macalloy tensile structure - bbr polska macalloy 460 & s460 bar systems 6 standard components...

Macalloy Tensile StructureSystem:

Macalloy 460Carbon Steel Bar Tendons

Macalloy S460Stainless Steel Bar Tendons

Macalloy 460 & S460Compression Struts

Macalloy SC460Stainless Steel Cable Tendons

Macalloy Guy LinkingStainless Steel Bar Tendons

Macalloy Guy LinkingStainless Steel Cable Tendons

Macalloy-TensoteciGalvanised Cable Tendons

E:Hh3Jan ’08

Experience Innovation Quality

NEW

NEW

ETA-07/0215

2

Olympia Stadion, Berlin

Architect: GMP

Engineer: Schlaich Bergermannand Partner

Contractor: DSD

Tensile Structure Systems

Since the 1940s Macalloy Ltd has been

leading the way in the design, manufacture

and supply of threaded bar systems,

consistently serving its various markets with

experience, innovation and quality.

Macalloy Ltd developed and introduced the

concept of Tensile Structures in the early

1980s, creating new systems and new

technology that were to change traditional

principles forever.

In recognition of this, the Macalloy portfolio

of projects continues to expand with new

and exciting opportunities being presented.

Throughout its history Macalloy Ltd has

gained much respect from architects,

engineers and contractors and this continues

to be the case today.

There are many reasons why specifiers and

contractors repeatedly choose the Macalloy

system. Here are but a few, Macalloy:

• Was the first to develop a structural tie

system with a yield stress of 460 N/mm2

• Only manufactures using rolled threads

• Offers the most comprehensive range

of bar and cable systems in both

carbon and stainless steel

• Pioneered the art of stressing tendons

(see page 8)

• Is the first to gain approval to BS ENV

1993-1 (EC3)

• Has German approval for both its carbon

and stainless steel systems

• Has a system proven in fatigue

• Is a CARES approved company

• Boasts almost 60 years of experience in

threaded bar systems

• Has an experienced team of engineers

who offer support and advice from

specification to construction stage

• Ensures all-round sound customer service

Experience, Innovation, Quality

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Tensile Structure Systems

Tensile Structure RangeThe following systems form part of

Macalloy’s standard range:

• Macalloy 460 (carbon steel bar system)

• Macalloy S460 (stainless steel bar system)

• Macalloy SC460 (stainless steel cable

system)

• Macalloy Guy Linking Bar system

(stainless steel bar system)

• Macalloy Guy Linking Cable system

(stainless steel cable system)

• Macalloy Compression Struts

• Macalloy Connection Discs

• Macalloy Bespoke Systems

• Macalloy-Tensoteci (galvanised steel

cable system)

Sazka Arena

Architect: ATIP, a.s.

Steel StructureDesign: Excon, a.s.

Contractor: Skanska CZ, a.s.

Porto Airport

Engineers: Talprojects

Contractor: Martifer

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Macalloy 460 & S460 Bar Systems

Macalloy 460 & S460 SteelTendonsDrawing on the experience, innovation and

quality of Macalloy Ltd, the 460 & S460

systems have been carefully developed to

incorporate fine grain steel with a minimum

yield stress of 460 N/mm2. This ensures that

the system is approximately 30% stronger

than the more common S355 grade steel

equivalent, enabling smaller diameters to be

used to take the same load.

Macalloy 460 Carbon BarMacalloy 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

weldable steel with a maximum carbon

equivalent of 0.55%. Arc welding may be

carried out using standard techniques and

low hydrogen rods.

Macalloy 460 bar has the following

mechanical properties:

Minimum Yield Stress 460 N/mm2

Minimum Breaking Stress 610 N/mm2

Minimum Elongation 19%

Minimum Charpy Impact Value 27J @-20˚C

Young’s Modulus 205 kN/mm2

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

M20 it is 9m. However, diameters M24 to

Thread Units M10 M12 M16 M20 M24 M30 M36 M42 M48 M56 M64 M76 M85 M90* M100*

Nominal Bar Dia. mm 10 11 15 19 22 28 34 39 45 52 60 72 82 87 97

Min. Yield Load kN 25 36 69 108 156 249 364 501 660 912 1204 1756 2239 2533 3172

Min. Break Load kN 33 48 91 143 207 330 483 665 875 1209 1596 2329 2969 3358 4206

Nominal Bar Weight kg/m 0.50 0.75 1.40 2.20 3.00 4.80 7.10 9.40 12.50 16.70 22.20 32.00 41.50 46.70 58.00

Table 1: Tendon Capacities for Carbon & Stainless Macalloy 460

* Full charpy v notch impact values available upon request only and may be subject to extended lead times

and are delivered to site with the appropriate

packaging in order to ensure minimal

damage during transportation.

Lock Cover Sealing In order to reduce

corrosion and ‘bleeding’ in the gap between

the bar and the lock cover a sealant can be

applied. Macalloy recommends Henkle/Loctite

Terostat - MS 939 or a similar proprietary

sealant as this can be painted over.

1. The joint should be made up and installed

as normal except that the inside of the lock

cover should be cleaned and, prior to

threading the lock cover back into the bar,

any grease should be removed using Loctite

7063 or a similar proprietary cleaner.

2. With the lock cover in place the “open” end

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

gun”, until the void is completely filled.

Lock Cover

M100 are available up to a maximum bar

length of 11.950m. Longer lengths may also

be available on request and are subject to

longer lead times.

Corrosion ProtectionAs a means of protecting against corrosion,

the Macalloy 460 system can be supplied

with a form of protection to suit your

specification.

Galvanising Hot dip galvanising can be

applied to the carbon bars after threading.

By galvanising after the threading process a

protection coat remains on the threaded

portion. The threads are then brushed to

remove any excess zinc and are delivered

fully assembled (dependent on length) to

ensure the components have a good fit. All

galvanising is done in accordance with the

current European Standard EN ISO 1461:1999.

Paint Macalloy can provide any form of paint

protection that is required by the client.

Painted systems are supplied fully assembled

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3. The tape should be removed immediately

from the end of the lock cover (or shortly

after applying the sealant).

4. Any excess sealant should be removed

from the end of the lock cover and around

the injection hole, and the sealant tooled to

produce a fillet.

5. The sealant should be left to cure and if

necessary any further tidying up can then be

carried out.

Macalloy S460 Stainless BarMacalloy S460 is an austenitic/duplex*

stainless steel tie bar system, selected from

high strength stainless steel to provide the

optimum balance of strength, ductility and

appearance. Austenitic stainless steel is

found to have excellent charpy v notch

impact properties adding to the system’s

appeal.

*Pin set bodies above SPA24 may be in martensitic

stainless steel

Macalloy S460 bar has the following

mechanical properties:

Minimum Yield Stress 460 N/mm2

Minimum Breaking Stress 610 N/mm2

Minimum Elongation 15%

Young’s Modulus 190 kN/mm2

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.

Stainless FinishAll 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 Adjustmentfor Carbon and StainlessBarsThe 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: +/- 1⁄2 thread diameter

- M64 to M100: +/- 25mm.

Turnbuckles give additional adjustment of:

- M10 to M24: +/- 25mm

- M30 to M100: +/- 50mm

FatigueThreads are rolled on to the bar rather than

cut to ensure minimum loss of cross sectional

area and to give excellent fatigue strength.

Testing on fatigue has been carried out over

2 million cycles, the results of which are

available from the Macalloy technical

department.

ApprovalsGenerally, Macalloy 460 should be used in

accordance with the local structural steel

design codes. The system is the first to be

designed and tested in accordance with the

requirements of the European Code of

Practice, BS ENV 1993 (EC3) and BS5950.

Macalloy 460 has also been tested and

approved for use in Germany under the

Zulassung Nr. Z-14.4-427.

Macalloy Bespoke SystemsIn addition to the standard systems that

Macalloy provides, it is also possible for

special items and systems to be designed

and produced. Macalloy has an exceptional

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

produced, there is an on-site bar threading

facility which means that one-off bar types

can be manufactured to individual

specifications. Once production has been

completed, the in-house Test Facility is then

able to check that components and bars meet

the initial design requirements, before finally

leaving the premises.

Special projects include:

• Dubai airport – a special 690 grade of bar

system was developed which included

special high strength connections to take

the full load of the bar

• Unique machined and cast components for

numerous glass façade projects

• Changi airport – 835 grade stainless bar

with special forks to suit

• T5, Heathrow – unique finish to the thread

form and polish for the glass wall

• T5 Rail Interchange, Heathrow – special

T-connection pieces to allow horizontal

and vertical bars to be joined in one

threaded connection.

Scottish Parliament.

Photograph courtesy of Press Office


6

Standard Components M460& S460 TendonsMacalloy offers a range of standard

components, including forks, spades, pins,

couplers and turnbuckles. These components

are designed and tested to match the tensile

capacity of the bar, which is itself based upon

the cross sectional area of the thread form.

Macalloy offers the same standard range of

components in stainless as it does in carbon

steel. With the exception of the lock covers,

all components are dimensionally the same

as the standard system.

Forks are designed to be connected to a BS

EN 10025 grade S355 plate (Grade 50 to

BS4360) of the dimensions shown in table 3.

This will ensure a connection which has a

yield strength equal to the minimum tendon

yield strength.

Spades are designed to be connected to forks

or between grade 355 plates, simulating a

fork/spade connection.

Pins connect the fork or spade to the host

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 PlatesConnection 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

ØP 11.5 13. 17 21.5 25.5 31.5 37.5 43.5 49.5 57.5

ØH (Optional) 50 70 90 105 115 160 185 205 235 290

load in to the bar, especially when used in

combination with the Macalloy

TechnoTensioner.

Connection Plate Solutionsfor Macalloy 460 & S460Standard Connection Plates Forks may be

connected to either carbon steel or stainless

steel connection plates, using material with

an equivalent strength to BS EN 10025 grade

S355.

If carbon steel connection plates are used

with stainless forks or vice versa, isolation

sleeves and washers may be required to

prevent bi-metallic corrosion. In such cases,

dimensions according to connection plate B

in table 3 should be followed.

Coupler Connector Available in all sizes,

these couplers are supplied with a welded

lug to create a hanger connection, removing

sag in long span applications, please contact

the Technical Department with your

requirements.

Central Connection Plates These are circular

central discs, commonly used in wind bracing

applications where tendons are used to cross

each other. Dimensions are given in table 2.

Bespoke Connection Plates Designed to

complement the Macalloy 460 and S460

systems, these can be manufactured to suit

your individual application requirements.

They are available in both carbon and

stainless steel with a choice of finishes, such

as painted, powder coated, and polished.

Your preferred company logo, lettering

and/or designs can be accommodated using

the latest laser cutting, chemical etching, or

screen printing techniques. For further

support and advice, please contact our

technical team.

Coupler Connector

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Thread Units M10 M12 M16 M20 M24 M30 M36 M42 M48 M56 M64 M76 M85 M90 M100

Fork Ref. FA10 FA12 FA16 FA20 FA24 FA30 FA36 FA42 FA48 FA56 FA64 FA76 FA85 FA90 FA100

L mm 63 75 99 122 148 178 204 232 266 314 348 410 459 489 555

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 43.5 49.5 57.5 65.5 78.5 91.5 96.5 111.5

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 97 115 146 154 169 174

H mm 30 34 45 53 64 81 94 109 123 147 169 201 236 248 289

Gusset Plate Ref. A* GPA10 GPA12 GPA16 GPA20 GPA24 GPA30 GPA36 GPA42 GPA48 GPA56 GPA64 GPA76 GPA85 GPA90 GPA100

T (thickness) mm 10 10 12 15 20 22 30 35 40 45 55 70 70 80 85

D mm 11.5 13 17 21.5 25.5 31.5 37.5 43.5 49.5 57.5 65.5 78.5 91.5 96.5 111.5

E mm 18 22 29 34 42 53 62 71 81 97 111 132 153 162 189

H (min) mm 30 34 45 53 63 81 95 109 123 147 169 201 236 248 289

Gusset Plate Ref. B** GPB10 GPB12 GPB16 GPB20 GPB24 GPB30 GPB36 GPB42 GPB48 GPB56 GP64 GP76

T (thickness) mm 8 9 12 15 20 22 30 35 40 45 55 70

D mm 15.5 17 21 25.5 30 36 42 48 55.5 63.5 72.5 85.5

E mm 20 24 31 36 44 55 64 72 83 99 111 132

H (min) mm 36 40 51 57 67 85 99 113 127 151 169 201

Spade Ref. SA10 SA12 SA16 SA20 SA24 SA30 SA36 SA42 SA48 SA56 SA64 SA76 SA85 SA90 SA100

B mm 78 92 118 147 174 213 249 284 321 364 408 471 524 555 625

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 11.5 13 17.5 21.5 25.5 31.5 37.5 43.5 49.5 57.5 65.5 78.5 91.5 96.5 111.5

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 95 109 123 147 169 201 236 248 289

Architectural Pin Ref. PA10 PA12 PA16 PA20 PA24 PA30 PA36 PA42 PA48 PA56 PA64 PA76 PA85 PA90 PA100

N 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 91 100 120 151 155 175 180

Turnbuckle Ref. TA10 TA12 TA16 TA20 TA24 TA30 TA36 TA42 TA48 TA56 TA64 TA76 TA85 TA90 TA100

O/D mm 17 19 25 29 35 43 52 60 68 80 91 108 121 129 143

Z mm 50 50 50 50 50 100 100 100 100 100 100 100 100 100 100

P mm 74 78 86 90 98 160 172 184 196 212 228 252 270 280 300

Coupler Ref. CA10 CA12 CA16 CA20 CA24 CA30 CA36 CA42 CA48 CA56 CA64 CA76 CA85 CA90 CA100

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 89 101 117 133 157 175 185 205

Fork/Spade/Turnbuckle Lockcovers LC24 LC30 LC36 LC42 LC48 LC56 LC64 LC76 LC85 LC90 LC100

X Dia. mm 34 42 51 59 67 79 90 107 120 128 142

N mm 74 105 111 117 123 136 144 156 165 170 180

Fork/Spade Lock Covers LCF10 LCF12 LCF16 LCF20

X Dia. mm 16.5 18.5 24 28

N mm 29 31 37 43

Turnbuckle Lock Covers LCT10 LCT12 LCT16 LCT20

X Dia. mm 16.5 18.5 24 28

N mm 44 44 46 48

Table 3: Component Dimensions - Macalloy 460 and Macalloy S460 Stainless

Macalloy 460 and S460 Bar Systems

* Standard S355 plate or equivalent strength** For use with isolation sleeves and washers

Note: The above M24-M100 lock covers are universal and can be

used for both forks and turnbuckles

Lock covers that are to be used with the TechnoTensioner will have a small groove that runs around the body to identify them.Unless requested otherwise standard non-TechnoTensioner lock covers will be quoted for and supplied.

8

Installation & Stressing

Installation Guidelines1. 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.

For full installation guidelines, please

contact a member of the Technical

Department.

In Situ AdjustmentMacalloy 460 and S460 systems allow a

certain amount of adjustment to be achieved:

1. Using a turnbuckle

M10 – M24 inclusive, +/- 25mm


2. Using left/right hand forks to the ends of

the bars.

Each fork will give the following adjustment:

M10 – M56 inclusive, +/- 1⁄2 thread diameter


Length Adjustment/Tensioning of Tendonwithout ForksIf a tendon does not include a fork at one or

both ends, the easiest way to adjust the

tendon length or induce a small amount of

load is to anchor the tendon via a nut and

washer, bearing onto suitable steelwork. The

nut can then be rotated with a spanner or

wrench to tighten the tendon or adjust its

length. If a small amount of known load

needs to be induced, a torque vs load

relationship can be 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.

Macalloy TechnoTensioner

Adjustment/Tensioning ofTendon without a TurnbuckleA tendon with fork ends but no turnbuckle is

configured with a right hand threaded fork to

one end of the bar and a left hand threaded

fork to the other end. Tendon length

adjustment or tightening can then be

achieved by screwing the lock covers back

from the forks and then rotating the bar

relative to the forks. This can be done by

gripping the bar directly using a strap

wrench, chain wrench or wrench. The lock

covers must be screwed tightly against the

forks in the tendon’s final position. If a small

amount of known load needs to be induced, a

torque vs load relationship can be provided.

Adjustment/Tensioning ofTendon with a TurnbuckleA tendon with a turnbuckle can be adjusted

in length or tightened by screwing the lock

covers back from the turnbuckle body and

then rotating the turnbuckle. This can be

achieved using a strap wrench, chain wrench

or wrench. The lock covers must be screwed

tightly against the turnbuckle in the tendon’s

final position. If a small amount of known

load needs to be induced, a torque vs load

relationship can be provided.

Stressing using the MacalloyTechnoTensionerSince the introduction of its Tension

Structures systems in the early 1980s,

Macalloy has provided the market with

original methods for stressing its tendons.

It was recognized that there was a need to

develop a way of accurately controlling the

amount of load in a tendon for certain

applications and so the Macalloy

TechnoTensioner, a patented tool, was

introduced in the 1990s.

The hydraulic stressing unit is placed over

the standard turnbuckle joint and is clamped

onto the lock covers at either side of the

turnbuckle. The live load is then induced into

the tendon through the TechnoTensioner and

can be measured with a degree of accuracy

of +/- 2.5%.

There are several units which cover the full

range of diameters available for hire from

the Macalloy Site Services department.

Similarly, should specialist supervision be

required on site to operate such equipment

this can also be provided.

Further details can be found in our Site

Services brochure or can be requested from

our Site Services or Technical Departments.

Please note that the TechnoTensioner should

only be used with the Stainless systems

under advice from Macalloy.

9

Macalloy 460 & S460 Compression Struts

Compression StrutsThese utilise standard Macalloy 460 and

S460 components together with standard

circular hollow sections in order to produce a

pin ended compression member. Since their

introduction, the Macalloy Compression

Struts have been used on several high profile

projects, including 88 Wood Street and

Wembley Stadium.

Hollow SectionsCircular Hollow Sections (CHS) are available

in carbon and stainless material. The carbon

range comes in diameters from 26.9mm to

Pin to Pin Length

508mm and in lengths of up to 14m. For

information on the stainless range, please

contact the Technical department.

The system contains tapered sections at

either end that are designed to suit and

connect the fork to the CHS.

ComponentsStandard Macalloy 460 and S460 fork and

pin sets are used together with Grade S275

or Grade S355 CHS. A locking collar may be

used at both ends to lock the forks in to

position after length adjustment.

Corrosion ProtectionThe 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 AdjustmentsThe cutting tolerance for CHS is +/-3mm.

Adjustment within each fork is:

M10 – M56 +/- 1⁄2 thread diameter

M64 – M100 +/- 25mm

88 Wood Street

Architect: Richard RogersPartnership

Engineers: Ove Arup and Partner

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Macalloy SC460 Stainless Cable Systems

Macalloy SC460 SteelTendonsAfter the success of the Macalloy 460 and

S460 systems, and also in order to meet the

ever increasing needs of its customers, the

Macalloy SC460 Stainless Cable System has

been introduced.

This specially designed system incorporates

cable adaptors, which allow standard

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,

continuity of design remains in projects

where standard Macalloy 460 & S460 bar

systems have been used alongside the

Macalloy SC460 Stainless Cable Systems.

Table 4: Tendon Capacity for the Macalloy SC460 Stainless Cable SystemsCable 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 34.8 45.5 71.1 102.0 139.0 182.0 212.0 285.0 398.0

Table 5: Component Dimensions – Macalloy SC460 Stainless Cable SystemsCable Dia. mm 3 4 5 6 7 8 10 12 14 16 19 22 26

Fork Required 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

Dia 1 17 17 19 19 25 25 29 35 35 44 44 60 60

Adjustment+ 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

between 0.10 and 0.75% of the cable length,

depending on the magnitude and frequency

of loading, and should always be considered

in the design of the structure.

Macalloy offers three types of cable:

1x19 spiral strand, has moderate initial

stretch properties. All the cable adaptor

fittings are designed to match the minimum

breaking load of the 1x19 cable

Compact strand has a higher breaking load

along with a lower initial stretch than the

1x19 strand cable and is available in most

diameters

7x19 strand is the most flexible cable and is

ideal where this property is paramount.

Standard Components SC460TendonsThe fork and pin components of the system

are all made from austenitic/duplex*

stainless steel. The swaged fittings are

factory swaged to either end of the cable,

and the strength of the connection exceeds

the break load of the cable.

*Pin set bodies above SPA24 may be in martensitic

stainless steel

The system is designed to match the

minimum break load of the 1x19 strand

cable. If fittings are required to match the

minimum break load of the compact strand,

please seek advice from the Macalloy

technical department with regard to

component sizes.

Connection PlatesAll forks may be connected to either carbon

steel or stainless steel connection plates with

an equivalent strength to BS EN 10025 grade

S275 or Grade 316 to BS 970.

Where carbon steel plates are used, isolation

sleeves and washers may be required to

prevent bi-metallic corrosion, in which case

the dimensions of Gusset Plate Ref B should

be used. For more details on other

connection plates please see page 7.

FinishAll components are finished in a Grit 220

(N3) polished finish. Other finishes are

available on request, please contact a

member of the Sales team.

Macalloy SC460 StainlessCableThe cable used in the system undergoes both

a conventional elastic stretch as well as an

initial stretch. This initial stretch can be

Note: Design length of tendon taken at zero adjustment.

Adjustment is per cable adaptor.

+ Lengthening

– Shortening

NOTE: L2 SHOWN ATMANUFACTURED LENGTH

11

Macalloy-Tensoteci Galvanised Cable Tendons

As well as the extensive range of bar and

cable systems in both carbon and stainless

steel, Macalloy Ltd is also able to provide a

galvanised cable range to complement its

existing tensile systems. Through a close

relationship with Tensoteci, a division of the

Radaelli Tecna Group of companies, Macalloy

offers large diameter galvanised steel cable

systems.

Tensoteci, Italy’s leading manufacturer of

steel wire ropes, cables and accessories,

boasts over 100 years of experience. Based

in Milan, the company has supplied many

prestigious projects throughout the world

with its large diameter galvanised steel cable

systems. Some of their notable reference

sites are the cable systems of the giant

London Eye observation wheel in the UK, the

suspension cables system of the Braga

Stadium in Portugal designed by Souto de

Moura and the Athens Olympic stadium roof

designed by Santiago Calatrava.

Macalloy offers both open spiral strand and

full locked coil strand in standard diameters

up to 88mm and 128mm respectively.

Standard eye components include fork

sockets, cylindrical sockets and bridge

sockets.

The partnership between the two well

established companies combines years of

experience in design, manufacture, erection

and stressing of tensile systems. Together

this newly formed partnership can offer the

market a complete and comprehensive

solution for wide span tensile structures

using steel bars and cables.

No other company can offer such a complete

package of bar and cable solutions in both

carbon and stainless steel for Tension

Structure applications to architects,

engineers and contractors worldwide.

Further information on these products can

be found in the Macalloy-Tensoteci brochure

or can be requested from the Macalloy

Technical Department.

Athens Olympic Stadium

Architect: Santiago Calatrava

12

Macalloy Guy Linking Bar & Cable Systems

The Macalloy Guy Linking systems are a

range of stainless steel architectural bar and

cable systems. Typical applications include:

• Membrane structures

• Lightweight steel structures

• Footbridges

• Glass Facades

• Balustrade

The mechanical and chemical properties of

the stainless steel are such that a corrosion

protection system is not normally necessary,

eliminating the need for costly paint systems

and their inherent long term maintenance.

Macalloy Guy LinkingStainless Bar Tendon

BarThe Macalloy Guy Linking bar has a

minimum yield stress of 315 N/mm2 for the

smaller diameters, falling to 205 N/mm2 for

the larger diameters. Likewise, the minimum

breaking stress ranges from 600 N/mm2 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

match the load of the bar.

The bar is available in all diameters up to

6m. Longer lengths are available on special

request but may be subject to increased lead

times. Alternatively, couplers provide an

unobtrusive full strength joint.

ComponentsAll components are made from austenitic

stainless steel Grade 316 to BS 970. The

standard component range includes forks,

pins, couplers and nuts.

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

appropriate connection plate.

Where extra adjustment is required,

turnbuckles can be provided.

Connection PlatesAs with the stainless Macalloy S460 range,

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. For plate

dimensions with isolation, please consult our

technical team.

FinishAll fittings are provided in an N2 bright

polished finish. The bar is finished in a Grit

220 (N3) polished finish.

AdjustmentThe 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.

Lisbon Expo

Glyndebourne Opera House, UK

13

Table 6: Tendon Capacities for Macalloy Guy Linking Bar Tendons


Thread UNF 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

Nominal Bar Dia. mm 6.4 8 9.5 11 12.7 16 19 22 25.4 28.6 31.8 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 21.7 33 44.6 60.3 92 140 164 213 226 348 427

Nominal Bar Weight 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

Table 7: Component Dimensions - Guy Linking BarThread UNF 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

Nominal Bar Dia. mm 6.4 8 9.5 11 12.7 16 19 22 25.4 28.6 31.8 34.9

Bar Fork Ref FB6 FB8 FB10 FB11 FB12 FB16 FB19 FB22 FB25 FB28 FB32 FB35

L mm 37 46.5 56 63 71 87 108 117 133 149 170 186

G mm 7 8.5 10 12 14 17 21 24 26.5 30 35 36.5

D Dia. mm 6.9 8.5 9.5 11.8 13.1 16.4 19.5 20.4 26 27.6 33.6 36

E mm 8.5 11.5 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 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

Gusset Plate Ref. GP6 GP8 GP10 GP11 GP12 GP16 GP19 GP22 GP25 GP28 GP32 GP35

T (thickness) mm 6 6 8 10 12 15 16 20 25 25 30 35

D Dia. mm 7 9 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

Coupler Ref. CB6 CB8 CB10 CB11 CB12 CB16 CB19 CB22 CB25 CB28 CB32 CB35

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

Oxford House, Hong KongArchitect: Wong & Ouyang HKFaçade Engineer: Meinhardt Façade Technology (HK)Façade Sub-Contractor: United Reliance Corporation

14


Macalloy Guy LinkingStainless Cable Systems

CableWire 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.

The most common strand used is the 1x19

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.

7x19 strand is constructed from 7 strands

each in turn constructed from 19 wires. It is

the least stiff of cables that can be swaged

and is ideal in situations where flexibility is

a primary requirement.

Young’s Modulus of theCableThe apparent Young’s Modulus (E) of the Guy

Linking Cable systems are:

1x19 Strand 107 kN/mm2

Compact Strand 133 kN/mm2

7x19 Strand 85 kN/mm2

The elastic stretch (d) of a cable may be

calculated by use of the following formula:

d = Load (kN) x Length (mm)

E (kN/mm2) x Cross Sectional Area (mm2)

Please note that the above E values have

been established empirically. No cable will

behave completely elastically and the

apparent E value will consequently change

over different stress ranges. Accurate

stiffness values can only be calculated using

a reduced cross sectional area. Please

consult our technical department for further

details if necessary.

ComponentsAs with the Guy Linking bar system, all

components are made from austenitic

stainless steel Grade 316 to BS 970. The

fittings are swaged to the end of the cable,

providing a connection strength that exceeds

the breaking load of the cable. The swaging

process is usually performed under factory

conditions to ensure the correct cable length

is achieved.

All components for our cable systems are

designed to match the minimum break load

of the 1x19 strand cable. If fittings are

required to match the minimum break load

of compact strand, please seek advice from

the Macalloy technical department with

regard to component sizes.

As detailed below table 8, there are 3 types

of standard tendons:

• the swaged adjustable fork system

• the swaged fork with swaged tensioner

system

• the swaged fork with in-line tensioner.

For applications where forks are not

required, tendons may also be supplied with

a simple LH/RH swaged stud at either end.

Shorter M8 metric threaded studs are also

available for balustrade applications.

Dimensions are detailed in table 9.

Additional components and fittings are

available on request. These include toggles,

dome nuts, standard nuts, spherical

seats, etc.

Table 8: Minimum Break Loads for Guy Linking Strand & CableNominal 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 34.8 45.5 71.1 102.0 139.0 182.0 212.0 285.0 398.0

Compact Strand kN 17.4 23.9 34.8 48.1 60.3 95.0 141.2 189.2 251.0

7x19 Cable kN 5.0 8.9 13.9 20.0 27.3 35.6 55.6 80.0 109.0 143.1

15


Nominal Cable Dia. mm 3 4 5 6 7 8 10 12 14 16 19 22 26

Swaged Adjustable Fork Ref SAF3 SAF4 SAF5 SAF6 SAF7 SAF8 SAF10 SAF12 SAF14 SAF16 SAF19 SAF22 SAF26

L mm 111 122 150 180 201 213 282 332 350 400 434 509 572

Adjustment +/- mm 12 12 16 20 22 22 32 36 36 45 45 55 60

G mm 7 7 8.5 10 12 12 17 21 21 26.5 26.5 35 36.5

D Dia. mm 6.9 6.9 8.5 9.5 11.8 11.8 16.4 19.5 19.5 26 26 33.6 36

E mm 8.5 8.5 11.5 12 18 18 21 26.5 26.5 36 36 48 52

OD mm 16 16 19 22.2 28.6 28.6 38.1 47.5 47.5 57.2 57.2 76.2 82.5

P Dia. mm 6.4 6.4 8 9 11.4 11.4 15.5 18.8 18.8 25.5 25.5 32 35.2

PL mm 21.6 21.6 25.3 27.7 34.1 34.1 44.6 56.1 56.1 69.8 69.8 92 98

Gusset Plate Ref. ** GP6 GP6 GP8 GP10 GP11 GP11 GP16 GP19 GP19 GP25 GP25 GP32 GP35

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 26.5 26.5 33 36.5

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

Swaged Fork Ref SF3 SF4 SF5 SF6 SF7 SF8 SF10 SF12 SF14 SF16 SF19 SF22 SF26

L mm 70 83 97 113 128 140 174 227 258 295 342 391 451

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 22.4 25.7 28.5 32.2 35.2

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 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 34.6

PL mm 20.4 24.3 29.6 33 37 37 47.6 57.6 63.7 75 81.1 91.1 97.7

Swaged Tensioner Ref ST3 ST4 ST5 ST6 ST7 ST8 ST10 ST12 ST14 ST16 ST19 ST22 ST26

L mm 206 237 287 319 375 400 482 577 656 761 870 965 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 22.4 25.7 28.5 32.2 35.2

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 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 34.6

PL mm 20.4 24.3 29.6 33 37 37 47.6 57.6 63.7 75 81.1 91.1 97.7

In-Line Tensioner Ref IT3 IT4 IT5 IT6 IT7 IT8 IT10 IT12 IT14 IT16 IT19 IT22 IT26

L mm 230 265 275 360 420 445 545 670 780 900 1020 1150 1325

Adjustment +/- mm 32 37 47 50 62 62 65 77 90 105 120 132 145

Swaged Stud Ref SS3 SS4 SS5 SS6 SS7 SS8 SS10 SS12 SS14 SS16 SS19 SS22 SS26

L mm 83 93.5 115 137 154 166 218 254 272 310 344 394 447

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 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

Table 9: Component Dimensions - Guy Linking Cable

* Max Break Load of the BSS5 Stud is 17.4kN ** For swaged adjustable fork only

16

Macalloy, Caxton Way, Dinnington, Sheffield S25 3QE, U.K. Tel: +44 1909 519200. Fax: +44 1909 519201Web site: www.macalloy.com Email: [email protected]

is a Registered Trade Mark of Macalloy Ltd.

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 tensile structure - bbr polska macalloy 460 & s460 bar systems 6 standard components...

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