Documente Academic
Documente Profesional
Documente Cultură
Jan ’08
ETA-07/0215
Architect: GMP
Contractor: DSD
There are many reasons why specifiers and carbon and stainless steel • Is a CARES approved company
contractors repeatedly choose the Macalloy • Pioneered the art of stressing tendons • Boasts almost 60 years of experience in
system. Here are but a few, Macalloy: (see page 8) threaded bar systems
• Is the first to gain approval to BS ENV • Has an experienced team of engineers
• Was the first to develop a structural tie
1993-1 (EC3) who offer support and advice from
system with a yield stress of 460 N/mm2
• Has German approval for both its carbon specification to construction stage
• Only manufactures using rolled threads
and stainless steel systems • Ensures all-round sound customer service
• Offers the most comprehensive range
• Has a system proven in fatigue
of bar and cable systems in both Experience, Innovation, Quality
3
Sazka Arena
Steel Structure
Design: Excon, a.s.
Porto Airport
Engineers: Talprojects
Contractor: Martifer
4
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
* Full charpy v notch impact values available upon request only and may be subject to extended lead times
Macalloy 460 & S460 Steel M100 are available up to a maximum bar and are delivered to site with the appropriate
Tendons 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.
Lock Cover Sealing In order to reduce
systems have been carefully developed to corrosion and ‘bleeding’ in the gap between
incorporate fine grain steel with a minimum Corrosion Protection the bar and the lock cover a sealant can be
yield stress of 460 N/mm2. This ensures that As a means of protecting against corrosion, applied. Macalloy recommends Henkle/Loctite
the system is approximately 30% stronger the Macalloy 460 system can be supplied Terostat - MS 939 or a similar proprietary
than the more common S355 grade steel with a form of protection to suit your sealant as this can be painted over.
equivalent, enabling smaller diameters to be specification.
1. The joint should be made up and installed
used to take the same load. Galvanising Hot dip galvanising can be
as normal except that the inside of the lock
applied to the carbon bars after threading. cover should be cleaned and, prior to
Macalloy 460 Carbon Bar By galvanising after the threading process a threading the lock cover back into the bar,
Macalloy 460 is a carbon steel with an
protection coat remains on the threaded any grease should be removed using Loctite
exceptional blend of mechanical properties,
portion. The threads are then brushed to 7063 or a similar proprietary cleaner.
combined with rolled threads to provide a
remove any excess zinc and are delivered
material with superior fatigue performance. 2. With the lock cover in place the “open” end
fully assembled (dependent on length) to
The carbon Macalloy 460 bar is also a of the lock cover should be taped over. It is
ensure the components have a good fit. All
weldable steel with a maximum carbon recommended that this is done by using a
galvanising is done in accordance with the
equivalent of 0.55%. Arc welding may be PTFE tape which is then overlaid with a stiffer
current European Standard EN ISO 1461:1999.
carried out using standard techniques and tape. The sealant is then injected into the hole
low hydrogen rods. Paint Macalloy can provide any form of paint in the side of the lock cover, using a “skeleton
protection that is required by the client. gun”, until the void is completely filled.
Macalloy 460 bar has the following
Painted systems are supplied fully assembled
mechanical properties:
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.
System Size M10 M12 M16 M20 M24 M30 M36 M42 M48 M56
ØD 130 164 218 248 294 386 444 502 572 694
T 10 10 12 15 20 22 30 35 40 45
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
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
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
T (thickness) mm 8 9 12 15 20 22 30 35 40 45 55 70
E mm 20 24 31 36 44 55 64 72 83 99 111 132
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
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
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
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
Fork/Spade/Turnbuckle Lockcovers LC24 LC30 LC36 LC42 LC48 LC56 LC64 LC76 LC85 LC90 LC100
N mm 74 105 111 117 123 136 144 156 165 170 180
N mm 29 31 37 43
X Dia. mm 16.5 18.5 24 28 Note: The above M24-M100 lock covers are universal and can be
N mm 44 44 46 48 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.
* Standard S355 plate or equivalent strength
** For use with isolation sleeves and washers
8
pin ended compression member. Since their either end that are designed to suit and
Circular Hollow Sections (CHS) are available used at both ends to lock the forks in to
in carbon and stainless material. The carbon position after length adjustment.
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.
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
Macalloy SC460 Steel between 0.10 and 0.75% of the cable length, The system is designed to match the
Tendons 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 please seek advice from the Macalloy
Macalloy offers three types of cable:
Macalloy SC460 Stainless Cable System has technical department with regard to
1x19 spiral strand, has moderate initial component sizes.
been introduced.
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
Connection Plates
imperial threaded swaged cables to be All forks may be connected to either carbon
Compact strand has a higher breaking load steel or stainless steel connection plates with
connected to the standard Macalloy S460
along with a lower initial stretch than the an equivalent strength to BS EN 10025 grade
range of forks. By using the standard
1x19 strand cable and is available in most S275 or Grade 316 to BS 970.
Macalloy S460 forks on the cable ends,
diameters
continuity of design remains in projects 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 be used. For more details on other
Tendons connection plates please see page 7.
The fork and pin components of the system
are all made from austenitic/duplex* Finish
Macalloy SC460 Stainless stainless steel. The swaged fittings are All components are finished in a Grit 220
Cable 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
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
NOTE: L2 SHOWN AT
MANUFACTURED LENGTH
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
steel wire ropes, cables and accessories, Standard eye components include fork engineers and contractors worldwide.
boasts over 100 years of experience. Based sockets, cylindrical sockets and bridge
Further information on these products can
sockets.
in Milan, the company has supplied many 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 Department.
Bar
turnbuckles can be provided. Finish
All fittings are provided in an N2 bright
The Macalloy Guy Linking bar has a Connection Plates polished finish. The bar is finished in a Grit
minimum yield stress of 315 N/mm2 for the
As with the stainless Macalloy S460 range, 220 (N3) polished finish.
smaller diameters, falling to 205 N/mm2 for
all forks may be connected to either carbon
the larger diameters. Likewise, the minimum
breaking stress ranges from 600 N/mm2 to
steel or stainless steel connection plates with Adjustment
an equivalent strength to BS EN 10025
510 N/mm . Minimum elongation is 15%.
2 The adjustment within each fork end is +/- 1
grade S275.
thread diameter. The bar is threaded with
Whilst the above yield stresses are the opposite threads at either end. The system
Where carbon steel connection plates are
standard, Macalloy frequently designs and may therefore be adjusted by rotating the
used, isolation sleeves and washers are
supplies higher grade systems using cold bar in situ.
required to prevent bi-metallic corrosion.
drawn rod, with bespoke components to
Dimensions of connection plates, without
match the load of the bar.
isolation, are given in table 7. For plate
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
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
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
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
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
14
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
Macalloy Guy Linking 7x19 strand is constructed from 7 strands stainless steel Grade 316 to BS 970. The
Stainless Cable Systems 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
and is ideal in situations where flexibility is the breaking load of the cable. The swaging
Cable a primary requirement. process is usually performed under factory
Wire cable undergoes two types of stretch conditions to ensure the correct cable length
under load – an initial stretch and a Young’s Modulus of the is achieved.
conventional elastic stretch. The initial Cable
stretch is dependent upon cable construction All components for our cable systems are
The apparent Young’s Modulus (E) of the Guy
and is caused by individual wires bedding designed to match the minimum break load
Linking Cable systems are:
down into a loaded position. This initial of the 1x19 strand cable. If fittings are
stretch can be between 0.10 and 0.75% of required to match the minimum break load
1x19 Strand 107 kN/mm2
the cable length, depending on the of compact strand, please seek advice from
Compact Strand 133 kN/mm2
magnitude and frequency of loading, and the Macalloy technical department with
7x19 Strand 85 kN/mm2
should always be considered when regard to component sizes.
designing tendons.
The elastic stretch (d) of a cable may be
calculated by use of the following formula: As detailed below table 8, there are 3 types
There are 3 different types of cables offered of standard tendons:
by Macalloy.
d= Load (kN) x Length (mm)
E (kN/mm ) x Cross Sectional Area (mm2)
2 • the swaged adjustable fork system
The most common strand used is the 1x19 • the swaged fork with swaged tensioner
spiral strand. The wires have a smooth system
Please note that the above E values have
bright finish and the cable has moderate • the swaged fork with in-line tensioner.
been established empirically. No cable will
initial stretch properties. All our cable
behave completely elastically and the
tendon fittings are designed to match the For applications where forks are not
apparent E value will consequently change
minimum breaking load of the 1x19 strand required, tendons may also be supplied with
over different stress ranges. Accurate
cable. a simple LH/RH swaged stud at either end.
stiffness values can only be calculated using
a reduced cross sectional area. Please Shorter M8 metric threaded studs are also
Compact Strand offers a 30% increase in available for balustrade applications.
consult our technical department for further
breaking load over the conventional 1x19
details if necessary.
strand and a much lower initial stretch. It Dimensions are detailed in table 9.
also has a higher elastic modulus making it
ideal for use where high strength and low
Components Additional components and fittings are
available on request. These include toggles,
stretch is required. As with the Guy Linking bar system, all
dome nuts, standard nuts, spherical
components are made from austenitic
seats, etc.
15
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
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
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
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
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
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
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
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
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
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
L mm 83 87 98
Lt mm 38 38 38
* Max Break Load of the BSS5 Stud is 17.4kN ** For swaged adjustable fork only
16
Z-14.4-427
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, Caxton Way, Dinnington, Sheffield S25 3QE, U.K. Tel: +44 1909 519200. Fax: +44 1909 519201
Web site: www.macalloy.com Email: sales@macalloy.com