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
leading the way in the design, manufacture
and supply of threaded bar systems,
consistently serving its various markets with
experience, innovation and quality.
Macalloy Ltd developed and introduced the
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
concept of Tensile Structures in the early
1980s, creating new systems and new
technology that were to change traditional
principles forever.
In recognition of this, the Macalloy portfolio
of projects continues to expand with new
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
and exciting opportunities being presented.
Throughout its history Macalloy Ltd has
gained much respect from architects,
engineers and contractors and this continues
to be the case today.
Olympia Stadion, Berlin
Architect: GMP
Engineer: Schlaich Bergermann
and Partner
Contractor: DSD
• 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
The following systems form part of
Macalloy’s standard range:
• Macalloy 460 (carbon steel bar system)
• Macalloy S460 (stainless steel bar system)
• Macalloy SC460 (stainless steel cable
system)
• Macalloy Guy Linking Bar system
(stainless steel bar system)
• Macalloy Guy Linking Cable system
(stainless steel cable system)
• Macalloy Compression Struts
• Macalloy Connection Discs
• Macalloy Bespoke Systems
• Macalloy-Tensoteci (galvanised steel
cable system)

Sazka Arena

Architect: ATIP, a.s.

Steel 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 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
Tendons
Drawing on the experience, innovation and
quality of Macalloy Ltd, the 460 & S460
systems have been carefully developed to
incorporate fine grain steel with a minimum
yield stress of 460 N/mm2. This ensures that
the system is approximately 30% stronger
than the more common S355 grade steel
equivalent, enabling smaller diameters to be
used to take the same load.
Macalloy 460 Carbon 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:
M100 are available up to a maximum bar
length of 11.950m. Longer lengths may also
be available on request and are subject to
longer lead times.
Corrosion Protection
As a means of protecting against corrosion,
the Macalloy 460 system can be supplied
with a form of protection to suit your
specification.
Galvanising Hot dip galvanising can be
applied to the carbon bars after threading.
By galvanising after the threading process a
protection coat remains on the threaded
portion. The threads are then brushed to
remove any excess zinc and are delivered
fully assembled (dependent on length) to
ensure the components have a good fit. All
galvanising is done in accordance with the
current European Standard EN ISO 1461:1999.
Paint Macalloy can provide any form of paint
protection that is required by the client.
Painted systems are supplied fully assembled
and are delivered to site with the appropriate
packaging in order to ensure minimal
damage during transportation.
Lock Cover Sealing In order to reduce
corrosion and ‘bleeding’ in the gap between
the bar and the lock cover a sealant can be
applied. Macalloy recommends Loctite 5068
or a similar proprietary sealant as this can be
painted over.
1. The joint should be made up and installed
as normal except that the inside of the lock
cover should be cleaned and, prior to
threading the lock cover back into the bar,
any grease should be removed using Loctite
7063 or a similar proprietary cleaner.
2. With the lock cover in place the “open” end
of the lock cover should be taped over. It is
recommended that this is done by using a
PTFE tape which is then overlaid with a stiffer
tape. The sealant is then injected into the hole
in the side of the lock cover, using a “skeleton
gun”, until the void is completely filled.

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
from the end of the lock cover (or shortly
after applying the sealant).
4. Any excess sealant should be removed
from the end of the lock cover and around
the injection hole, and the sealant tooled to
produce a fillet.
5. The sealant should be left to cure and if
necessary any further tidying up can then be
carried out.
Macalloy S460 Stainless Bar
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.
*Pin set bodies above SPA24 may be in martensitic
stainless steel
Macalloy S460 bar has the following
mechanical properties:
Minimum Yield Stress 460 N/mm2
Minimum Breaking Stress 610 N/mm2
Minimum Elongation 15%
Young’s Modulus 190 kN/mm2
Turnbuckles give additional adjustment of:
- M10 to M24: +/- 25mm
- M30 to M100: +/- 50mm
Fatigue
Threads are rolled on to the bar rather than
cut to ensure minimum loss of cross sectional
area and to give excellent fatigue strength.
Testing on fatigue has been carried out over
2 million cycles, the results of which are
available from the Macalloy technical
department.
Approvals
Generally, Macalloy 460 should be used in
accordance with the local structural steel
design codes. The system is the first to be
designed and tested in accordance with the
requirements of the European Code of
Practice, BS ENV 1993 (EC3) and BS5950.
Macalloy 460 has also been tested and
approved for use in Germany under the
Zulassung Nr. Z-14.4-427.
Macalloy Bespoke Systems
In addition to the standard systems that
Macalloy provides, it is also possible for
special items and systems to be designed
and produced. Macalloy has an exceptional
technical department who are willing to offer
expert advice and solutions for particular
projects. As well as our own machining
facility enabling special accessories to be
produced, there is an on-site bar threading
facility which means that one-off bar types
can be manufactured to individual
specifications. Once production has been
completed, the in-house Test Facility is then
able to check that components and bars meet
the initial design requirements, before finally
leaving the premises.
Special projects include:
• Dubai airport – a special 690 grade of bar
system was developed which included
special high strength connections to take
the full load of the bar
• Unique machined and cast components for
numerous glass façade projects
• Changi airport – 835 grade stainless bar
with special forks to suit
• T5, Heathrow – unique finish to the thread
form and polish for the glass wall
• T5 Rail Interchange, Heathrow – special
T-connection pieces to allow horizontal
and vertical bars to be joined in one
threaded connection.

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
& S460 Tendons
Macalloy offers a range of standard
components, including forks, spades, pins,
couplers and turnbuckles. These components
are designed and tested to match the tensile
capacity of the bar, which is itself based upon
the cross sectional area of the thread form.
Macalloy offers the same standard range of
components in stainless as it does in carbon
steel. With the exception of the lock covers,
all components are dimensionally the same
as the standard system.
Forks are designed to be connected to a BS
EN 10025 grade S355 plate (Grade 50 to
BS4360) of the dimensions shown in table 3.
This will ensure a connection which has a
yield strength equal to the minimum tendon
yield strength.
Spades are designed to be connected to forks
or between grade 355 plates, simulating a
fork/spade connection.
Pins connect the fork or spade to the host
structure and may be held in place with
either circlips or architectural caps.
Lock covers not only help to lock the
components in place and hide the remainder
of the bar thread form, but they also provide
an aesthetic and smooth transition from
component to bar. They may be used either
side of a turnbuckle or coupler and at the
back end of a fork or spade.
Couplers and turnbuckles are a small and
unobtrusive way of joining 2 or more bars
together when tendons are longer than the
maximum bar length. The turnbuckles can
further be used to apply a torque or induce a
load in to the bar, especially when used in
combination with the Macalloy
TechnoTensioner.
Connection Plate Solutions
for Macalloy 460 & S460
Standard Connection Plates Forks may be
connected to either carbon steel or stainless
steel connection plates, using material with
an equivalent strength to BS EN 10025 grade
S355.
If carbon steel connection plates are used
with stainless forks or vice versa, isolation
sleeves and washers may be required to
prevent bi-metallic corrosion. In such cases,
dimensions according to connection plate B
in table 3 should be followed.
Coupler Connector Available in all sizes,
these couplers are supplied with a welded
lug to create a hanger connection, removing
sag in long span applications, please contact
the Technical Department with your
requirements.
Coupler Connector
Central Connection Plates These are circular
central discs, commonly used in wind bracing
applications where tendons are used to cross
each other. Dimensions are given in table 2.
Bespoke Connection Plates Designed to
complement the Macalloy 460 and S460
systems, these can be manufactured to suit
your individual application requirements.
They are available in both carbon and
stainless steel with a choice of finishes, such
as painted, powder coated, and polished.
Your preferred company logo, lettering
and/or designs can be accommodated using
the latest laser cutting, chemical etching, or
screen printing techniques. For further
support and advice, please contact our
technical team.

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.
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
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.
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,
Macalloy has provided the market with
original methods for stressing its tendons.
It was recognized that there was a need to
develop a way of accurately controlling the
amount of load in a tendon for certain
applications and so the Macalloy
TechnoTensioner, a patented tool, was
introduced in the 1990s.
The hydraulic stressing unit is placed over
the standard turnbuckle joint and is clamped
onto the lock covers at either side of the
turnbuckle. The live load is then induced into
the tendon through the TechnoTensioner and
can be measured with a degree of accuracy
of +/- 2.5%.
There are several units which cover the full
range of diameters available for hire from
the Macalloy Site Services department.
Similarly, should specialist supervision be
required on site to operate such equipment
this can also be provided.
Further details can be found in our Site
Services brochure or can be requested from
our Site Services or Technical Departments.
Please note that the TechnoTensioner should
only be used with the Stainless systems
under advice from Macalloy.
Macalloy TechnoTensioner
 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
Tendons
After the success of the Macalloy 460 and
S460 systems, and also in order to meet the
ever increasing needs of its customers, the
Macalloy SC460 Stainless Cable System has
been introduced.
This specially designed system incorporates
cable adaptors, which allow standard
imperial threaded swaged cables to be
connected to the standard Macalloy S460
range of forks. By using the standard
Macalloy S460 forks on the cable ends,
continuity of design remains in projects
where standard Macalloy 460 & S460 bar
systems have been used alongside the
Macalloy SC460 Stainless Cable Systems.
Macalloy SC460 Stainless
Cable
The cable used in the system undergoes both
a conventional elastic stretch as well as an
initial stretch. 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
in the design of the structure.
Macalloy offers three types of cable:
1x19 spiral strand, has moderate initial
stretch properties. All the cable adaptor
fittings are designed to match the minimum
breaking load of the 1x19 cable
Compact strand has a higher breaking load
along with a lower initial stretch than the
1x19 strand cable and is available in most
diameters
7x19 strand is the most flexible cable and is
ideal where this property is paramount.
Standard Components SC460
Tendons
The fork and pin components of the system
are all made from austenitic/duplex*
stainless steel. The swaged fittings are
factory swaged to either end of the cable,
and the strength of the connection exceeds
the break load of the cable.
*Pin set bodies above SPA24 may be in martensitic
stainless steel
The system is designed to match the
minimum break load of the 1x19 strand
cable. If fittings are required to match the
minimum break load of the compact strand,
please seek advice from the Macalloy
technical department with regard to
component sizes.
Connection Plates
All forks may be connected to either carbon
steel or stainless steel connection plates with
an equivalent strength to BS EN 10025 grade
S275 or Grade 316 to BS 970.
Where carbon steel plates are used, isolation
sleeves and washers may be required to
prevent bi-metallic corrosion, in which case
the dimensions of Gusset Plate Ref B should
be used. For more details on other
connection plates please see page 7.
Finish
All components are finished in a Grit 220
(N3) polished finish. Other finishes are
available on request, please contact a
member of the Sales team.

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

Macalloy-Tensoteci Galvanised Cable Tendons
As well as the extensive range of bar and
cable systems in both carbon and stainless
steel, Macalloy Ltd is also able to provide a
galvanised cable range to complement its
existing tensile systems. Through a close
relationship with Tensoteci, a division of the
Radaelli Tecna Group of companies, Macalloy
offers large diameter galvanised steel cable
systems.
Tensoteci, Italy’s leading manufacturer of
steel wire ropes, cables and accessories,
boasts over 100 years of experience. Based
in Milan, the company has supplied many
prestigious projects throughout the world
with its large diameter galvanised steel cable
Athens Olympic Stadium
Architect: Santiago Calatrava
systems. Some of their notable reference
sites are the cable systems of the giant
London Eye observation wheel in the UK, the
suspension cables system of the Braga
Stadium in Portugal designed by Souto de
Moura and the Athens Olympic stadium roof
designed by Santiago Calatrava.
Macalloy offers both open spiral strand and
full locked coil strand in standard diameters
up to 88mm and 128mm respectively.
Standard eye components include fork
sockets, cylindrical sockets and bridge
sockets.
The partnership between the two well
established companies combines years of
11
experience in design, manufacture, erection
and stressing of tensile systems. Together
this newly formed partnership can offer the
market a complete and comprehensive
solution for wide span tensile structures
using steel bars and cables.
No other company can offer such a complete
package of bar and cable solutions in both
carbon and stainless steel for Tension
Structure applications to architects,
engineers and contractors worldwide.
Further information on these products can
be found in the Macalloy-Tensoteci brochure
or can be requested from the Macalloy
Technical Department.
12
Macalloy Guy Linking Bar & Cable Systems
The Macalloy Guy Linking systems are a
range of stainless steel architectural bar and
cable systems. Typical applications include:
• Membrane structures
• Lightweight steel structures
• Footbridges
• Glass Facades
• Balustrade
The mechanical and chemical properties of
the stainless steel are such that a corrosion
protection system is not normally necessary,
eliminating the need for costly paint systems
and their inherent long term maintenance.
Macalloy Guy Linking
Stainless Bar Tendon
Bar
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%.
2 The adjustment within each fork end is +/- 1
Whilst the above yield stresses are the
standard, Macalloy frequently designs and
supplies higher grade systems using cold
drawn rod, with bespoke components to
match the load of the bar.
Glyndebourne Opera House, UK
The bar is available in all diameters up to
6m. Longer lengths are available on special
request but may be subject to increased lead
times. Alternatively, couplers provide an
unobtrusive full strength joint.
Components
All components are made from austenitic
stainless steel Grade 316 to BS 970. The
standard component range includes forks,
pins, couplers and nuts.
All forks and pins are designed to match the
minimum yield and break load of the bar, as
Lisbon Expo
given in table 6, when used with the
appropriate connection plate. dimensions with isolation, please consult our
technical team.
Where extra adjustment is required,
turnbuckles can be provided. Finish
All fittings are provided in an N2 bright
Connection Plates polished finish. The bar is finished in a Grit
As with the stainless Macalloy S460 range, 220 (N3) polished finish.
all forks may be connected to either carbon
steel or stainless steel connection plates with Adjustment
an equivalent strength to BS EN 10025
grade S275.
thread diameter. The bar is threaded with
opposite threads at either end. The system
Where carbon steel connection plates are
may therefore be adjusted by rotating the
used, isolation sleeves and washers are
bar in situ.
required to prevent bi-metallic corrosion.
Dimensions of connection plates, without
isolation, are given in table 7. For plate
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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
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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
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.
The most common strand used is the 1x19
spiral strand. The wires have a smooth
bright finish and the cable has moderate
initial stretch properties. All our cable
tendon fittings are designed to match the
minimum breaking load of the 1x19 strand
cable.
Compact Strand offers a 30% increase in
breaking load over the conventional 1x19
strand and a much lower initial stretch. It
also has a higher elastic modulus making it
ideal for use where high strength and low
stretch is required.
7x19 strand is constructed from 7 strands stainless steel Grade 316 to BS 970. The
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
a primary requirement. process is usually performed under factory
conditions to ensure the correct cable length
Young’s Modulus of the is achieved.
Cable
All components for our cable systems are
The apparent Young’s Modulus (E) of the Guy
designed to match the minimum break load
Linking Cable systems are:
of the 1x19 strand cable. If fittings are
required to match the minimum break load
1x19 Strand 107 kN/mm2
of compact strand, please seek advice from
Compact Strand 133 kN/mm2
the Macalloy technical department with
7x19 Strand 85 kN/mm2
regard to component sizes.
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
of standard tendons:
d= Load (kN) x Length (mm)
E (kN/mm ) x Cross Sectional Area (mm2)
2 • the swaged adjustable fork system
• the swaged fork with swaged tensioner
system
Please note that the above E values have
• the swaged fork with in-line tensioner.
been established empirically. No cable will
behave completely elastically and the
For applications where forks are not
apparent E value will consequently change
required, tendons may also be supplied with
over different stress ranges. Accurate
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
available for balustrade applications.
consult our technical department for further
details if necessary.
Dimensions are detailed in table 9.
Components Additional components and fittings are
available on request. These include toggles,
As with the Guy Linking bar system, all
dome nuts, standard nuts, spherical
components are made from austenitic
seats, etc.
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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
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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.