E:Hh3

Aug ’04

Macalloy Cable Structures:

Macalloy-Tensoteci Galvanised
Cable Tendons
Macalloy Guy Linking
Stainless Steel Cable Tendons
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Tensile Structure Systems

Macalloy Ltd has been the leader in the In the early 1980’s it pioneered the concept Now, through a close relationship with
design, manufacture and supply of threaded of Tensile Structures and, since this time, has Tensoteci a division of Radaelli Tecna Group
bar systems since 1948. led the world in the development of new of companies, Macalloy is able to offer large
systems and in the introduction of new diameter cable systems in galvanized steel
technology in this field. and stainless steel of both locked coil and
open spiral strand construction.

Tensoteci cable system

British Airways London Eye

Architect: David Marks & Julia Barfield

Engineer: Hollandia & Iv-Infra

Contractor: Hollandia

Tensoteci, based in Milan, is Italy’s leading observation wheel in the UK, the suspension market a complete and comprehensive
manufacturer of steel wire ropes, cables and cables system of the Braga Stadium in solution for wide span tensile structures
accessories. Tensoteci, founded in 1890 and Portugal designed by Souto de Moura and using steel bars and cables.
part of the Radaelli Tecna Group of the Athens Olympic stadium roof designed
companies, supply a range of tensile cable by Santiago Calatrava. No other company can offer such a complete
systems in locked coil and open strand package of bar and cable solutions in both
construction as standard up to 128mm The partnership between the two well carbon and stainless steels for Tension
diameter. established companies combines years of Structure applications to architects,
experience in design, manufacture, erection engineers and contractors worldwide.
Some of their notable reference sites are the and stressing of tensile systems. Together
cable systems of the giant London Eye this newly formed partnership can offer the
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Tensile Structure Systems

Galvanised Cable Range Stainless Steel Cable Range Carbon and Stainless Steel
Macalloy offers both open spiral strand and Alongside the new galvanized cable range, Bar Tendons
full locked coil strand in standard diameters Macalloy still offers the stainless steel Macalloy Macalloy’s existing tensile structure bar
up to 88mm and 128mm respectively. Guy Linking Cable system with swaged ends systems include:
Standard end components include fork in diameters up to 26mm as standard and up • Macalloy 460 (carbon steel bar system)
sockets, cylindrical sockets and bridge to 36mm on request. Larger diameters are • Macalloy S460 (stainless steel bar system)
sockets. also available with resin socket ends. • Macalloy Guy Linking Bar System
(stainless steel bar system)
Full details of these systems are found in the
Macalloy Tensile Structure System brochure.

Tensoteci cable systems. Cappelle a/d IJssel Rivium Bridge

Architect: Iv-Consult

Engineers: Iv-Infra

Tensoteci cable systems. Braga Stadium, Portugal

Architect: Eduado Souto de Moura

Engineer: A.F.A

Contractor: Assoc/Soares da Costa Ace

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Macalloy-Tensoteci Galvanised Cable Systems

Open Spiral Strand (OSS) The strand is built by an inner core of round The Z shape of the wires helps to prevent
wires and by one or more external layers of external agents entering inside the cables.
The open spiral strands are made from hot dip
Z shaped wires.
galvanised high strength steel wires.
The Z shape of the wires is specially made in a Tensofill Corrosion Inhibitor
The strand is built by several layers of round
self locking formation to give a compact section. The spiral strands and the locked coil strands
wires helically wound around the core.
are generally filled in the inner layers by
The special shape of the Z shaped wires allows
Typical properties of the wires are: Tensofill. This is a corrosion inhibitor compound
for flat contact surfaces and low contact
• tensile strength ft=1570 to 1760 MPa minimum made by Severe Atmosphere Corrosion
stresses between the wires.
• proof stress Rp0,2=1180 to 1320 MPa minimum Inhibitor, resin and zinc powder, in a grade to
Typical properties of the wires are:
optimise the resin anti-corrosion shield and the
• elongation at break A=4% minimum on
• tensile strength ft=1570 to 1660 MPa minimum galvanic protection.
250mm gauge length
• proof stress Rp0,2=1180 to 1245 MPa minimum
• the zinc coating and the wire ductility The filler helps to prevent the entry and
• elongation at break A=4% minimum on diffusion of moisture inside the cable and gives
comply with UNI 7304 class A, ISO 2232
250mm gauge length additional protection to the galvanised wires.
class A, DIN 2078 heavy galvanising, ASTM
A586 class A, 10264-3 class A, or other • the zinc coating and the wire ductility comply
standards as required. with UNI 7304 class A, ISO 2232 class A, Prestretching and Marking
DIN 2078 heavy galvanising, ASTM A586 The strands for structural application are
Full Locked Coil Strands (FLC) class A, 10264-3 class A or other standards as usually prestretched in the works, to remove
The full locked coil strands are made from hot required. The minimum zinc coating of the Z the initial inelastic deformation due to the
dip galvanised high strength steel wires. shaped wires is 300g/m2 . helical structure of the cables and to stabilise
the elastic modulus.
Table 1: Open Spiral Strand
The prestretching operation is executed on a
Diameter Cross Section Minimum Break Elastic Stiffness Weight
(mm) A (mm2) Load MBL (kN) E-A (MN) (kg/m) special plant, with a capacity of 5000kN, where
the cable is anchored and pulled.
12 88 135 14.6 0.7

16 157 240 25.9 1.3 The prestretching is made usually by 4 or more

cycles from 10% to 50-60% of the minimum
20 245 380 40.4 2.0
breaking force; after the last cycle the force is
24 353 545 58.2 2.9
adjusted to the specified load to allow
28 480 745 79.3 4.0
measurement of the cable.
32 628 970 104 5.2
The cables are then measured and marked
36 794 1230 131 6.5
under the specified load for cutting to length
40 981 1520 162 8.1 and the position of the intermediate clamps are
44 1186 1840 196 9.8 marked, when required.
48 1412 2190 233 11.6 The measurement method takes into account
52 1657 2570 273 13.7 automatic compensation of the thermal
56 1922 2980 317 15.8 elongation, and is performed in monitored
thermal conditions.
60 2206 3425 364 18.2

64 2477 3815 404 20.4

Defining the lengths is done by ourselves using
load-geometry data from the structural model
68 2796 4290 456 23.0
and taking into consideration the actual sizes,
72 3135 4795 511 25.8
offsets and dimensions of the connection pieces.
76 3493 5325 569 28.8
Additionally the expected long term creep and
80 3870 5885 631 31.9
setting of the anchor ends is considered in the
84 4267 6475 695 35.2 prefabricated lengths.
88 4683 7090 763 38.6
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Macalloy-Tensoteci Galvanised Cable Systems

Socketing toughness of the cable. The resin forms a Corrosion Protection
solid cone with the cable wires. This cone
The cable ends are terminated by sockets that The corrosion protection of the high strength
acts as a wedge inside the socket’s conical
match the breaking strength of the cable. steel cables is obtained by the following
hole. The resin cast at room temperature also
There is a wide range of sockets available. They systems combined together:
preserves the anticorrosion filler inside
are fixed to the cables by one of the following the cable near the socket; • hot dip galvanising of the wires; galfan
methods: (zinc aluminium) coating of the wires can
• socketing using metal (pure zinc or zamak
• socketing using polyester resin for structural alloy), melted inside the socket. This method also be provided;
use, cast at room temperature; this method also takes the full strength of the cable; • internal anticorrosion compound Tensofill
takes the full strength of the cable through • swaging is used on small cable sizes, up to surrounding the internal galvanised wires;
the resin interface, without any kind of of approximately 45mm diameter. Here the • Z shaped external locked coil wires,
mechanical grip or stress concentration on terminals are pressed onto the cable. Swaging preventing the entry of external agents;
the wires, thereby allowing high fatigue reduces the tendon capacity by around 10%. • The following special protection systems can
also be used:
– a final coat of Tensocoat Wax, made up of
Severe Atmosphere Corrosion Inhibitor,
Table 2: Full Locked Coil Strand resin and aluminium microflakes; this
Diameter Cross Section Minimum Break Elastic Stiffness Weight
(mm) A (mm2) Load MBL (kN) E-A (MN) (kg/m) coating is applied during and after the
installation of the cables;
32 681 1015 112 5.6
– a final coat of Tensocoat Epoxy, a two part
36 862 1285 142 7.1
polyamine epoxy with added aluminium
40 1077 1605 178 8.9 microflakes, this coating is applied after the
44 1303 1945 215 10.7 installation of the cables;
48 1551 2315 256 12.8 – High Density Polyethylene sheath applied
52 1841 2750 304 15.2 by hot extrusion on the cable surface; this
provides complete waterproofing. The HDPE
56 2136 3190 352 17.6
is of a grade suitable for long term reliability.
60 2452 3660 405 20.2

64 2789 4165 460 23.0

68 3149 4700 513 26.0

72 3530 5210 575 29.1

76 3933 5790 641 32.4

80 4358 6405 710 35.9

84 4805 7045 783 39.6

88 5274 7720 860 43.5

92 5764 8430 940 47.5

96 6276 9165 1023 51.7

100 6890 10050 1123 56.8

104 7452 10860 1215 61.4

108 8037 11700 1310 66.2

112 8643 12575 1409 71.2

116 9271 13480 1511 76.4

120 9922 14415 1617 81.8

124 10594 15385 1727 87.3

128 11289 16385 1840 93.0

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Macalloy-Tensoteci Galvanised Cable Systems

Fork Sockets
The fork sockets are made from high
strength, hardened and tempered cast steel.
Charpy-V impact value is 27J at –20 °C.

Surface protection is by hot dip galvanizing

to a minimum thickness of 80 ␮m. Additional
protection can be obtained by applying
Epoxy Tensocoat.

Whilst the table gives dimensions of our

standard sockets, Macalloy is also able to
provide special sockets for specific projects
or applications.

Table 3: Fork Socket Dimensions

Socket Type Minimum Break Cable Diameter D A max B max C E
Load MBL (kN) (mm) (mm) (mm) (mm) (mm) (mm)

F-196 165 10-12 25 22 41 25 49

F-198 250 13-16 31 29 52 29 57

F-104 440 17-20 41 40 73 45 90

F-108 680 21-25 51 47 82 60 120

F-111 980 26-28 57 53 93 65 130

F-115 1220 29-32 63 59 104 72 144

F-118 1470 33-36 70 65 137 80 160

F-120 1960 36-38 76 71 138 88 176

F-125 2550 39-44 89 84 145 100 200

F-128 2740 45-49 95 96 190 108 216

F-130 3530 50-52 108 108 207 118 236

F-132 4410 53-56 121 120 227 132 264

F-135 4700 57-64 127 126 231 138 276

F-138 5100 64-69 133 139 232 142 284

F-140 5880 70-76 140 151 240 148 296

F-142 6860 77-80 152 163 255 170 340

F-144 8580 81-88 178 183 272 181 362

F-146 10790 89-102 190 200 402 220 440

F-150 12260 103-111 250 200 424 280 560

F-160 13240 112-118 275 220 416 300 600

F-170 15690 119-128 290 240 507 325 650

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Macalloy-Tensoteci Galvanised Cable Systems

Table 4: Cylindrical Socket Dimensions Cylindrical Sockets

Cable Diameter CA LA CB LB The cylindrical sockets and nuts are made
(mm) (mm) (mm) (mm) (mm)
from high strength NiCrMo hardened and
12 40 65 40 100 tempered alloy steel. Charpy-V impact value
16 55 85 55 130 is 27J at –20 °C.
20 65 105 65 160

24 75 130 75 190 Surface protection is by hot dip galvanizing

to a minimum thickness of 80 ␮m. Additional
28 85 150 85 215
protection can be obtained by applying
32 95 170 95 255
Epoxy Tensocoat. After installation, threads
36 110 190 110 295
are protected with Tensocoat Wax.
40 120 210 120 325

44 130 235 130 360

48 145 255 145 390

52 155 275 155 430

56 165 295 165 460

60 180 315 180 485

64 190 340 190 525

68 200 360 200 550

72 210 380 210 585

76 225 400 225 615

80 235 420 235 645

84 245 445 245 680

88 260 465 260 705

92 270 485 270 745

96 280 505 280 775

100 295 525 295 800

104 305 550 305 840

108 315 570 315 875

112 325 590 325 905

116 340 610 340 935

120 350 630 350 965

124 360 655 360 1000

128 370 675 370 1030

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Macalloy-Tensoteci Galvanised Cable Systems

Cylindrical Sockets

Table 5: Cylindrical Socket Dimensions

Cable Diameter CC LC N CD LD R
(mm) (mm) (mm) (mm) (mm) (mm) (mm)

12 45 95 55 40 100 18

16 55 125 70 55 130 24

20 70 155 85 65 160 27

24 80 185 100 75 190 33

28 90 215 115 85 215 39

32 100 245 130 95 255 45

36 110 275 145 110 295 48

40 125 305 155 120 325 56

44 135 335 175 130 360 60

48 150 365 190 145 390 68

52 160 395 205 155 430 76

56 175 425 220 165 460 80

60 185 455 235 180 485 85

64 200 485 250 190 525 90

68 210 515 265 200 550 95

72 220 545 280 210 585 110

76 235 575 295 225 615 115

80 245 605 310 235 645 120

84 260 635 325 245 680 125

88 270 670 340 260 705 130

92 285 695 355 270 745 135

96 295 725 370 280 775 140

100 305 755 385 295 800 145

104 320 785 405 305 840 150

108 330 820 420 315 875 160

112 345 845 435 325 905 165

116 355 875 450 340 935 170

120 370 905 465 350 965 175

124 380 935 480 360 1000 180

128 395 970 495 370 1030 185

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Macalloy-Tensoteci Galvanised Cable Systems

Bridge Sockets
The bridge sockets and pins are made
from high strength NiCrMo hardened
and tempered alloy steel. Charpy-V
impact value is 27J at –20 °C.

Surface protection is by hot dip

galvanizing to a minimum
thickness of 80 ␮m. Additional
protection can be obtained by
applying Epoxy Tensocoat.

Table 6: Bridge Socket Dimensions

Cable Diameter D A max B
(mm) (mm) (mm) (mm)

12 35 35 90

16 45 45 120

20 55 55 145

24 65 60 170

28 80 65 190

32 90 75 210

36 100 75 240

40 110 75 255

44 120 80 270

48 130 90 310

52 145 95 325

56 155 95 340

60 170 100 360

64 180 110 395

68 190 110 410

72 200 115 420

76 210 125 445

80 220 130 460

84 230 130 490

88 240 135 505

92 265 135 545

96 275 140 560

100 285 140 585

104 295 145 595

108 305 150 615

112 320 150 640

116 330 160 665

120 345 160 690

124 355 165 710

128 360 180 720

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Macalloy Guy Linking Stainless Cable Systems

Macalloy Guy Linking 7x19 strand is constructed from 7 strands stainless steel Grade 316 to BS 970. The
Stainless Cable Systems 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
Cable a primary requirement process is usually performed under factory
Wire cable undergoes two types of stretch conditions to ensure the correct cable length
under load – an initial stretch and a Young’s Modulus of the is achieved.
conventional elastic stretch. The initial Cable
stretch is dependent upon cable construction All components for our cable systems are
The apparent Young’s Modulus (E) of the Guy
and is caused by individual wires bedding designed to match the minimum break load
Linking Cable systems are:
down into a loaded position. This initial of the 1 x 19 strand cable. If fittings are
stretch can be between 0.10 and 0.75% of required to match the minimum break load
1 x 19 Strand 107 kN/mm2
the cable length, depending on the of compact strand, please seek advice from
Compact Strand 133 kN/mm2
magnitude and frequency of loading, and the Macalloy technical department with
7 x 19 Strand 85 kN/mm2
should always be considered when regard to component sizes.
designing tendons.
The elastic stretch (d) of a cable may be
calculated by use of the following formula: As detailed below table 7, there are 3 types
There are 3 different types of stainless cables of standard tendons:
offered by Macalloy.
d= Load (kN) x Length (mm)
E (kN/mm2) x Cross Sectional Area (mm2) • The swaged adjustable fork system
The most common strand used is the 1 x 19 • the swaged fork with swaged tensioner
spiral strand. The wires have a smooth system
Please note that the above E values have
bright finish and the cable has moderate • the swaged fork with in-line tensioner.
been established empirically. No cable will
initial stretch properties. All our cable
behave completely elastically and the
tendon fittings are designed to match the For applications where forks are not
apparent E value will consequently change
minimum breaking load of the 1 x 19 strand required, tendons may also be supplied with
over different stress ranges. Accurate
cable. 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
Compact Strand offers a 30% increase in available for balustrade applications.
consult our technical department for further
breaking load over the conventional 1x19
details if necessary.
strand and a much lower initial stretch. It Dimensions are detailed in table 8.
also has a higher elastic modulus making it
ideal for use where high strength and low
Components Additional components and fittings are
available on request. These include toggles,
stretch is required. As with the Guy Linking bar system, all
dome nuts, standard nuts, spherical
components are made from austenitic
seats, etc.

Table 7: 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

1 x 19 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 95.0 141.2 189.2 251.0 313.7

7 x 19 Cable kN 5.0 8.9 13.9 20.0 27.3 35.6 55.6 80.0 109.0 143.1
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Macalloy Guy Linking Stainless Cable Systems

Table 6: 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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Cable Structure Systems

Tensoteci cable systems. Olympic Stadium, Athens

Architect: Santiago Calatrava

Contractor: Costruzioni Cimolai Armando SPA

Nokia HQ, Finland

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, 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 Macalloy Ltd. is a mark of Radaelli Tecna spa