GP6
GP8
GP10
GP11
GP12
GP16 GP
GP19
GP22
GP25
GP28 GP
GP32
GP35
Gusset Plate Ref. T (thickness)
mm
6
6
8
10
12
15
16
20
25
25 25
30
35
D Dia.
mm
7
9
10 10
12.5
14.5
16.5
19
21
26.5
28.5
33
36.5
E
mm
11
15
17
20
22
23
30
28
32
35
40
44
H
mm
17
24
27
30
34
36
46
46
52
57
66
71
CB6
CB8
CB10 CB
CB11
CB12
CB16
CB19
CB22
CB25
CB28
CB32
CB35
Coupler Ref. L
mm
25
30
35
40
45
55
65
75
85
95
105
120
OD
mm
10
12
16
16
19
22
28
32
35
41
44
50
14
Macalloy Guy Linking Bar & Cable Systems Table 8: Minimum Break Loads for Guy Linking Strand & Cable Nominal Cable Dia.
mm
3
4
5
6
7
8
10
12
14
16
19
22
26
1x19 Strand
kN
7.1
12.6
19.6
28.2 28 .2
34.8 34 .8
45.5 45 .5
71. 1.11
102 02.0 .0
139 39.0 .0
182 82.0 .0
212.0
285. 28 5.0
398. 39 8.00
Compact Strand
kN
17.4
23.9
34.8
48.1
60.3
95.0
141.2
189.2
251.0
7x19 Cable
kN
8.9
13.9
20.0
27.3
35.6
55.6
80.0
109.0
143.1
5.0
Macalloy Guy Linking Stainless Cable Systems
7x19 strand is constructed from 7 strands
stainless steel Grade 316 to BS 970. The
each in turn constructed from 19 wires. It is
fittings are swaged to the end of the cable,
the least stiff of cables that can be swaged
providing a connection strength that exceeds
Cable
and is ideal in situations where flexibility is
the breaking load of the cable. The swaging
a primary requirement.
process is usually performed under factory
Wire cable undergoes two types of stretch under load – an initial stretch and a conventional elastic stretch. The initial stretch is dependent upon cable construction and is caused by individual wires bedding down into a loaded position. This initial stretch can be between 0.10 and 0.75% of the cable length, depending on the magnitude and frequency of loading, and should always be considered when designing tendons. There are 3 different types of cables offered by Macalloy M acalloy..
conditions to ensure the correct cable length
Young’s Modulus of the Cable
is achieved.
The apparent Young’s Modulus (E) of the Guy
All components for our cable systems are
Linking Cable systems are:
designed to match the minimum break load of the 1x19 strand cable. If fittings are
1x19 Strand
2
required to match the minimum break load
2
of compact strand, please seek advice from
107 kN/mm
Compact Strand
133 kN/mm
7x19 Strand
85 kN/mm
2
regard to component sizes. The elastic stretch (d ) of a cable may be calculated by use of the following formula:
spiral strand. The wires have a smooth bright finish and the cable has moderate initial stretch properties. All our cable tendon fittings are designed to match the minimum breaking load of the 1x19 strand cable.
Compact Strand offers a 30% increase in breaking load over the conventional 1x19 strand and a much lower initial stretch. It also has a higher elastic modulus making it ideal for use where high strength and low stretch is required.
As detailed below table 8, there are 3 types of standard tendons:
d =
Load (kN) x Length (mm) 2
The most common strand used is the 1x19
the Macalloy technical department with
E (kN/mm2) x Cross Sectional Area (mm )
• the swaged swaged adjustabl adjustablee fork system system • the swaged swaged fork fork with swaged swaged tensioner tensioner
Please note that the above E values have been established empirically. No cable will
system • the swaged swaged fork fork with in-line in-line tensioner tensioner..
behave completely elastically and the apparent E value will consequently change
For applications where forks are not
over different stress ranges. Accurate
required, tendons may also be supplied with
stiffness values can only be calculated using
a simple LH/RH swaged stud at either end.
a reduced cross sectional area. Please
Shorter M8 metric threaded studs are also
consult our technical department for further
available for balustrade applications.
details if necessary necessary.. Dimensions are detailed in table 9.
Components As with the Guy Linking bar system, all components are made from austenitic
Additional components and fittings are available on request. These include toggles, dome nuts, standard nuts, spherical seats, etc.
15
Macalloy Guy Linking Bar & Cable Systems Table 9: Component Dimensions - Guy Linking Cable Nominal Cable Dia.
mm
Swaged Adjustable Fork Ref
3
4
5
6
7
SAF3 SA F3
SAF4 SA F4
SAF5 SA F5
SAF6 SA F6
SAF7 SAF7
8
10
SAF8 SA SAF1 F100
12
14
16
19
SAF12 SAF 12 SA SAF1 F144
SAF16 SAF 16
SAF199 SAF1
22
26
SAF22 SAF 22 SA SAF2 F266
L
mm
111
122
150
180
201
213
282
3 32
35 0
40 0
43 4
50 9
572
Adjustment +/-
mm
12
12
16
20
22
22
32 32
36 36
36
45 45
45 45
55 55
60 60
G
mm
7
7
8.5
10
12
12
17
21 21
21
26.5
26.5
35 35
3 6. 5
D Dia.
mm
6.99 6.
6.9 6.9
8.55 8.
9.5 9.5
11. 1.88
11. 1.88
16. 6.44
19.5
19.5
26
26
33.6 33 .6
36
E
mm
8.5
8.5
11.5
12
18
18
21
2 6. 5
2 6. 5
36
36
48
52
OD
mm
16
16
19
22.2 22 .2
28.6 28 .6
28.6 28 .6
38.1 38 .1
47.5
47.5
57.2 57
57.2
76.2 76 .2
82.5 82 .5
P Dia.
mm
6. 4
6 .4 .4
8
9
11.4
11.4
15.5
18.8
18.8
25.5
25.5 25
32
3 5. 2
PL
mm
21.6
21.6
25.3
27.7
34.1
34 . 1
44.6
5 6. 1
5 6. 1
69.8
69.8
92
98
GP66 GP
GP66 GP
GP88 GP
GP110 GP
GP111 GP
GP111 GP1
GP16 GP1
GP19 GP1
GP119 GP
GP25 GP 25
GP25 GP25
GP32 GP 32
GP35 GP 35
Gusset Plate Ref. ** T (thickness)
mm
6
6
6
8
10
10
15
16
16
25
25
30
35
D Dia.
mm
7
7
9
10
12.5
12.5
16.5
19
19 19
26.5
26.5
33
3 6. 5
E
mm
11
11
15
17
20
20
23
30
30
32
32
40
44
H
mm
17
17
24
27
30
30
36
46
46
52
52
66
71
SF3
SF4 SF
SF5 SF
SF6
SF7
SF8
SF10
SF12
SF14
SF16
SF19
SF22
SF26
Swaged Fork Ref L
mm
70
83
97
113
128
140
174
22 7
25 8
2 95
3 42
391
451
G
mm
6. 3
8
10
11
12.7
12.7
16
19
2 2. 2
25.4
28.6
32
35
D D ia .
mm
6. 1
8.1
9.7
11.2
12.1
12.1
16.1
19.2
22 . 4
25.7
28.5
32.2
3 5. 2
E
mm
7
9
11
12
15
15
18
23
26
31
33
39
43
OD
mm
14.3
18
22.2
25.4
28.6
28.6
38.1
47.6
54
63.5
69.9 69
76.2
82.5
P Dia.
mm
5. 9
7.9 7.
9.5
10.8
11.8
11.8
15.8
18.7
21.9
25.1
27.9
31.6
3 4. 6
PL
mm
2 0. 4
24.3
29.6
33
37 37
37
47.6
57.6
6 3. 7
75
81.1
91.1
97.7
ST33 ST
ST44 ST
ST55 ST
ST66 ST
ST7
ST8
ST110 ST
ST122 ST1
ST114 ST
ST166 ST1
ST19 ST19
ST22 ST 22
ST26 ST 26
Swaged Tensioner Ref L
mm
20 6
237
287
319
375
40 0
482
577
65 6
761
870
9 65
1105
Adjustment +/-
mm
32
37
47
50
62
62
65
77
90
105
120
132
145
G
mm
6. 3
8
10
11
12.7
12.7
16
19
22 . 2
25.4
28.6
32
35
D Dia.
mm
6. 1
8.1
9.7
11.2
12.1
12.1
16.1
19.2
2 2. 4
25.7
28.5
32.2
3 5. 2
E
mm
7
9
11
12
15
15
18
23
26
31
33
39
43
OD
mm
14.3
18
22.2
25.4
28.6
28.6
38.1
47.6
54
63.5
69.9 69
76.2
82.5
P Dia.
mm
5. 9
7.9
9.5
10.8
11.8
11.8
15.8
18.7
21.9
25.1
27.9
31.6
3 4. 6
PL
mm
2 0. 4
24.3
29.6
33 33
37 37
37
47.6
57.6
6 3. 7
75
81.1
91.1
97.7
IT3
IT4
IT5
IT6
IT7
IT8
IT10
IT12
IT14
IT16
IT19
IT22
IT26
In-Line Tensioner Ref L
mm
23 0
26 5
275
3 60
4 20
44 5
5 45
670
780
9 00
1020
1150
1325
Adjustment +/-
mm
32
37
47
50
62
62
65
77
90
105
120
132
145
SS3
SS4 SS
S S5 SS
SS6 SS
SS7
SS8
SS10
SS12
SS14
SS16
SS19
SS22
SS26
Swaged Stud Ref L
mm
83
93.5
115
137
154
166
218
25 4
272
310
3 44
3 94
447
Lt
mm
40
40
52
64
71
71
103
116
116
146
146
180
196
OD
mm
6. 3
7.5
9.1
12.5
14.3
16.1
17.8
21.4
25 25
28.1
34.5
40.4
46
Balustrade Swaged Stud Ref
BSS3
BSS4 BSS5*
L
mm
83
87
98
Lt
mm
38
38
38
OD
mm
6. 3
7.5
9.1
* Max Break Load of the BSS5 Stud Stud is 17.4kN 17.4kN
** For swaged adjustable fork only
16
Tensile Structure System
Z-14.4-427
Macalloy Ltd Local Representative:
This publication provides the technical details currently used by Macalloy Ltd in the manufacture of its components. The company reserves the right to amend technical details as and where necessary in line with its policy of continuous development.
Macalloy, Hawke Street, Sheffield Sheffi eld S9 2LN, U.K. Tel: +44 114 114 242 6704. Fax: +44 114 114 243 1324 Web site: www.macalloy.com www.macalloy.com Email:
[email protected] sales@macal loy.com is a Registered Trade Mark of Macalloy Ltd.
