Tension Structures - Nov 2005

E:Hh3 Nov ’05

Macalloy Tensile Structure System: Macalloy 460 Carbon Steel Bar Tendons Macalloy S460 Stainless Steel Bar Tendons Macalloy 460 & S460 Compression Struts

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

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. Macalloy Ltd developed and introduced the

In recognition of this, the Macalloy portfolio

to be the case today.

of projects continues to expand with new

Olympia Stadion, Berlin Architect:

GMP

Engineer:

Schlaich Bergermann and Partner

Contractor: DSD

There are many reasons why specifiers and contractors repeatedly choose the Macalloy system. Here are but a few, Macalloy: • Was the first to develop a structural tie system with a yield stress of 460 N/mm2 • Only manufactures using rolled threads • Offers the most comprehensive range of bar and cable systems in both

carbon and stainless steel • Pioneered the art of stressing tendons (see page 8) • Is the first to gain approval to BS ENV 1993-1 (EC3) • Has German approval for both its carbon and stainless steel systems • Has a system proven in fatigue

• Is a CARES approved company • Boasts almost 60 years of experience in threaded bar systems • Has an experienced team of engineers who offer support and advice from specification to construction stage • Ensures all-round sound customer service Experience, Innovation, Quality

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.

Steel Structure Design: Excon, a.s. Contractor: Skanska CZ, a.s.

Porto Airport Engineers: Talprojects Contractor: Martifer

4

Macalloy 460 & S460 Bar Systems Table 1: Tendon Capacities for Carbon & Stainless Macalloy 460 Thread

Units

M10

M12

M16

M20

M24

M30

M36

M42

M48

M56

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. Break Load

kN

33

48

91

143

207

330

483

665

875

1209

1596

2329

2969

3358

4206

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

Nominal Bar Dia.

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 11.950m. Longer lengths may also

packaging in order to ensure minimal

Drawing on the experience, innovation and

be available on request and are subject to

damage during transportation.

quality of Macalloy Ltd, the 460 & S460

longer lead times.

systems have been carefully developed to

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. 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.

used to take the same load.

Galvanising Hot dip galvanising can be

1. 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, combined with rolled threads to provide a material with superior fatigue performance. The carbon Macalloy 460 bar is also a weldable steel with a maximum carbon equivalent of 0.55%. Arc welding may be carried out using standard techniques and low hydrogen rods. Macalloy 460 bar has the following mechanical properties: Minimum Yield Stress

460 N/mm2

Minimum Breaking Stress

610 N/mm2

Minimum Elongation

19%

Minimum Charpy Impact Value 27J @-20˚C Young’s Modulus

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. 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

as normal except that the inside of the lock

applied to the carbon bars after threading.

cover should be cleaned and, prior to

By galvanising after the threading process a

threading the lock cover back into the bar,

protection coat remains on the threaded

any grease should be removed using Loctite

portion. The threads are then brushed to

7063 or a similar proprietary cleaner.

remove any excess zinc and are delivered fully assembled (dependent on length) to ensure the components have a good fit. All galvanising is done in accordance with the current European Standard EN ISO 1461:1999.

2. With the lock cover in place the “open” end of the lock cover should be taped over. It is recommended that this is done by using a PTFE tape which is then overlaid with a stiffer tape. The sealant is then injected into the hole

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.

Painted systems are supplied fully assembled

Lock Cover

5

Macalloy 460 & S460 Bar Systems 3. The tape should be removed immediately from the end of the lock cover (or shortly after applying the sealant). 4. Any excess sealant should be removed from the end of the lock cover and around the injection hole, and the sealant tooled to produce a fillet.

Turnbuckles give additional adjustment of: - M10 to M24:

+/- 25mm

- M30 to M100: +/- 50mm

technical department who are willing to offer expert advice and solutions for particular projects. As well as our own machining facility enabling special accessories to be

Fatigue

produced, 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.

specifications. Once production has been

Testing on fatigue has been carried out over

completed, the in-house Test Facility is then

2 million cycles, the results of which are

able to check that components and bars meet

available from the Macalloy technical

the initial design requirements, before finally

Macalloy S460 Stainless Bar

department.

leaving the premises.

Macalloy S460 is an austenitic/duplex* stainless steel tie bar system, selected from high strength stainless steel to provide the optimum balance of strength, ductility and appearance. Austenitic stainless steel is found to have excellent charpy v notch impact properties adding to the system’s appeal.

Approvals

Special projects include:

Generally, 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. 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. The sealant should be left to cure and if necessary any further tidying up can then be carried out.

*Pin set bodies above SPA24 may be in martensitic stainless steel

requirements of the European Code of Practice, BS ENV 1993 (EC3) and BS5950. Macalloy 460 has also been tested and approved for use in Germany under the Zulassung Nr. Z-14.4-427.

Macalloy 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, Heathrow – unique finish to the thread form and polish for the glass wall

Macalloy Bespoke Systems

• T5 Rail Interchange, 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, it is also possible for

and vertical bars to be joined in one

special items and systems to be designed

threaded connection.

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.

T-connection pieces to allow horizontal

and produced. Macalloy has an exceptional

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 & S460 Tendons

load in to the bar, especially when used in

Central Connection Plates These are circular

combination with the Macalloy

central discs, commonly used in wind bracing

Macalloy offers a range of standard

TechnoTensioner.

applications where tendons are used to cross each other. Dimensions are given in table 2.

components, including forks, spades, pins,

Bespoke Connection Plates Designed to

are designed and tested to match the tensile

Connection Plate Solutions for Macalloy 460 & S460

capacity of the bar, which is itself based upon

Standard Connection Plates Forks may be

systems, these can be manufactured to suit

the cross sectional area of the thread form.

connected to either carbon steel or stainless

your individual application requirements.

Macalloy offers the same standard range of

steel connection plates, using material with

They are available in both carbon and

components in stainless as it does in carbon

an equivalent strength to BS EN 10025 grade

stainless steel with a choice of finishes, such

steel. With the exception of the lock covers,

S355.

as painted, powder coated, and polished.

all components are dimensionally the same

If carbon steel connection plates are used

Your preferred company logo, lettering

as the standard system.

with stainless forks or vice versa, isolation

and/or designs can be accommodated using

sleeves and washers may be required to

the latest laser cutting, chemical etching, or

Forks are designed to be connected to a BS

prevent bi-metallic corrosion. In such cases,

screen printing techniques. For further

EN 10025 grade S355 plate (Grade 50 to

dimensions according to connection plate B

support and advice, please contact our

BS4360) of the dimensions shown in table 3.

in table 3 should be followed.

technical team.

This will ensure a connection which has a

Coupler Connector Available in all sizes,

yield strength equal to the minimum tendon

these couplers are supplied with a welded

yield strength.

lug to create a hanger connection, removing

Spades are designed to be connected to forks

sag in long span applications, please contact

or between grade 355 plates, simulating a

the Technical Department with your

fork/spade connection.

requirements.

couplers and turnbuckles. These components

Pins connect the fork or spade to the host

complement the Macalloy 460 and S460

Coupler Connector

structure and may be held in place with either circlips or architectural caps. Lock covers not only help to lock the components in place and hide the remainder of the bar thread form, but they also provide an aesthetic and smooth transition from component to bar. They may be used either side of a turnbuckle or coupler and at the back end of a fork or spade. Couplers and turnbuckles are a small and unobtrusive way of joining 2 or more bars together when tendons are longer than the maximum bar length. The turnbuckles can further be used to apply a torque or induce a

Table 2: Standard Central Connection Plates Connection Disc

D/10

D/12

D/16

D/20

D/24

D/30

D/36

D42

D/48

D/56

System Size

M10

M12

M16

M20

M24

M30

M36

M42

M48

M56

ØD

130

164

218

248

294

386

444

502

572

694

ØI

96

120

160

180

210

280

320

360

410

500

T

10

10

12

15

20

22

30

35

40

45

ØP

11.5

13.

17

21.5

25.5

31.5

37.5

43.5

49.5

57.5

50

70

90

105

115

160

185

205

235

290

ØH (Optional)

7

Macalloy 460 and S460 Bar Systems Table 3: Component Dimensions - Macalloy 460 and Macalloy S460 Stainless Thread

Units

Fork Ref.

M10

M12

M16

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.)

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** T (thickness)

GPB10 GPB12 GPB16 GPB20 GPB24 GPB30 GPB36 GPB42 GPB48 GPB56

mm

8

D

mm

E

mm

H (min)

mm

Spade Ref.

9

12

15

20

15.5

17

21

25.5

30

20

24

31

36

44

22

30

35

40

45

36

42

48

55.5

63.5

55

64

72

83

99

36

40

51

57

67

85

99

113

127

151

SA10

SA12

SA16

SA20

SA24

SA30

SA36

SA42

SA48

SA56

SA64

SA76

SA85

SA90

SA100

78

92

118

147

174

213

249

284

321

364

408

471

524

555

625

B

mm

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

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

CA10

CA12

CA16

CA20

CA24

CA30

CA36

CA42

CA48

CA56

CA64

CA76

CA85

CA90

CA100

O/D

Coupler Ref. O/D

mm

17

19

25

29

35

43

52

60

68

80

91

108

121

129

143

L

mm

25

29

37

45

53

65

77

89

101

117

133

157

175

185

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

LCS16 LCS20 LCS24 LCS30 LCS36 LCS42

Stainless Lock Cover Ref. LCS10 LCS12

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. For full installation guidelines, please contact a member of the Technical Department.

In Situ Adjustment Macalloy 460 and S460 systems allow a certain amount of adjustment to be achieved: 1. Using a turnbuckle M10 – M24 inclusive, +/- 25mm M30 – M100 inclusive, +/- 50mm 2. Using left/right hand forks to the ends of the bars. Each fork will give the following adjustment: M10 – M56 inclusive, +/- 1⁄2 thread diameter M64 – M100 inclusive, +/- 25mm

Length Adjustment/ Tensioning of Tendon without Forks If a tendon does not include a fork at one or both ends, the easiest way to adjust the tendon length or induce a small amount of load is to anchor the tendon via a nut and washer, bearing onto suitable steelwork. The nut can then be rotated with a spanner or wrench to tighten the tendon or adjust its length. If a small amount of known load needs to be induced, a torque vs load relationship can be provided. If a large and/or accurate load needs to be induced, this can be achieved using a calibrated hydraulic jack at the nut end of the bar tendon.

Adjustment/Tensioning of Tendon without a Turnbuckle

Macalloy has provided the market with original methods for stressing its tendons.

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. Tendon length adjustment or tightening can then be achieved by screwing the lock covers back from the forks and then rotating the bar relative to the forks. This can be done by gripping the bar directly using a strap wrench, chain wrench or wrench. The lock covers must be screwed tightly against the forks in the tendon’s final position. If a small amount of known load needs to be induced, a torque vs load relationship can be provided.

It was recognized that there was a need to develop a way of accurately controlling the amount of load in a tendon for certain applications and so the Macalloy TechnoTensioner, a patented tool, was introduced in the 1990s.

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. This can be achieved using a strap wrench, chain wrench or wrench. The lock covers must be screwed tightly against the turnbuckle in the tendon’s final position. If a small amount of known load needs to be induced, a torque vs load relationship can be provided.

Stressing using the Macalloy TechnoTensioner Since the introduction of its Tension Structures systems in the early 1980s,

The hydraulic stressing unit is placed over the standard turnbuckle joint and is clamped onto the lock covers at either side of the turnbuckle. The live load is then induced into the tendon through the TechnoTensioner and can be measured with a degree of accuracy of +/- 2.5%. There are several units which cover the full range of diameters available for hire from the Macalloy Site Services department. Similarly, should specialist supervision be required on site to operate such equipment this can also be provided. Further details can be found in our Site Services brochure or can be requested from our Site Services or Technical Departments. Please note that the TechnoTensioner should only be used with the Stainless systems under advice from Macalloy.

Macalloy TechnoTensioner

9

Macalloy 460 & S460 Compression Struts Pin to Pin Length

Compression Struts

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

These utilise standard Macalloy 460 and

contact the Technical department.

information on the stainless range, please

S460 components together with standard circular hollow sections in order to produce a

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 Wembley Stadium.

Components 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:

M64 – M100 +/- 25mm

Richard Rogers 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 Tendons

between 0.10 and 0.75% of the cable length,

The system is designed to match the

depending on the magnitude and frequency

minimum break load of the 1x19 strand

After the success of the Macalloy 460 and

of loading, and should always be considered

cable. If fittings are required to match the

S460 systems, and also in order to meet the

in the design of the structure.

minimum break load of the compact strand,

ever increasing needs of its customers, the

Macalloy offers three types of cable:

Macalloy SC460 Stainless Cable System has

please seek advice from the Macalloy technical department with regard to

1x19 spiral strand, has moderate initial

been introduced.

component sizes.

stretch properties. All the cable adaptor

This specially designed system incorporates

fittings are designed to match the minimum

cable adaptors, which allow standard

breaking load of the 1x19 cable

imperial threaded swaged cables to be connected to the standard Macalloy S460 range of forks. By using the standard Macalloy S460 forks on the cable ends,

All forks may be connected to either carbon

Compact strand has a higher breaking load

steel or stainless steel connection plates with

along with a lower initial stretch than the

an equivalent strength to BS EN 10025 grade

1x19 strand cable and is available in most

S275 or Grade 316 to BS 970.

diameters

continuity of design remains in projects

Connection Plates

Where carbon steel plates are used, isolation

where standard Macalloy 460 & S460 bar

7x19 strand is the most flexible cable and is

sleeves and washers may be required to

systems have been used alongside the

ideal where this property is paramount.

prevent bi-metallic corrosion, in which case

Macalloy SC460 Stainless Cable Systems.

the dimensions of Gusset Plate Ref B should

Standard Components SC460 Tendons

be used. For more details on other connection plates please see page 7.

The fork and pin components of the system are all made from austenitic/duplex*

Macalloy SC460 Stainless Cable

Finish

stainless steel. The swaged fittings are

All components are finished in a Grit 220

factory swaged to either end of the cable,

(N3) polished finish. Other finishes are

The cable used in the system undergoes both

and the strength of the connection exceeds

available on request, please contact a

a conventional elastic stretch as well as an

the break load of the cable.

member of the Sales team.

initial stretch. This initial stretch can be

*Pin set bodies above SPA24 may be in martensitic stainless steel

Table 5: Component Dimensions – Macalloy SC460 Stainless Cable Systems Cable Dia.

mm

3

4

5

6

7

8

10

12

14

16

19

22

26

M10

M10

M12

M12

M16

M16

M20

M24

M24

M30

M30

M42

M42

L1

90

90

112

122

149

149

201

235

235

288

288

367

383

L2

168.5

168.5

206

233.9

275.7

287.6

378.6

443

461

539

573

689

749.5

17

17

19

19

25

25

29

35

35

44

44

60

60

+

8

8

11

13.7

15

15

22

24.7

24.7

30.7

30.7

37.7

41

–

16

16

22

27.3

30

30

44

49.3

49.3

61.3

61.3

75.3

82

Fork Required

Dia 1 Adjustment

Note:

Design length of tendon taken at zero adjustment. Adjustment is per cable adaptor. + Lengthening – Shortening

NOTE: L2 SHOWN AT MANUFACTURED LENGTH

11

Macalloy-Tensoteci Galvanised Cable Tendons As well as the extensive range of bar and

systems. Some of their notable reference

experience in design, manufacture, erection

cable systems in both carbon and stainless

sites are the cable systems of the giant

and stressing of tensile systems. Together

steel, Macalloy Ltd is also able to provide a

London Eye observation wheel in the UK, the

this newly formed partnership can offer the

galvanised cable range to complement its

suspension cables system of the Braga

market a complete and comprehensive

existing tensile systems. Through a close

Stadium in Portugal designed by Souto de

solution for wide span tensile structures

relationship with Tensoteci, a division of the

Moura and the Athens Olympic stadium roof

using steel bars and cables.

Radaelli Tecna Group of companies, Macalloy

designed by Santiago Calatrava.

offers large diameter galvanised steel cable

Macalloy offers both open spiral strand and

package of bar and cable solutions in both

systems.

full locked coil strand in standard diameters

carbon and stainless steel for Tension

Tensoteci, 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

in Milan, the company has supplied many

sockets.

No other company can offer such a complete

Further information on these products can be found in the Macalloy-Tensoteci brochure

prestigious projects throughout the world

The partnership between the two well

or can be requested from the Macalloy

with its large diameter galvanised steel cable

established companies combines years of

Technical 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

Components

• Footbridges • Glass Facades

All components are made from austenitic

• Balustrade

stainless steel Grade 316 to BS 970. The

The mechanical and chemical properties of the stainless steel are such that a corrosion

standard component range includes forks, pins, couplers and nuts.

protection system is not normally necessary, eliminating the need for costly paint systems and their inherent long term maintenance.

All forks and pins are designed to match the minimum yield and break load of the bar, as given in table 6, when used with the appropriate connection plate.

Macalloy Guy Linking Stainless Bar Tendon

Where extra adjustment is required, turnbuckles can be provided.

The Macalloy Guy Linking bar has a minimum yield stress of 315 N/mm2 for the 2

smaller diameters, falling to 205 N/mm for the larger diameters. Likewise, the minimum breaking stress ranges from 600 N/mm2 to 510 N/mm . Minimum elongation is 15%.

Connection Plates As with the stainless Macalloy S460 range,

Whilst the above yield stresses are the standard, Macalloy frequently designs and supplies higher grade systems using cold drawn rod, with bespoke components to

Finish All fittings are provided in an N2 bright polished finish. The bar is finished in a Grit 220 (N3) polished finish.

all forks may be connected to either carbon steel or stainless steel connection plates with an equivalent strength to BS EN 10025

2

Glyndebourne Opera House, UK

dimensions with isolation, please consult our technical team.

Bar

match the load of the bar.

Lisbon Expo

grade S275. Where carbon steel connection plates are used, isolation sleeves and washers are required to prevent bi-metallic corrosion. Dimensions of connection plates, without isolation, are given in table 7. For plate

Adjustment The adjustment within each fork end is +/- 1 thread diameter. The bar is threaded with opposite threads at either end. The system may therefore be adjusted by rotating the bar in situ.

13

Macalloy Guy Linking Bar & Cable Systems Table 6: Tendon Capacities for Macalloy Guy Linking Bar Tendons 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

6.4

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

kg/m

0.25

0.39

0.56

0.76

0.99

1.55

2,24

3.04

3.98

5.03

6.21

7.52

Nominal Bar Dia.

Nominal Bar Weight

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

Table 7: Component Dimensions - Guy Linking Bar Thread UNF Nominal Bar Dia.

Units

1/4

5/16

3/8

7/16

1/2

5/8

3/4

7/8

1

1 1/8

1 1/4

1 3/8

mm

6.4

8

9.5

11

12.7

16

19

22

25.4

28.6

31.8

34.9

FB6

FB8

FB10

FB11

FB12

FB16

FB19

FB22

FB25

FB28

FB32

FB35

Bar Fork Ref 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

GP6

GP8

GP10

GP11

GP12

GP16

GP19

GP22

GP25

GP28

GP32

GP35

Gusset Plate Ref. 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

8.9

13.9

20.0

27.3

35.6

55.6

80.0

109.0

143.1

5.0

Macalloy Guy Linking Stainless Cable Systems Cable Wire cable undergoes two types of stretch under load – an initial stretch and a conventional elastic stretch. The initial stretch is dependent upon cable construction and is caused by individual wires bedding down into a loaded position. This initial stretch can be between 0.10 and 0.75% of the cable length, depending on the magnitude and frequency of loading, and should always be considered when designing tendons. There are 3 different types of cables offered by Macalloy.

7x19 strand is constructed from 7 strands each in turn constructed from 19 wires. It is the least stiff of cables that can be swaged and is ideal in situations where flexibility is a primary requirement.

Young’s Modulus of 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. The wires have a smooth bright finish and the cable has moderate initial stretch properties. All our cable tendon fittings are designed to match the minimum breaking load of the 1x19 strand cable. Compact Strand offers a 30% increase in breaking load over the conventional 1x19 strand and a much lower initial stretch. It also has a higher elastic modulus making it ideal for use where high strength and low stretch is required.

Please note that the above E values have been established empirically. No cable will behave completely elastically and the apparent E value will consequently change over different stress ranges. Accurate stiffness values can only be calculated using a reduced cross sectional area. Please consult our technical department for further details if necessary.

Components As with the Guy Linking bar system, all components are made from austenitic

stainless steel Grade 316 to BS 970. The fittings are swaged to the end of the cable, providing a connection strength that exceeds the breaking load of the cable. The swaging process is usually performed under factory conditions to ensure the correct cable length is achieved. All components for our cable systems are designed to match the minimum break load of the 1x19 strand cable. If fittings are required to match the minimum break load of compact strand, please seek advice from the Macalloy technical department with regard to component sizes. As detailed below table 8, there are 3 types of standard tendons: • the swaged adjustable fork system • the swaged fork with swaged tensioner system • the swaged fork with in-line tensioner. For applications where forks are not required, tendons may also be supplied with a simple LH/RH swaged stud at either end. Shorter M8 metric threaded studs are also available for balustrade applications. Dimensions are detailed in table 9. Additional components and fittings are available on request. These include toggles, dome nuts, standard nuts, spherical seats, etc.

15

Macalloy Guy Linking Bar & Cable Systems Table 9: Component Dimensions - Guy Linking Cable Nominal Cable Dia.

mm

Swaged Adjustable Fork Ref

3

4

5

6

7

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

8.5

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

GP6

GP6

GP8

GP10

GP11

GP11

GP16

GP19

GP19

GP25

GP25

GP32

GP35

Gusset Plate Ref. ** T (thickness)

mm

6

6

6

8

10

10

15

16

16

25

25

30

35

D Dia.

mm

7

7

9

10

12.5

12.5

16.5

19

19

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

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

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

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

6.3

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

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

93.5

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

6.3

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: [email protected] is a Registered Trade Mark of Macalloy Ltd.