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Macalloy 1030
Macalloy S1030
Post Tensioning System
2
Quality Control Among other requirements, the following Fittings: A sample of all fittings is taken at
controls apply to all cold worked Macalloy random from each batch manufactured, and
Macalloy operates a quality assurance system
1030 production: checked for dimensional tolerances, thread
complying with the provisions of BS EN
tolerances, hardness and the presence of
ISO 9001: 2000, and have product approval to Bars: After cold working, a bar is taken from cracks. Couplers are 100% checked to detect
BS4486 and BS4447 from CARES
each 5 tonne batch. The sample is tested to cracks. All fittings are marked to ensure full
(UK Certification Authority for Reinforcing
destruction at our works using a NAMAS traceability.
Steels).
calibrated 2500kN capacity tensile testing Assemblies: Anchorage and coupled joint
The details within this brochure are in
machine, to verify that the specified tensile assemblies of all sizes of bar are tested to
accordance with the current British
properties are achieved. The identity and test destruction at a rate governed by production,
Standards, however the system has approval
status of all material is closely monitored to ensure compliance with the provisions
to the National Standards in Germany and
during production and processing until of BS4447.
France.
receipt by the customer. Proof Loading: Facilities are available to test
load tendon assemblies up to 2500kN.
mm kN kN kN kN
20 – 323 – 262
36 1049 – 850 –
50 2022 – 1639 –
75 4311 – 3495 –
4
The working load factor to be used in a design Anchorage strength – anchorage efficiency Welding
is at the discretion of the Engineer but will tests in accordance with the requirements of Macalloy 1030 and Macalloy S1030
normally be that specified in the appropriate BS4447 are carried out to verify that the must not be welded, subjected to
British Standard. failing load in the anchorage is not less than high local heating or splashed with
92% of the actual failing load in the adjacent weld metal.
For prestressed concrete construction, the
parent bar, and that the failing load in a
current standard for buildings is BS8110 and
coupled joint is not less than the characteristic
for bridges BS5400, which suggest an initial
prestressing force of 70% of the characteristic
failing load of the bar diameter under test. Threads
failing load. For ties and similar applications Stress corrosion – Macalloy 1030 bars have A coarse thread is rolled directly on to the bar
in structural steel construction, the been subjected to the F.I.P. standard stress surface, of a form specially designed to give
requirements of BS5950:Parts 1 and 2 apply. corrosion test. No bars failed during the 200 speed and ease in assembly. The thread has
hour duration of the test and subsequent excellent fatigue properties and attains the
Ground anchorage design is dealt with in
tensile tests to failure showed no significant desired anchorage strengths.
BS8081 which gives recommended load
reduction in the ultimate or 0.1% proof The bond value of the coarse thread when
factors for permanent and temporary
stresses. Under normally occurring cast into concrete, or grouted into a preformed
applications.
conditions, Macalloy 1030 is not susceptible hole, complies with the requirements for a
to stress corrosion. Macalloy 1030 is, of class 2 deformed bar.
Properties course, subject to surface corrosion when
The threads are rolled on the bars in the
exposed to moisture and deep corrosion
Extensive data and test reports on bars and factory with stringent controls on tolerance
pitting is harmful. Further data is available
components are available from Macalloy’s and form. Load is transferred from bar to
from the Technical Department.
Technical Department. fittings for the full circumference of the bars.
Macalloy S1030 has very good general Hence the fittings are compact and load
The main properties are summarised
corrosion properties similar to grades transfer efficiency easily complies with the
as follows:
303 and 304 austenitic stainless steel requirements of BS4447.
Fatigue – threaded assemblies have a fatigue bars. In industrial atmospheres some
resistance in excess of two million cycles of Short, fully threaded bars can be used
surface discolouration may occur over a
loading over a tensile stress range of 590-670 satisfactorily for short tendons and bolts as
period of time.
N/mm2, exceeding the requirements laid loss of load due to ‘take up’ in the threads on
It has excellent stress corrosion and fatigue transfer of load is minimised by the controlled
down in BS4447.
properties, well in excess of the code limits on clearance between internal and
Relaxation – the requirement laid down in requirements and, where surface appearance external threads.
BS4486 for the loss of stress due to relaxation is not critical, Macalloy S1030 provides an
in a bar loaded to 70% of its characterisic All available lengths of bar can be
excellent high strength, long life tendon.
failure load after 1000 hours at room fully threaded.
temperature, is 3.5% maximum. This is
comfortably achieved with typical results
5
Torque Loadings
Calibrated torque wrenches may be used to
apply loads up to 25% of the characteristic
failing load. The accuracy of the load induced
in the bar is in this case much less than when
applied by hydraulic jack as it is not possible
to determine the friction loss in the threads
with any precision.
3000 50 kgs 3000kN 75 170 250 187 135 330 – 855 1300 500 200
50 160 90 450
1000 26kgs 1000kN 40 120 176 125 75 301 385 564 850 300 135
36 116 65 370
32 114 60 360
450 15kgs 450kN 26.5 90 129 100 50 281 340 566 870 300 110
25 88 45 330
All jacks have 50 mm stroke. All dimensions in mm.
6
Flat nuts* Nut reference FSSN20 FN25 FN26.5 FN32 FN36 FN40 FN50 FN75
Length mm 25 33 37 41 46 51 71 100
Width across flats (DIA for 75mm bar) mm 42 46 50 56 62 65 90 135
Flat washers* Washer reference FSSW20 FSW25 FSW26.5 FSW32 FSW36 FSW40 FSW50
Outside diameter mm 50 60 65 70 75 80 105
Thickness mm 5 5 5 5 5 5 5
Couplers Coupler reference FSSC20 FC25 FC26.5 FC32 FC36 FC40 FC50 FC75
Outside diameter mm 35 42.5 42.5 50 57.5 62.5 76 110
Length – standard mm – 85 90 115 130 140 170 230
Length – stainless mm 65 80 – 95 – 120 – –
End plates Plate reference FSSP20 FP25 FP26.5 FP32 FP36 FP40 FP50 FP75
Length mm 100 100 110 125 140 150 200 300
Width mm 100 100 110 125 140 150 175 250
Thickness – standard mm 25 40 40 50 50 60 60 75
Hole diameter mm 26 35 36 41 45 52 61 82
Thickness – threaded mm – 40 40 50 50 60 70 110
Threads Pitch mm 2.5 6.0 6.0 6.0 6.0 8.0 8.0 8.0
Standard thread Length – jacking end (standard) S1 mm 250 250 250 250 250 250 250 360
lengths (see fig 2) – dead end (standard) S2 mm 100 100 100 100 100 100 100 160
– coupler (standard) mm 40 45 50 60 65 75 85 150
X1 (MIN) mm 75 82 91 105 115 130 165 235
X2 (MIN) mm 42 49 53 57 62 71 91 116
X3 (MIN) mm 12 12 12 12 12 16 16 16
*Spherical nuts and washers are available to accommodate rotation if required. †Available in stainless grade only.
X1 = live end
X2 = dead end
X3 = length of bar past
nut or thro’ threaded plate
= 12 for 6mm pitch
16 for 8mm pitch
Shape code 61
Helix - 6 turns of
12mm dia. mild steel rod
25 12 130 40 5 8 70 3
26.5 12 130 40 5 8 70 3
32 12 165 40 6 8 80 3
36 12 195 40 7 8 80 4
40 12 220 40 7 8 80 4
50 16 250 50 8 10 100 4
75 20 350 75 8 16 100 6
Note: A longitudinal length of rod may be Detailing More detailed explanation of the Macalloy
used to attach the links but it is not required Post Tensioning System is available in the
There are many permutations possible to
as part of the reinforcement. Macalloy Design Data Handbook.
achieve satisfactory construction details,
and advice is readily available from the
technical department.
nut
duct
fixing bolts coupler duct ducting
reducer plain hole threaded
threaded
end plate end plate grout
entry
nut
nut
June 2004
ducting grout entry
40mm to 75mm dia.
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Macalloy, Caxton Way, Dinnington, Sheffield S25 3QE, U.K. Tel: +44 1909 519200. Fax: +44 1909 519201
Web site: www.macalloy.com Email: sales@macalloy.com
is a registered trade mark of McCalls Special Products Ltd.
BAR & CABLE SYSTEMS is a trading name of McCalls Special Products Ltd.