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E:Hh3

Nov ’05

Macalloy Tensile Structure


System:
Macalloy 460
Carbon Steel Bar Tendons
Macalloy S460
Stainless Steel Bar Tendons
Macalloy 460 & S460 NEW
Compression Struts
Macalloy SC460 NEW
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. to be the case today.
In recognition of this, the Macalloy portfolio
Macalloy Ltd developed and introduced the of projects continues to expand with new

Olympia Stadion, Berlin

Architect: GMP

Engineer: Schlaich Bergermann


and Partner

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

Tensile Structure Systems


Tensile Structure Range • Macalloy SC460 (stainless steel cable • Macalloy Compression Struts
system) • Macalloy Connection Discs
The following systems form part of
• Macalloy Guy Linking Bar system • Macalloy Bespoke Systems
Macalloy’s standard range:
(stainless steel bar system) • Macalloy-Tensoteci (galvanised steel
• Macalloy 460 (carbon steel bar system) • Macalloy Guy Linking Cable system cable system)
• Macalloy S460 (stainless steel bar system) (stainless steel cable system)

Sazka Arena

Architect: ATIP, a.s.

Steel Structure
Design: Excon, a.s.

Contractor: Skanska CZ, a.s.

Porto Airport

Engineers: Talprojects

Contractor: Martifer
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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 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

* 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 Loctite 5068
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.
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:

Minimum Yield Stress 460 N/mm2 Lock Cover


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
5

Macalloy 460 & S460 Bar Systems


3. The tape should be removed immediately Turnbuckles give additional adjustment of: technical department who are willing to offer
from the end of the lock cover (or shortly - M10 to M24: +/- 25mm expert advice and solutions for particular
after applying the sealant). - M30 to M100: +/- 50mm projects. As well as our own machining
facility enabling special accessories to be
4. Any excess sealant should be removed
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
5. The sealant should be left to cure and if
Testing on fatigue has been carried out over completed, the in-house Test Facility is then
necessary any further tidying up can then be
2 million cycles, the results of which are able to check that components and bars meet
carried out.
available from the Macalloy technical the initial design requirements, before finally
department. leaving the premises.
Macalloy S460 Stainless Bar
Macalloy S460 is an austenitic/duplex*
stainless steel tie bar system, selected from
Approvals Special projects include:
Generally, Macalloy 460 should be used in • Dubai airport – a special 690 grade of bar
high strength stainless steel to provide the
accordance with the local structural steel system was developed which included
optimum balance of strength, ductility and
design codes. The system is the first to be special high strength connections to take
appearance. Austenitic stainless steel is
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 • Unique machined and cast components for
appeal. Practice, BS ENV 1993 (EC3) and BS5950. numerous glass façade projects
Macalloy 460 has also been tested and • Changi airport – 835 grade stainless bar
*Pin set bodies above SPA24 may be in martensitic
stainless steel approved for use in Germany under the with special forks to suit
Zulassung Nr. Z-14.4-427. • T5, Heathrow – unique finish to the thread
Macalloy S460 bar has the following form and polish for the glass wall
mechanical properties: Macalloy Bespoke Systems • T5 Rail Interchange, Heathrow – special
In addition to the standard systems that T-connection pieces to allow horizontal
Minimum Yield Stress 460 N/mm2
Minimum Breaking Stress 610 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

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: 1⁄2 thread diameter
- M64 to M100: +/- 25mm.
Photograph courtesy of Press Office
6

Macalloy 460 & S460 Bar Systems


Standard Components M460 load in to the bar, especially when used in Central Connection Plates These are circular
& S460 Tendons 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
components, including forks, spades, pins, each other. Dimensions are given in table 2.
couplers and turnbuckles. These components Connection Plate Solutions Bespoke Connection Plates Designed to
are designed and tested to match the tensile for Macalloy 460 & S460 complement the Macalloy 460 and 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.
Pins connect the fork or spade to the host
structure and may be held in place with Coupler Connector
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

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


7

Macalloy 460 and S460 Bar Systems


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

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

D mm 15.5 17 21 25.5 30 36 42 48 55.5 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

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

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

Engineering Pin Ref. PE10 PE12 PE16 PE20 PE24 PE30 PE36 PE42 PE48 PE56 PE64 PE76 PE85 PE90 PE100

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 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

Standard Lock Cover Ref. LC10 LC12 LC16 LC20 LC24 LC30 LC36 LC42 LC48 LC56 LC64 LC76 LC85 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 74 105 111 117 123 136 144 156 165 170 180

Stainless Lock Cover Ref. LCS10 LCS12 LCS16 LCS20 LCS24 LCS30 LCS36 LCS42 LCS48 LCS56

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 M20 are longer than those shown

* Standard S355 plate or equivalent strength


** For use with isolation sleeves and washers
8

Installation & Stressing


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. Macalloy has provided the market with
Adjustment/Tensioning of
For full installation guidelines, please original methods for stressing its tendons.
contact a member of the Technical
Tendon without a Turnbuckle
A tendon with fork ends but no turnbuckle is It was recognized that there was a need to
Department.
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
In Situ Adjustment fork to the other end. Tendon length applications and so the Macalloy
Macalloy 460 and S460 systems allow a TechnoTensioner, a patented tool, was
adjustment or tightening can then be
certain amount of adjustment to be achieved: introduced in the 1990s.
achieved by screwing the lock covers back
1. Using a turnbuckle from the forks and then rotating the bar The hydraulic stressing unit is placed over
M10 – M24 inclusive, +/- 25mm relative to the forks. This can be done by the standard turnbuckle joint and is clamped
M30 – M100 inclusive, +/- 50mm 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 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.
There are several units which cover the full
range of diameters available for hire from
Length Adjustment/ Adjustment/Tensioning of the Macalloy Site Services department.
Tensioning of Tendon Tendon with a Turnbuckle Similarly, should specialist supervision be
without Forks 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
Further details can be found in our Site
tendon length or induce a small amount of then rotating the turnbuckle. This can be
Services brochure or can be requested from
load is to anchor the tendon via a nut and achieved using a strap wrench, chain wrench
our Site Services or Technical Departments.
washer, bearing onto suitable steelwork. The or wrench. The lock covers must be screwed
Please note that the TechnoTensioner should
nut can then be rotated with a spanner or tightly against the turnbuckle in the tendon’s
only be used with the Stainless systems
wrench to tighten the tendon or adjust its final position. If a small amount of known
under advice from Macalloy.
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. Macalloy TechnoTensioner
relationship can be provided. If a large
and/or accurate load needs to be induced, this Stressing using the Macalloy
can be achieved using a calibrated hydraulic TechnoTensioner
jack at the nut end of the bar tendon.
Since the introduction of its Tension
Structures systems in the early 1980s,
9

Macalloy 460 & S460 Compression Struts


Pin to Pin Length

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


information on the stainless range, please
These utilise standard Macalloy 460 and contact the Technical department.
S460 components together with standard
circular hollow sections in order to produce a The system contains tapered sections at

pin ended compression member. Since their either end that are designed to suit and

introduction, the Macalloy Compression connect the fork to the CHS.

Struts have been used on several high profile


projects, including 88 Wood Street and
Components
Wembley Stadium.
Standard Macalloy 460 and S460 fork and
pin sets are used together with Grade S275
Hollow Sections or Grade S355 CHS. A locking collar may be

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.

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

Architect: Richard Rogers M64 – M100 +/- 25mm


Partnership

Engineers: Ove Arup and Partner


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 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

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

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

+ 8 8 11 13.7 15 15 22 24.7 24.7 30.7 30.7 37.7 41


Adjustment
– 16 16 22 27.3 30 30 44 49.3 49.3 61.3 61.3 75.3 82

Note: Design length of tendon taken at zero adjustment.


Adjustment is per cable adaptor.
+ Lengthening
– Shortening
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 Group of companies, Macalloy designed by Santiago Calatrava.
No other company can offer such a complete
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, 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 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.

Athens Olympic Stadium

Architect: Santiago Calatrava


12

Macalloy Guy Linking Bar & Cable Systems


The Macalloy Guy Linking 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, couplers provide an
• Membrane structures unobtrusive full strength joint.
• Lightweight steel structures
• Footbridges Components
• Glass Facades
All components are made from austenitic
• Balustrade
stainless steel Grade 316 to BS 970. The
standard component range includes forks,
The mechanical and chemical properties of
pins, couplers and nuts.
the stainless steel are such that a corrosion
protection system is not normally necessary,
All forks and pins are designed to match the
eliminating the need for costly paint systems
minimum yield and break load of the bar, as
and their inherent long term maintenance. Lisbon Expo
given in table 6, when used with the
appropriate connection plate. dimensions with isolation, please consult our
Macalloy Guy Linking
technical team.
Stainless Bar Tendon
Where extra adjustment is required,

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
2
As with the stainless Macalloy S460 range, 220 (N3) polished finish.
smaller diameters, falling to 205 N/mm 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

Glyndebourne Opera House, UK


13

Macalloy Guy Linking Bar & Cable Systems


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

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 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
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 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

Macalloy Guy Linking Bar & Cable Systems


Table 9: Component Dimensions - Guy Linking Cable
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

* Max Break Load of the BSS5 Stud is 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 S9 2LN, U.K. Tel: +44 114 242 6704. Fax: +44 114 243 1324
Web site: www.macalloy.com Email: sales@macalloy.com

is a Registered Trade Mark of Macalloy Ltd.