E:Hh3Nov ’05 Macalloy Tensile Structure System: Macalloy 460 Carbon Steel Bar Tendons Macalloy S460 Stainless Steel Bar Tendons Macalloy 460 & S460 Compression Struts NEW 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 Here are but a few. consistently serving its various markets with principles forever. Macalloy Ltd developed and introduced the In recognition of this. Berlin Architect: GMP Engineer: Schlaich Bergermann and Partner Contractor: DSD There are many reasons why specifiers and contractors repeatedly choose the Macalloy system. manufacture 1980s.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. Innovation. of projects continues to expand with new Olympia Stadion. technology that were to change traditional gained much respect from architects. the Macalloy portfolio to be the case today. innovation and quality. creating new systems and new Throughout its history Macalloy Ltd has and supply of threaded bar systems. Quality . 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. engineers and contractors and this continues experience. a. a.s. Contractor: Skanska CZ.s. Porto Airport Engineers: Talprojects Contractor: Martifer . Steel Structure Design: Excon.3 Tensile Structure Systems Tensile Structure Range • Macalloy SC460 (stainless steel cable system) The following systems form part of • Macalloy Guy Linking Bar system Macalloy’s standard range: (stainless steel bar system) • Macalloy 460 (carbon steel bar system) • Macalloy S460 (stainless steel bar system) • Macalloy Guy Linking Cable system • Macalloy Compression Struts • Macalloy Connection Discs • Macalloy Bespoke Systems • Macalloy-Tensoteci (galvanised steel cable system) (stainless steel cable system) Sazka Arena Architect: ATIP. a.s. 50 0. gun”. systems have been carefully developed to Lock Cover Sealing In order to reduce corrosion and ‘bleeding’ in the gap between incorporate fine grain steel with a minimum Corrosion Protection yield stress of 460 N/mm2. The carbon Macalloy 460 bar is also a weldable steel with a maximum carbon equivalent of 0.4 Macalloy 460 & S460 Bar Systems Table 1: Tendon Capacities for Carbon & Stainless Macalloy 460 Thread Units M10 M12 M16 M20 M24 M30 M36 M42 M48 M56 M64 M76 M85 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. remove any excess zinc and are delivered fully assembled (dependent on length) to ensure the components have a good fit.950m. Arc welding may be carried out using standard techniques and low hydrogen rods. The sealant is then injected into the hole Paint Macalloy can provide any form of paint in the side of the lock cover. combined with rolled threads to provide a material with superior fatigue performance. until the void is completely filled. equivalent.55%. applied. With the lock cover in place the “open” end of the lock cover should be taped over. innovation and be available on request and are subject to damage during transportation.00 Nominal Bar Dia. protection coat remains on the threaded any grease should be removed using Loctite portion. The threads are then brushed to 7063 or a similar proprietary cleaner.75 1.20 32.40 2. For tendon diameters up to M16 the maximum bar length available is in 6m lengths and for M20 it is 9m. prior to By galvanising after the threading process a threading the lock cover back into the bar. Painted systems are supplied fully assembled Lock Cover .70 58. However.20 3. Nominal Bar Weight M90* M100* * Full charpy v notch impact values available upon request only and may be subject to extended lead times Macalloy 460 & S460 Steel Tendons M100 are available up to a maximum bar and are delivered to site with the appropriate length of 11. diameters M24 to as normal except that the inside of the lock applied to the carbon bars after threading.00 41.00 4. enabling smaller diameters to be specification.10 9. All galvanising is done in accordance with the current European Standard EN ISO 1461:1999. The joint should be made up and installed Macalloy 460 Carbon Bar Macalloy 460 is a carbon steel with an exceptional blend of mechanical properties. 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 the bar and the lock cover a sealant can be 205 kN/mm2 The standard diameter range for this particular system is from M10 to M100. Longer lengths may also packaging in order to ensure minimal Drawing on the experience. Break Load kN 33 48 91 143 207 330 483 665 875 1209 1596 2329 2969 3358 4206 kg/m 0.50 46.40 12. quality of Macalloy Ltd. Galvanising Hot dip galvanising can be 1.80 7. used to take the same load. It is recommended that this is done by using a PTFE tape which is then overlaid with a stiffer tape.70 22. 2. cover should be cleaned and.50 16. using a “skeleton protection that is required by the client. 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. the 460 & S460 longer lead times. This ensures that As a means of protecting against corrosion. Heathrow – unique finish to the thread form and polish for the glass wall Macalloy Bespoke Systems • T5 Rail Interchange. Any excess sealant should be removed from the end of the lock cover and around the injection hole. Macalloy S460 bar has the following mechanical properties: • Unique machined and cast components for numerous glass façade projects • Changi airport – 835 grade stainless bar with special forks to suit • T5. The system is the first to be special high strength connections to take designed and tested in accordance with the the full load of the bar 5. Z-14. 4. specifications. Adjustment within each fork or spade are: .25mm.5m in diameters M10 to M56 and lengths of 6m for M64 and M76. Macalloy 460 should be used in • Dubai airport – a special 690 grade of bar accordance with the local structural steel system was developed which included design codes. Macalloy S460 is an austenitic/duplex* stainless steel tie bar system. Approvals Special projects include: Generally. Once production has been Testing on fatigue has been carried out over completed. Austenitic stainless steel is found to have excellent charpy v notch impact properties adding to the system’s appeal. The sealant should be left to cure and if necessary any further tidying up can then be carried out. ductility and appearance. Bars are available in lengths of up to 7. although a whole range of other finishes are available from mirror finish to glass bead. it is also possible for and vertical bars to be joined in one special items and systems to be designed threaded connection. selected from high strength stainless steel to provide the optimum balance of strength. Heathrow – special Minimum Yield Stress 460 N/mm2 In addition to the standard systems that Minimum Breaking Stress Minimum Elongation Young’s Modulus 610 N/mm2 15% 190 kN/mm2 Macalloy provides.6mm for diameters less than 72mm and +/.M64 to M100: +/. As well as our own machining facility enabling special accessories to be Fatigue produced. Turnbuckles give additional adjustment of: . before finally Macalloy S460 Stainless Bar department. the results of which are able to check that components and bars meet available from the Macalloy technical the initial design requirements.25mm for larger diameters. Photograph courtesy of Press Office .25mm .50mm technical department who are willing to offer expert advice and solutions for particular projects. leaving the premises. The system comes as standard in diameters M10 to M76. Tolerance and Adjustment for Carbon and Stainless Bars The cutting tolerance for bars is +/.5 Macalloy 460 & S460 Bar Systems 3.M10 to M24: +/.4-427. there is an on-site bar threading Threads are rolled on to the bar rather than facility which means that one-off bar types cut to ensure minimum loss of cross sectional can be manufactured to individual area and to give excellent fatigue strength.M10 to M56: 1⁄2 thread diameter . and the sealant tooled to produce a fillet. T-connection pieces to allow horizontal and produced. Macalloy 460 has also been tested and approved for use in Germany under the Zulassung Nr. *Pin set bodies above SPA24 may be in martensitic stainless steel requirements of the European Code of Practice. Stainless Finish All bar and components are finished in a Grit 220 (N3) polished finish.M30 to M100: +/. BS ENV 1993 (EC3) and BS5950. the in-house Test Facility is then 2 million cycles. Please discuss your requirements with our Sales team. Macalloy has an exceptional Scottish Parliament. The tape should be removed immediately from the end of the lock cover (or shortly after applying the sealant). commonly used in wind bracing Macalloy offers a range of standard TechnoTensioner. connected to either carbon steel or stainless your individual application requirements. This will ensure a connection which has a Coupler Connector Available in all sizes. In such cases. as painted. Macalloy offers the same standard range of steel connection plates. 17 21.5 37. yield strength equal to the minimum tendon these couplers are supplied with a welded yield strength. these can be manufactured to suit the cross sectional area of the thread form. powder coated. These components Pins connect the fork or spade to the host complement the Macalloy 460 and S460 Coupler Connector structure and may be held in place with either circlips or architectural caps. technical team. applications where tendons are used to cross each other.5 13. chemical etching. components. which is itself based upon Standard Connection Plates Forks may be systems. lettering as the standard system. They may be used either side of a turnbuckle or coupler and at the back end of a fork or spade. With the exception of the lock covers.5 43. in table 3 should be followed. especially when used in Central Connection Plates These are circular combination with the Macalloy central discs. removing Spades are designed to be connected to forks sag in long span applications. Lock covers not only help to lock the components in place and hide the remainder of the bar thread form. requirements. S355. 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. 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. please contact or between grade 355 plates. spades. screen printing techniques. and polished. 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.5 25. but they also provide an aesthetic and smooth transition from component to bar. Dimensions are given in table 2. or Forks are designed to be connected to a BS prevent bi-metallic corrosion. isolation and/or designs can be accommodated using sleeves and washers may be required to the latest laser cutting. with stainless forks or vice versa. all components are dimensionally the same If carbon steel connection plates are used Your preferred company logo.5 31. such steel. simulating a the Technical Department with your fork/spade connection.5 49. lug to create a hanger connection. pins.6 Macalloy 460 & S460 Bar Systems Standard Components M460 & S460 Tendons load in to the bar. couplers and turnbuckles. 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. including forks. Bespoke Connection Plates Designed to are designed and tested to match the tensile Connection Plate Solutions for Macalloy 460 & S460 capacity of the bar.5 57.5 50 70 90 105 115 160 185 205 235 290 ØH (Optional) . 5 18. mm 17 19 25 29 35 44 52 60 69 80 91 108 121 129 143 D Dia mm 11. 9 12 15 20 15.5 111. mm 16.5 30 20 24 31 36 44 GP64 GP76 30 35 40 45 55 70 36 42 48 55.5 78.5 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.5 49.5 12 16 20 24 29 35 41 47 55 63 76 90 93 108 Architectural Pin Ref. Unless requested otherwise standard non-TechnoTensioner lock covers will be quoted for and supplied.5 31. * Standard S355 plate or equivalent strength ** For use with isolation sleeves and washers .4 25.5 91.5 78.5 111.5 18.5 65.5 63.) mm 8 9 12 15 20 22 30 35 40 45 55 70 72 80 85 C Dia.5 25.5 31.5 17 21 25.5 65.5 91.5 13 17 21.Macalloy 460 and Macalloy S460 Stainless Thread Units Fork Ref.5 85.5 37.5 37.5 43. 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 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 PA10 PA12 PA16 PA20 PA24 PA30 PA36 PA42 PA48 PA56 PA64 PA76 PA85 PA90 PA100 10.5 96.5 78.5 13 17 21.5 21.5 91.5 37.5 57.5 24 28 N mm 29 31 37 43 Turnbuckle Lock Covers LCT10 LCT12 LCT16 LCT20 X Dia. 22 24 30 39 46 52 66 78 91 100 120 151 155 175 180 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 Coupler Ref.5 55 64 72 83 99 111 132 22 36 40 51 57 67 85 99 113 127 151 169 201 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.5 57.5 25.5 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 GPB10 GPB12 GPB16 GPB20 GPB24 GPB30 GPB36 GPB42 GPB48 GPB56 Gusset Plate Ref.) mm 11 12 15 19 24 26 34 39 44 49 59 76 78 86 91 C Dia. mm L mm Turnbuckle Ref. mm 16.5 72.5 13 17.5 43.5 31.7 Macalloy 460 and S460 Bar Systems Table 3: Component Dimensions .5 43. B** T (thickness) mm 8 D mm E mm H (min) mm Spade Ref.5 49.5 57. mm N mm Fork/Spade Lock Covers LCF10 LCF12 LCF16 LCF20 X Dia.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. 74 78 86 90 98 160 172 184 196 212 228 252 270 280 300 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 LC24 LC30 LC36 LC42 LC48 LC56 LC64 LC76 LC85 LC90 LC100 34 42 51 59 67 79 90 107 120 128 142 74 105 111 117 123 136 144 156 165 170 180 Fork/Spade/Turnbuckle Lockcovers X Dia. N Dia.5 49.5 65.5 96.5 111. M10 M12 M16 M20 M24 M30 M36 M42 M48 M56 M64 M76 M85 M90 M100 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.5 96. mm 17 19 25 29 35 43 52 60 68 80 91 108 121 129 143 D Dia mm 11. If a small amount of known load needs to be induced. For full installation guidelines. +/. Using a turnbuckle M10 – M24 inclusive. Macalloy TechnoTensioner . but the length of the overall tendon should be set at the required pin-to-pin dimension. a patented tool. The tendon should then be lifted in to place with the appropriate lifting equipment. was introduced in the 1990s. Further details can be found in our Site Services brochure or can be requested from our Site Services or Technical Departments. the tendon is now in a position to be adjusted and tensioned. When the pins are in place and secured. The live load is then induced into the tendon through the TechnoTensioner and can be measured with a degree of accuracy of +/.8 Installation & Stressing Installation Guidelines 1. this can be achieved using a calibrated hydraulic jack at the nut end of the bar tendon.25mm Length Adjustment/ Tensioning of Tendon without Forks If a tendon does not include a fork at one or both ends. a torque vs load relationship can be provided. Once the fork is located over the structural connection plate the pin should be placed through the fork. The lock covers must be screwed tightly against the turnbuckle in the tendon’s final position. The full tendon should be assembled on the ground with all the necessary forks.1⁄2 thread diameter M64 – M100 inclusive. This can be done by gripping the bar directly using a strap wrench. a torque vs load relationship can be provided. chain wrench or wrench. This can be achieved using a strap wrench.25mm M30 – M100 inclusive. Adjustment/Tensioning of Tendon without a Turnbuckle Macalloy has provided the market with original methods for stressing its tendons.50mm 2. In Situ Adjustment Macalloy 460 and S460 systems allow a certain amount of adjustment to be achieved: 1. Similarly. If a small amount of known load needs to be induced. Using left/right hand forks to the ends of the bars.5%. The nut can then be rotated with a spanner or wrench to tighten the tendon or adjust its length. The hydraulic stressing unit is placed over the standard turnbuckle joint and is clamped onto the lock covers at either side of the turnbuckle. please contact a member of the Technical Department. Adjustment/Tensioning of Tendon with a Turnbuckle A 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. bearing onto suitable steelwork. Stressing using the Macalloy TechnoTensioner Since the introduction of its Tension Structures systems in the early 1980s. 4. should specialist supervision be required on site to operate such equipment this can also be provided. +/. The lock covers must be screwed tightly against the forks in the tendon’s final position. 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. There are several units which cover the full range of diameters available for hire from the Macalloy Site Services department. Each fork will give the following adjustment: M10 – M56 inclusive. +/. 3. Please note that the TechnoTensioner should only be used with the Stainless systems under advice from Macalloy. a torque vs load relationship can be provided.2. 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. 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. turnbuckles and couplers in place ensuring a minimum of 1 x thread engagement to provide a full strength joint. 2. If a large and/or accurate load needs to be induced. +/. chain wrench or wrench. The pins should not be in place at this stage. A 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. If a small amount of known load needs to be induced. including 88 Wood Street and Wembley Stadium. 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. Since their either end that are designed to suit and introduction. Struts have been used on several high profile projects. For These utilise standard Macalloy 460 and contact the Technical department. range comes in diameters from 26.25mm Richard Rogers Partnership Engineers: Ove Arup and Partner . please S460 components together with standard circular hollow sections in order to produce a The system contains tapered sections at pin ended compression member.9mm to Corrosion Protection The Macalloy Compression Strut system can be provided with corrosion protection if required. Components Standard Macalloy 460 and S460 fork and pin sets are used together with Grade S275 Hollow Sections or Grade S355 CHS. This can take the form of galvanising or painting to your preferred specification. Tolerances and Adjustments The cutting tolerance for CHS is +/-3mm.9 Macalloy 460 & S460 Compression Struts Pin to Pin Length Compression Struts 508mm and in lengths of up to 14m. information on the stainless range. Adjustment within each fork is: 88 Wood Street M10 – M56 +/. the Macalloy Compression connect the fork to the CHS.1⁄2 thread diameter Architect: M64 – M100 +/. The carbon position after length adjustment. mm 3 4 5 6 7 8 10 12 14 16 19 22 26 M10 M10 M12 M12 M16 M16 M20 M24 M24 M30 M30 M42 M42 L1 90 90 112 122 149 149 201 235 235 288 288 367 383 L2 168.3 30 30 44 49. which allow standard breaking load of the 1x19 cable imperial threaded swaged cables to be connected to the standard Macalloy S460 range of forks. initial stretch.0 139.3 75. prevent bi-metallic corrosion.3 61.5 71. If fittings are required to match the S460 systems. + Lengthening – Shortening NOTE: L2 SHOWN AT MANUFACTURED LENGTH .7 37.9 275. the Macalloy offers three types of cable: Macalloy SC460 Stainless Cable System has please seek advice from the Macalloy technical department with regard to 1x19 spiral strand.7 24. All the cable adaptor This specially designed system incorporates fittings are designed to match the minimum cable adaptors. and should always be considered cable.7 30. component sizes.5 17 17 19 19 25 25 29 35 35 44 44 60 60 + 8 8 11 13.6 378.6 443 461 539 573 689 749. The swaged fittings are All components are finished in a Grit 220 factory swaged to either end of the cable.3 49. in which case Macalloy SC460 Stainless Cable Systems. 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. ever increasing needs of its customers. The system is designed to match the depending on the magnitude and frequency minimum break load of the 1x19 strand After the success of the Macalloy 460 and of loading.3 82 Fork Required Dia 1 Adjustment Note: Design length of tendon taken at zero adjustment. All forks may be connected to either carbon Compact strand has a higher breaking load steel or stainless steel connection plates with along with a lower initial stretch than the an equivalent strength to BS EN 10025 grade 1x19 strand cable and is available in most S275 or Grade 316 to BS 970.3 61.0 398.7 30.7 287.8 45.5 206 233. please contact a a conventional elastic stretch as well as an the break load of the cable. the dimensions of Gusset Plate Ref B should Standard Components SC460 Tendons be used. Adjustment is per cable adaptor. has moderate initial been introduced.7 15 15 22 24. Other finishes are The cable used in the system undergoes both and the strength of the connection exceeds available on request.6 28. The fork and pin components of the system are all made from austenitic/duplex* Macalloy SC460 Stainless Cable Finish stainless steel.2 34.10 and 0.0 285.1 12.6 19.1 102.0 182. and also in order to meet the in the design of the structure. diameters continuity of design remains in projects Connection Plates Where carbon steel plates are used. (N3) polished finish.7 41 – 16 16 22 27.0 212. mm 3 4 5 6 7 8 10 12 14 16 19 22 26 Break Load kN 7.10 Macalloy SC460 Stainless Cable Systems Table 4: Tendon Capacity for the Macalloy SC460 Stainless Cable Systems Cable Dia.0 Macalloy SC460 Steel Tendons between 0. 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.5 168. By using the standard Macalloy S460 forks on the cable ends.75% of the cable length. member of the Sales team. stretch properties. For more details on other connection plates please see page 7. minimum break load of the compact strand. Athens Olympic Stadium Architect: Santiago Calatrava . cables and accessories. manufacture. 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.11 Macalloy-Tensoteci Galvanised Cable Tendons As well as the extensive range of bar and systems. the company has supplied many sockets. Structure applications to architects. Some of their notable reference experience in design. Standard eye components include fork engineers and contractors worldwide. Based sockets. Through a close Stadium in Portugal designed by Souto de solution for wide span tensile structures relationship with Tensoteci. Macalloy designed by Santiago Calatrava. No other company can offer such a complete Further information on these products can be found in the Macalloy-Tensoteci brochure prestigious projects throughout the world The partnership between the two well or can be requested from the Macalloy with its large diameter galvanised steel cable established companies combines years of Technical Department. Italy’s leading manufacturer of up to 88mm and 128mm respectively. Together steel. erection cable systems in both carbon and stainless sites are the cable systems of the giant and stressing of tensile systems. Macalloy Ltd is also able to provide a London Eye observation wheel in the UK. full locked coil strand in standard diameters carbon and stainless steel for Tension Tensoteci. a division of the Moura and the Athens Olympic stadium roof using steel bars and cables. boasts over 100 years of experience. Radaelli Tecna Group of companies. offers large diameter galvanised steel cable Macalloy offers both open spiral strand and package of bar and cable solutions in both systems. steel wire ropes. cylindrical sockets and bridge in Milan. Bar match the load of the bar. Macalloy Guy Linking Stainless Bar Tendon Where extra adjustment is required. Likewise. without isolation. UK dimensions with isolation. the minimum breaking stress ranges from 600 N/mm2 to 510 N/mm . isolation sleeves and washers are required to prevent bi-metallic corrosion. Minimum elongation is 15%. The system may therefore be adjusted by rotating the bar in situ. Whilst the above yield stresses are the standard. all forks may be connected to either carbon steel or stainless steel connection plates with an equivalent strength to BS EN 10025 2 Glyndebourne Opera House. Typical applications include: request but may be subject to increased lead times. falling to 205 N/mm for the larger diameters. For plate Adjustment The adjustment within each fork end is +/. Lisbon Expo grade S275. The bar is finished in a Grit 220 (N3) polished finish. Where carbon steel connection plates are used. as given in table 6. All forks and pins are designed to match the minimum yield and break load of the bar. Macalloy frequently designs and supplies higher grade systems using cold drawn rod. The Macalloy Guy Linking bar has a minimum yield stress of 315 N/mm2 for the 2 smaller diameters. Connection Plates As with the stainless Macalloy S460 range. Alternatively. please consult our technical team. Longer lengths are available on special cable systems. Dimensions of connection plates. pins. couplers provide an • Membrane structures unobtrusive full strength joint. eliminating the need for costly paint systems and their inherent long term maintenance. couplers and nuts. The bar is threaded with opposite threads at either end. are given in table 7. . • Lightweight steel structures Components • Footbridges • Glass Facades All components are made from austenitic • Balustrade stainless steel Grade 316 to BS 970. with bespoke components to Finish All fittings are provided in an N2 bright polished finish. when used with the appropriate connection plate.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. turnbuckles can be provided. The The mechanical and chemical properties of the stainless steel are such that a corrosion standard component range includes forks. protection system is not normally necessary.1 thread diameter. 1 47.5 56 63 71 87 108 117 133 149 170 186 G mm 7 8.7 34. Nominal Bar Weight Oxford House.5 19 21 26.13 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 mm 6.5 11.4 8 9. T (thickness) mm 6 6 8 10 12 15 16 20 25 25 30 35 D Dia.52 Nominal Bar Dia.5 21.98 5.5 D Dia.6 31.Guy Linking Bar Thread UNF Nominal Bar Dia.5 76.99 1.4 8 9.2 63.7 33 44.5 14.4 26 27.76 0.04 3.4 69.5 36 43 48 52 OD mm 16 19 22. 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 .03 6.1 61.6 33.5 15.1 16. Break Load kN 13.8 38. Hong Kong Architect: Wong & Ouyang HK Façade Engineer: Meinhardt Façade Technology (HK) Façade Sub-Contractor: United Reliance Corporation Table 7: Component Dimensions .7 16 19 22 25.56 0.9 8.21 7.5 11 12.6 25.5 28.55 2.5 33 36.5 18.2 82.8 13.4 8 9 11.39 0.5 27.6 31.6 36 E mm 8.3 27.5 16.5 21 26.8 19.4 19.25 0.5 20.9 FB6 FB8 FB10 FB11 FB12 FB16 FB19 FB22 FB25 FB28 FB32 FB35 Bar Fork Ref L mm 37 46.1 11. mm 6.5 31.8 34.3 92 140 164 213 226 348 427 kg/m 0.5 11.8 34.4 28.4 28.5 50. Yield Load kN 7.8 25.3 23.8 57.5 12 18 17.3 32 35.6 31.2 28. Units 1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 mm 6.6 60.6 56.7 38 59 69 90 100 140 171 Min.5 30 35 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.5 9.8 76.9 Min.5 P Dia.1 38. mm 6.4 31.7 16 19 22 25.5 10 12 14 17 21 24 26.4 17.4 12.24 3.2 PL mm 21.3 44.1 92 98 GP6 GP8 GP10 GP11 GP12 GP16 GP19 GP22 GP25 GP28 GP32 GP35 Gusset Plate Ref. mm 7 9 10 12.5 11 12. 4 23.0 27.0 7x19 Cable kN 8.0 141. tendons may also be supplied with a simple LH/RH swaged stud at either end. If fittings are required to match the minimum break load of compact strand. all components are made from austenitic stainless steel Grade 316 to BS 970. providing a connection strength that exceeds the breaking load of the cable. 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. The initial stretch is dependent upon cable construction and is caused by individual wires bedding down into a loaded position. All our cable tendon fittings are designed to match the minimum breaking load of the 1x19 strand cable. For applications where forks are not required.75% of the cable length.0 398. and should always be considered when designing tendons.6 80. All components for our cable systems are designed to match the minimum break load of the 1x19 strand cable.8 45.2 251. Compact Strand offers a 30% increase in breaking load over the conventional 1x19 strand and a much lower initial stretch. Please consult our technical department for further details if necessary. Dimensions are detailed in table 9.3 35. spherical seats. depending on the magnitude and frequency of loading.0 Macalloy Guy Linking Stainless Cable Systems Cable Wire cable undergoes two types of stretch under load – an initial stretch and a conventional elastic stretch.1 5. etc.0 285.10 and 0. mm 3 4 5 6 7 8 10 12 14 16 19 22 26 1x19 Strand kN 7. The swaging process is usually performed under factory conditions to ensure the correct cable length is achieved. dome nuts. please seek advice from the Macalloy technical department with regard to component sizes. Accurate stiffness values can only be calculated using a reduced cross sectional area. Shorter M8 metric threaded studs are also available for balustrade applications.8 48. 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.0 182.3 95. There are 3 different types of cables offered by Macalloy.2 34. .0 139. Components As with the Guy Linking bar system.9 13. As detailed below table 8.0 Compact Strand kN 17. Additional components and fittings are available on request.6 19. Please note that the above E values have been established empirically.0 212. This initial stretch can be between 0. It is the least stiff of cables that can be swaged and is ideal in situations where flexibility is a primary requirement.1 12. No cable will behave completely elastically and the apparent E value will consequently change over different stress ranges.6 55.1 60.2 189. Young’s Modulus of the Cable The apparent Young’s Modulus (E) of the Guy Linking Cable systems are: 1x19 Strand Compact Strand 7x19 Strand 107 kN/mm2 133 kN/mm2 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/mm ) x Cross Sectional Area (mm2) 2 The most common strand used is the 1x19 spiral strand.6 28.1 102. standard nuts. These include toggles.0 109.9 20.0 143. The wires have a smooth bright finish and the cable has moderate initial stretch properties.14 Macalloy Guy Linking Bar & Cable Systems Table 8: Minimum Break Loads for Guy Linking Strand & Cable Nominal Cable Dia.9 34.5 71. The fittings are swaged to the end of the cable. 8 21. mm 6.5 P Dia.1 27.6 PL mm 20.8 18.9 76.2 E mm 7 9 11 12 15 15 18 23 26 31 33 39 43 OD mm 14.2 22.6 57.7 75 81.1 97.6 32 35 D Dia.9 25.5 26 26 33. ** T (thickness) mm 6 6 6 8 10 10 15 16 16 25 25 30 35 D Dia.4 25 28.1 47.5 P Dia. mm 7 7 9 10 12.2 76.6 32 35 D Dia.8 11.5 33 36.5 32 35.9 7.8 11.1 27.4 28.3 7.2 PL mm 21.1 91.1 8.5 35 36.9 31.6 33 37 37 47.5 10 12 12 17 21 21 26.2 82.2 35.7 12.3 29.1 * Max Break Load of the BSS5 Stud is 17.5 57.5 11.1 34.1 19.6 54 63.2 25.3 7.7 34. mm Swaged Adjustable Fork Ref 3 4 5 6 7 8 10 SAF3 SAF4 SAF5 SAF6 SAF7 SAF8 SAF10 12 14 16 SAF12 SAF14 SAF16 19 22 26 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 8.7 28.1 47.6 33 37 37 47.7 21.1 16.5 12.6 38. mm 6.1 12.4 25.5 26.8 15.5 10.8 11.2 57.Guy Linking Cable Nominal Cable Dia.7 75 81.8 25.9 9.15 Macalloy Guy Linking Bar & Cable Systems Table 9: Component Dimensions .6 28.3 29.7 11.6 54 63.5 14.8 16.5 16.7 12.6 38.5 69.4 24.6 34.1 12.1 16.3 8 10 11 12.9 8.4 8 9 11.5 12 18 18 21 26.6 36 E mm 8.7 ST3 ST4 ST5 ST6 ST7 ST8 ST10 ST12 ST14 ST16 ST19 ST22 ST26 Swaged Tensioner Ref 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 6.8 69.2 12.6 63.1 8.6 28.9 31.2 82.4 24.2 25.2 25. mm 6.4 46 Balustrade Swaged Stud Ref BSS3 BSS4 BSS5* L mm 83 87 98 Lt mm 38 38 38 OD mm 6.9 6.7 16 19 22.4 28.5 P Dia.5 36 36 48 52 OD mm 16 16 19 22.4 6.5 115 137 154 166 218 254 272 310 344 394 447 Swaged Stud Ref L mm Lt mm 40 40 52 64 71 71 103 116 116 146 146 180 196 OD mm 6.1 19.7 11.4 19.5 9.8 11.2 12.2 E mm 7 9 11 12 15 15 18 23 26 31 33 39 43 OD mm 14.5 47. mm 6.5 E mm 11 11 15 17 20 20 23 30 30 32 32 40 44 H mm 17 17 24 27 30 30 36 46 46 52 52 66 71 SF3 SF4 SF5 SF6 SF7 SF8 SF10 SF12 SF14 SF16 SF19 SF22 SF26 83 97 113 128 140 174 227 258 295 342 391 451 Swaged Fork Ref L mm 70 G mm 6.3 18 22.4 15.6 56.6 25.1 44.2 28.4 11.1 97.7 28.6 63.2 25.5 9.1 9.5 26.6 PL mm 20.5 10.9 25.6 28.5 8.4 25.5 32.7 21.5 9.8 11.9 9.1 9.5 D Dia.3 8 10 11 12.7 16 19 22.9 76.7 IT3 IT4 IT5 IT6 IT7 IT8 IT10 IT12 IT14 IT16 IT19 IT22 IT26 In-Line Tensioner Ref 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 SS3 SS4 SS5 SS6 SS7 SS8 SS10 SS12 SS14 SS16 SS19 SS22 SS26 83 93.4 28. mm 5.5 40.1 12.1 34.9 7.8 18.1 91.1 47.5 11.8 15.1 17.1 56.6 34.5 18.5 19 19 26.5 26.5 19.6 57. mm 5.4 28.5 32.1 69.6 38.3 27.8 18.5 25.3 16.2 22.5 69.2 35.8 92 98 GP6 GP6 GP8 GP10 GP11 GP11 GP16 GP19 GP19 GP25 GP25 GP32 GP35 Gusset Plate Ref.3 18 22.4kN ** For swaged adjustable fork only .2 82.6 21. 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.com is a Registered Trade Mark of Macalloy Ltd.com Email: sales@macalloy. Tel: +44 1909 519200.macalloy. . Macalloy. Caxton Way.K. U. Fax: +44 1909 519201 Web site: www. The company reserves the right to amend technical details as and where necessary in line with its policy of continuous development. Dinnington. Sheffield S25 3QE.