Macalloy Post Tensioning System

1 July 2017. Macalloy Post Tensioning System Macalloy 1030. MANAGEMENT. SYSTEMS Macalloy S1030. 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 for 50mm obtain their specified properties and 75mm diameter. Greater The Macalloy 1030 Post Tensioning via a quenching and tempering tendon lengths can be obtained by System consists of high tensile process. joining Macalloy bars together with alloy steel bars in diameters from threaded Macalloy couplers. 25mm to 75mm, provided with cold rolled threads for part or full Sizes Non-standard bar diameters can length, together with a range of also be provided by arrangement.

2 Fittings. Bars from 25mm to 40mm Macalloy bars of standard quality Physical parameters of Macalloy diameter obtain their specified are available in lengths up to 1030 bar are given in table 1. Millau Viaduct, France Architect - Fosters and Partners Contractor - Eiffage Engineers - Michel Virlogeux, Bureau d' tudes Greisch, Setec Table 1: Range of Macalloy 1030 Bar Nominal Cross Mass Major diameter Minimum hole Diameter sectional area Macalloy 1030 Macalloy S1030 Stainless of threads diameter in Steelwork mm mm2 kg/m kg/m mm mm 20 322 - 24. 25 530 31. 572 - 33. 32 847 40. 36 1075 - 44. 40 1320 49. 50 1963 59. 75 4185 82.

3 2. 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. in table 2. Rigorous inspection and Macalloy 1030 is a carbon-chrome testing is carried out, both during Macalloy S1030 has very good steel with a composition designed and after treatment, to ensure general corrosion properties, similar to give the specified properties. All consistent tensile properties. The to grades (303) and bars are hot rolled. Diameters from mechanical performance of the bar (304) austenitic stainless steel bars. 25mm to 40mm are cold worked is monitored through the tensile In industrial atmospheres some by stretching.

4 The stretching load testing of machined specimens surface discolouration may occur and permanent elongation are rather than section testing. over a period of time. predetermined by preliminary tests 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.

5 Table 2: Mechanical Properties Nominal ultimate Nominal Minimum Approximate modulus Grade tensile strength proof stress elongation of elasticity N/mm2 N/mm2 % kN/mm2. Macalloy 1030 25-40mm 1030 835 6 170*. Macalloy 1030 50-75mm 1030 835 6 205. Macalloy S1030 20-75mm 1030 835 10 185. *Secant Modulus of Elasticity in range 5 - 70% UTS. Izmit Bay Bridge, Turkey Main Contractor IHI. 3. Macalloy Post Tensioning System Strength Typical pical stress strain diagram m for cold worked Macalloy acalloy 1030 bar (25-40mm). The specified characteristic failing loads and proof loads for Macalloy and Macalloy S1030 bar steels are given in Table 3.

6 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.

7 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 proof load Diameter Macalloy 1030 Macalloy S1030 Macalloy 1030 Macalloy S1030. mm kN kN kN kN. 20 - 323 - 262. 25 506 506 410 410.

8 569 - 460 - 32 828 828 670 670. 36 1049 - 850 - 40 1295 1295 1050 1050. 50 2022 2022 1639 1639. 75 4311 4311 3495 3495. 4. Macalloy Post Tensioning System Working Load Factors gives recommended load factors achieved by the 1030 bars, with for permanent and temporary typical results below 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.

9 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.

10 Loading over a tensile stress range 1030 bars have been subjected to of 590-670 N/mm2, exceeding the 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 proof stresses. System European Technical stress due to relaxation in a bar NOTE: document ETA-07/0046.