A4 Post tensioning bar 1030

July 2016

1244-CPD-1007 Macalloy Post Tensioning System

MANAGEMENT Macalloy 1030
SYSTEMS Macalloy S1030

1055

EXPERIENCE INNOVATION QUALITY

ETA-07/0046

Macalloy Post Tensioning System

Macalloy 1030 properties by cold working. Bars for diameters between 25mm and
of 50mm and 75mm diameter 40mm and up to 9.6m for 50mm
The Macalloy 1030 Post Tensioning obtain their specified properties and 75mm diameter. Greater
System consists of high tensile via a quenching and tempering tendon lengths can be obtained by
alloy steel bars in diameters from process. joining Macalloy bars together with
25mm to 75mm, provided with threaded Macalloy couplers.
cold rolled threads for part or full Sizes
length, together with a range of Non-standard bar diameters can
fittings. Bars from 25mm to 40mm Macalloy bars of standard quality also be provided by arrangement.
diameter obtain their specified are available in lengths up to 11.8m Physical parameters of Macalloy
1030 bar are given in table 1.

Millau Viaduct, France
Architect - Fosters and Partners
Contractor - Eiffage
Engineers - Michel Virlogeux, Bureau d’études Greisch, Setec

Table 1: Range of Macalloy 1030 Bar

Nominal Cross Macalloy 1030 Mass Major diameter Minimum hole
Diameter sectional area kg/m Macalloy S1030 Stainless of threads diameter in Steelwork
- kg/m mm
mm mm2 4.17 2.57 22.0 mm
20 322 4.49 4.2 28.9 24
25 530 - 30.4 31
26.5 572 6.65 33
8.44 6.65 36.2
32 847 10.36 - 40.2 40
36 1075 15.66 45.3 44
40 1320 32.86 10.36 54.8 49
50 1963 15.66 77.2 59
75 4185 32.86 82

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Macalloy Post Tensioning System

Steel Quality to ensure that the steel achieves in lengths up to 6m for all
the mechanical properties stated diameters from 20mm to 75mm.
Macalloy 1030 is a carbon-chrome in table 2. Rigorous inspection and
steel with a composition designed testing is carried out, both during Macalloy S1030 has very good
to give the specified properties. All and after treatment, to ensure general corrosion properties, similar
bars are hot rolled. Diameters from consistent tensile properties. The to grades 1.4305 (303) and 1.4301
25mm to 40mm are cold worked mechanical performance of the bar (304) austenitic stainless steel bars.
by stretching. The stretching load is monitored through the tensile In industrial atmospheres some
and permanent elongation are testing of machined specimens surface discolouration may occur
predetermined by preliminary tests rather than section testing. over a period of time.
and the properties are monitiored
during production to ensure that Macalloy S1030 Macalloy S1030 is a martensitic
the bars as supplied comply nickel-chrome alloy steel, hardened
in all respects with the provisions Stainless Macalloy S1030 bars in during manufacture to attain
of BS4486. diameters from 20mm to 75mm are the specified properties.
made from precipation hardened
Bars of 50mm and 75mm diameter stainless steel. The mechanical properties of
are heat treated after rolling at a both Macalloy 1030 and S1030 bars
controlled temperature and time Macalloy S1030 bars are available are listed in table 2.

Table 2: Mechanical Properties

Grade Nominal ultimate Nominal 0.1% Minimum Approximate modulus
tensile strength proof stress elongation of elasticity
kN/mm2
N/mm2 N/mm2 %
170*
Macalloy 1030 25-40mm 1030 835 6
205
Macalloy 1030 50-75mm 1030 835 6
185
Macalloy S1030 20-75mm 1030 835 10

*Secant Modulus of Elasticity in range 5 - 70% UTS

Izmit Bay Bridge, Turkey
Main Contractor IHI

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Macalloy Post Tensioning System

Strength Typical stress strain diagram for cold worked
Macalloy 1030 bar (25-40mm)
The specified characteristic failing
loads and 0.1% proof loads for
Macalloy and Macalloy S1030 bar
steels are given in Table 3.

Bars can be supplied with nuts,
washers, plates, or couplers as
required. All fittings are designed
to exceed the failing load of the
threaded bars.

Quality Control The Macalloy 1030 Post factory production control test plan
Tensioning System European is implemented. Bars and fittings
Macalloy operates a quality Technical Approval document ETA- are routinely tested in accordance
assurance system complying 07/0046 is available as a separate with this document.
with the provisions of BS EN ISO document.
9001. Macalloy 1030 bars are Proof Loading: Facilities are
independently approved to the The details within this brochure available to load test tendon
requirements of BS4486. The are in accordance with the current assemblies up to 2500kN in house
Macalloy 1030 system up to 40mm British and European Standards. or to greater capacities, out of
is independently approved to the The system also has approval to house.
requirements of ETAG 013. It is a the National Standards in France.
prerequisite of ETAG 013 that the
bars comply with the preliminary In accordance with the
European standard prEN 10138. requirements of ETAG 013 a

Table 3: Characteristic Loads

Nominal Failing Load 0.1% proof load
Diameter Macalloy S1030
Macalloy 1030 kN Macalloy 1030 Macalloy S1030
mm kN 323
20 - 506 kN kN
25 506 -
26.5 569 - 262

32 410 410
36
40 460 -
50
75 828 828 670 670
1049 - 850 -
1295 1050
2022 1295 1639 1050
4311 2022 3495 1639
4311 3495

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Macalloy Post Tensioning System

Working Load Factors gives recommended load factors achieved by the 1030 bars, with
for permanent and temporary typical results below 3.0%.
The working load factor to be used applications.
in a design is at the discretion of Anchorage strength – anchorage
the Engineer but will normally be Properties efficiency tests in accordance with
that specified in the appropriate the requirements of ETAG 013 are
Standard. Extensive data and test reports carried out to verify that the failing
on bars and components are load in the anchorage is not less
For prestressed concrete available from Macalloy’s Technical than 95% of the actual failing load
construction, the current standard Department. in the parent bar or 95% of the
for buildings is BS8110 and for specified characteristic failure load.
bridges BS5400, which suggest The main properties of the 1030 Anchorage testing also verifies
an initial prestressing force of 70% bars are summarised as follows: that the ultimate failure occurs in
of the characteristic failing load. the bar and is not influenced by the
For ties and similar applications in Fatigue – threaded assemblies anchorage or coupler.
structural steel construction, the have a fatigue resistance in
requirements of BS5950: Parts 1 excess of two million cycles of Stress Corrosion – Macalloy
and 2 apply. loading over a tensile stress range 1030 bars have been subjected to
of 590-670 N/mm2, exceeding the F.I.P. standard stress corrosion
Maximum prestress forces in the requirements laid down in test. No bars failed during the
accordance with EN 1992-1- ETAG 013. 200 hour duration of the test and
1: 2004 Eurocode 2: Design of subsequent tensile tests to failure
concrete structures, are given in Relaxation – the requirement laid showed no significant reduction in
the Macalloy 1030 Post Tensioning down in BS4486 for the loss of the ultimate or 0.1% proof stresses.
System European Technical stress due to relaxation in a bar
document ETA-07/0046. loaded to 70% of its characteristic NOTE: ETAG 013 approvals are
failure load, after 1000 hours for 1030 system only not S1030.
Ground anchorage design is at room temperature, is 3.5%
dealt with in BS8081, which maximum. This is comfortably

Millenium Bridge, London
Architect - Fosters and Partners
Main Contractor - Monberg Thorsen and Sir Robert McAlpine
Engineer - Arups

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Macalloy Post Tensioning System

Stress corrosion testing has also Welding thread, when cast into concrete,
been conducted in accordance or grouted into a preformed hole,
with pr EN 10138-4: 2005-2009 and Macalloy 1030 and Macalloy complies with requirements for a
satisfies the requirements in full. S1030 must not be welded, Class 2 deformed bar. This is as per
subjected to high local heating 8110-1:1997 Section 3.12.8.
Under normal circumstances, or splashed with weld metal.
Macalloy 1030 is not susceptible Short, fully threaded bars can
to stress corrosion. Macalloy 1030 Threads be used satisfactorily for short
is, of course, subject to surface tendons and bolts, as loss of load
corrosion when exposed to A coarse thread is cold rolled due to ‘take up’ in the threads on
moisture and deep corrosion pitting directly on to the bar. Bars can be transfer of load, is minimised by
is harmful. Further data is available end threaded or fully threaded. the controlled limits on clearance,
from the Technical Department. between internal and external
The bond value of the coarse threads.

KL8 Footbridge, near Poz´nan, Poland

Architect - Bartołomiej Grotte,
Contractor - Skanska / Intercor,
Engineer - Transprojekt Warszawa, prof. Henryk Zobel

Wind Turbines, Uljabuouda, Sweden
Foundation Sub-Contractor – Peikko Sverige
Turbine Manufacturer – Dynawind AB, Sweden
Client – Skellefteå Kraft AB

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Macalloy Post Tensioning System

Protection Against Corrosion Two or more of these systems and upon the friction within the
may be combined, to enhance the threads and between nut, washer
For normal prestressed concrete degree of protection. and end plate. Accuracy of the
construction, the alkaline tensile force cannot be expected to
environment, provided by a layer Particular care is always needed be more than ±25%.
of cement grout, injected into the at end connections and coupled
duct enclosing the bar gives good joints, to ensure continuity of The relationship, between the
protection. protection, over the whole tendon. torque applied to a nut bearing onto
a standard washer and the resultant
If bars are used in any exposed Advice is available from Macalloy’s load, is as shown in Table 4.
application, corrosion protection Technical department.
is essential for Macalloy 1030 and
can be advantageous for Macalloy Torque Loadings
S1030.
Macalloy 1030 bars are also used
The type of protection will be for non post tensioned concrete
governed by the conditions of applications, which require only a
exposure, appearance and cost. relatively small tensioning load.
Amongst the available options are:-
For these applications, it is
• paint systems (comprising possible to develop a load in a
Macalloy bar up to 25% of the
of primer and one or more characteristic failure load, by
finishing coats) applying a predetermined torque to
the Macalloy nut. Torque wrenches
• grease impregnated tape are available from Macalloy that
have a dial, indicating the torque
wrapping value exerted, or which can be
preset to slip at a specified torque
• adhesive coated plastic tape value.

wrapping The axial tension, induced by a
given torque, depends upon the
• shrink wrap diameter and pitch of the threads
• plastic tubing
• ridged plastic tubing, with

injected grease or grout.

• Thermal metal spray

Macalloy 1030 should never be
galvanised.

Table 4: K Values for Macalloy Coarse Threads

Torque (Nm) = PxD Bar Diameter K
K mm 4.1
25 4.3
Where 26.5 4.7
P is desired axial load in kN 32
D is the nominal bar diameter in mm 4.9
K is a constant obtained by test measurements 36 4.5
4.1
40
50

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Macalloy Post Tensioning System

Stressing Procedure stressing bridge or stool, to seat on
the end plate and for access to the
Hydraulic jacking equipment is ring or box spanner, to tighten the
available to apply load to the bars. nut. Clearance is also required on
Jacks are provided, with gauges one axis for the hose connections
calibrated against a certified load to the body of the jack.
cell, to register the force exerted on
the bars. In addition, load cells are Hand and air operated pumps are
available to give an independent available, to drive the full range of
check on the accuracy of the pump jacks.
gauge, if necessary.
Stressing procedures and
Anchorage recess dimensions jack details are available from
must give clearance for the Macalloy’s Technical Department.

Figure 1 Jack details

NOTE If it is necessary to stress 75mm bars with a /PULLER
stressing bridge L1 must be 320 long and the puller
is replaced by Bearing Plate and Nuts.

25 - 50mm Bars (See above note) 75mm Bars and 25mm-50mm Bar in 200mm deep
Jack with stressing bridge and puller pockets jack with stressing stool and drawbar

Table 5: Jacking Dimensions

Max Min L1 L2 L3 L4 L5 L6 Min pocket

Jack type Weight load Bar dia. bar centres D.Dia S. Dia (min) dia.
3000
50 kgs 3000kN 75 170 250 187 135 330 - 865 1300 500 200
1000
50 160 90 450

26kgs 1000kN 40 120 176 125 75 301 385 564 850 300 135

36 116 65 370
114 60 360
32 90 129 100 50 281 340 566 870 300 110
88 45 330
450 15kgs 450kN 26.5

25

All jacks have 50mm stroke. All dimensions in mm

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Macalloy Post Tensioning System

Table 6: Physical Parameters

Item Unit † Nominal Bar Diameter -mm
20
Sectional Area mm2 322 25 26.5 32 36 40 50 75
Mass per metre kg 2.57 530 572 1963.5 4185.4
Bars Metre run of bar per tonne mm2 404 4.17 4.49 847 1075 1320 15.66 32.86
Characteristic failing load kN 314 246 219
Flat Nuts* Prestress at 70% characteristic kN 220 506 569 6.65 8.44 10.36 62 30
Flat Washers* Nut reference FSSN20 354 398 150 118 96 2022 4311
Couplers Length mm 25 FN25 FN26.5 1415 3018
Wide across flats (DIA for 75mm bar) mm 42 34.5 38.5 828 1049 1295 FN50 FN75
Washer reference FSSW20 46 50 73.5 100
Outside diameter mm 50 FSW25 FSW26.5 580 734 907 135
Thickness mm 5 60 65 FN32 FN36 FN40 90 FSW75
Coupler reference FSSC20 FSW50
Outside diameter mm 35 5 5 43 48 53 -
FC25 FC26.5 105 -
42.5 56 62 72 5 FC75
42.5 110
FSW32 FSW36 FSW40 FC50
76
70 75 90
5 5 5
FC32 FC36 FC40
50 57.5 62.5

Length - standard mm - 85 90 115 130 140 170 230
Length - stainless - 120 - -
Plate reference mm 65 80 - 95 FP40
FP36 FP50 FP75
End Plates FSSP20 FP25 FP26.5 FP32

Length mm 100 100 110 125 140 160 200 300
Width
Thickness - standard mm 100 100 110 125 140 160 200 300
Hole diameter
Thickness - threaded mm 25 40 40 50 50 60 60 75
Recommended Duct ID
mm 24 34 36 41 45 51 61 82

mm 0 40 40 50 60 60 70 110

Ducts** mm 30 38 40 48 54 60 75 109

LARGER DIAMETER DUCTS MAY BE REQUIRED LOCALLY TO ACCOMODATE COUPLERS.

Threads Pitch mm 2.5 6 6 66 8 8 8

Standard thread Length - jacking end (standard) S1 mm 250 250 250 250 250 250 250 360
lengths (see fig 2)
mm 100 100 100 100 100 100 100 160
- Dead end (standard) S2

- Coupler (standard) mm 40 45 50 60 65 75 85 150

X1 (MIN) mm 75 90 100 120 125 140 175 240

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.
** Note Duct size does not accomodate a coupler

Figure 2 End thread dimensions

dead end jacking end

X1 = live end
X2 = dead end
X3 = length of bar past

nut or threaded plate
= 12 for 6mm

16 for 8mm

S1 = live end thread
S2 = dead end thread

L = length over plates

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Macalloy Post Tensioning System

Figure 3 Typical end block reinforcement

Table 7 Reinforcement details

Macalloy HELIX LINKS RECOMMENDED

dia. mm Bar DUCT INSIDE

A Pitch mm OD Turns mm Bar B CRS mm SQU Number DIAMETER

25 12 20 40 175 4 8 25 70 199 6 38

26.5 12 20 40 180 4 8 25 70 205 6 40

32 12 20 40 190 5 8 30 70 216 7 48

36 12 20 40 210 6 8 30 70 235 7 54

40 12 20 40 240 7 10 35 75 265 8 60

50 12 20 40 300 8 12 40 80 330 9 75

75 16 30 50 450 8 16 50 100 490 10 109

Anchorage Zone of these, should be provided in the Macalloy Post Tensioning
Reinforcement each end block. The design of System, including Anchorage Zone
the anchorage reinforcement is Reinforcement, is available in the
Bursting tensile forces are induced, covered by Section 4.1 of BS8110 Macalloy Design Data Handbook.
in the concrete, immediately and described in greater detail by Contact the Technical Department
behind the anchorage end plates, CIRIA GUIDE 1- June 1976. for further information.
due to the compressive load
applied through the end plates. Macalloy does not design or
Reinforcement in the form of supply the helical reinforcement.
links, helices, or a combination A more detailed explanation of

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Macalloy Post Tensioning System

Detailing A more detailed explanation of the
Macalloy Post Tensioning System
There are many permutations is available in the Macalloy 1030
possible, to achieve satisfactory European Technical Approval,
construction details and advice is document ETA-07/0046.
readily available from the Technical
Department.

Figure 4 shows typical tendon
assemblies.

Figure 4 Typical tendon assembly for Macalloy bars

*Threaded end plate not currently part of European Technical Approval

Site Services Services offered by Macalloy Site Site Services please contact the
Services includes advice and Technical Department.
Macalloy Site Services offers a supervision, on and off site training
wide range of hydraulic jacks, or complete site stressing.
pumps and torque wrenches,
plus the patented Macalloy Should you require your own
TechnoTensioner, which enables technicians to carry out the site
the stressing of every type of bar stressing then all equipment can
and tendon that is produced by be hired directly from Macalloy. For
Macalloy. further information on Macalloy

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Macalloy Post Tensioning System

Applications • Stressed connections • Hangers
• Structural steel frame ties
Macalloy bars were developed, -concrete to concrete • Ground and rock anchorages
initially, for use in prestressed • High strength portal, ground or
concrete construction but have -concrete to steel
been adapted for many structural sheet pile ties
applications. Among these are:- -steel to steel
• Temporary or partial
• Prestressed block and brick
prestressing
construction
• Pile testing
• Anchor bolts for tension ties
• Holding down bolts
• Friction grip bolts and clamps

Sheikh Zayed Bridge, Contract 3, Abu Dhabi
Main Contractor - Archirodon Construction (O) Co. S.A.
Architect - Zaha Hadid Architects
Engineer - High Point Rendel, London

Yavuz Sultan Selim Bridge
(aka Third Bosphorus Bridge)

Designer Hyundai & SK Engineering JV Installation and Stressing by Intekno

This publication provides the technical details currently used by Macalloy 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, Caxton Way, Dinnington, Sheffield S25 3QE, U.K. Tel: +44 (0)1909 519200. Fax: +44 (0)1909 519201
Website: www.macalloy.com Email: [email protected] [email protected] [email protected]

is a Registered Trade Mark of McCalls Special Products Ltd.

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