September 2018 V1
Macalloy Sheet Piling System:
Macalloy TB460
Macalloy TB520
Macalloy TB590
Macalloy TB700
EXPERIENCE INNOVATION QUALITY
Macalloy Sheet Piling System
A Introduction of system P. 2 Plates P. 8
Macalloy TB460 and Macalloy TB520 System P. 3 End Terminations P. 9
Macalloy TB590 and Macalloy TB700 System P. 4 Joints P. 10
Corrosion Protection P. 5 Macalloy TB Components Table P. 11
Macalloy Sheet Piling Application P. 6 – 7 Macalloy Sheet Piling Projects P. 12
Introduction where it employs state of the art for sheet piling and other general
Macalloy has been the leader machinery to provide consistent threading applications .
in the design, manufacture and quality products. Since developing
supply of threaded bar systems the world’s first post tensioning This system has now been
since the 1940’s. Offering various bar system in 1948, Macalloy has extended with, the following
grades of threaded bar, its used its unique skills in threading systems forming part of Macalloy’s
products go into applications as technology to lead the world in new range:
diverse as post tensioning and the development of new systems - Macalloy TB460 System
ground engineering, steelwork and in the introduction of new - Macalloy TB520 System
structures and glass façades. technology in this field. - Macalloy TB590 System
- Macalloy TB700 System
Macalloy’s manufacturing facility Macalloy is well known for its
is based in Sheffield, England, Macalloy 17 MHS Tie Bar System,
Sea Commercial Port - Ust-Luga Russia
Image supplied by Pst Group, Russia
Quality
All our products and systems
follow strict quality guidelines in
accordance with BS EN ISO 9001
Macalloy also has its own in house Thread Rolling for crack propagation. The
testing facility where tensile testing process of thread rolling is faster
Roll threading is a process by
and anchorage testing is carried than cut threading and the thread
which a steel bar is fed into a
out on the bar and threaded roll life is also extended. These
series of thread rolls to form the
connections to ensure the system advantages, combined with the
male thread. In the cold forming
meets the specification. ability to use smaller diameter
process, the grain structure of the
bars, makes this manuf actur ing
material is aligned with the peaks
Macalloy is proud of its quality and process a much more sustainable
and troughs of the thread,
is a company with systems you and efficient process than cut
providing a smooth running thread
can trust. threading.
form and reducing the potential
2
Macalloy TB460 and Macalloy TB520 System
Table 1 – Tendon Capacities for Macalloy TB460 System
Thread Diameter Units M42 M48 M56 M64 M76 M85 M90 M100 M105
Nominal Bar Diameter mm 39 45 52 60 72 82 87 97 102
Yield Load kN 501 660 912 1204 1756 2239 2533 3172 3519
Ultimate Load kN 664 875 1209 1597 2329 2969 3359 4206 4667
Permanent Working Load (0.5*Py) kN 251 330 456 602 878 1120 1267 1586 1760
Tension Resistance EN1993-5 Kt=0.6 kN 319 420 580 766 1118 1443 1612 2019 2240
Tension Resistance EN1993-5 Kt=0.9 kN 479 630 870 1149 1677 2165 2418 3029 3360
Weight per Metre kg/m 9.4 12.5 16.7 22.2 32 41.5 46.7 58 64.1
Macalloy TB460 System Minimum Yield Stress: 460 N/mm2 The system may be considered
Available in diameters M42 to Minimum Break Stress: 610 N/mm2 a weldable steel. The maximum
M105, the system has a yield Minimum Elongation: 19% carbon equivalent is 0.55%,
stress of 460 N/mm2. This makes although typically the carbon
the system approximately 30% For diameters up to M90, the equivalent of the steel comes in
stronger than the more common maximum standard length of bar is at less than 0.47%. Arc Welding
S355 grade steel, allowing smaller 11.80m. may be carried out using standard
diameters to take the same load. techniques and low hydrogen rods.
All fittings are designed to carry the
The Macalloy TB460 bar has the full capacity of the bar.
following mechanical properties:
Table 2 – Tendon Capacities for Macalloy TB520 System
Thread Diameter Units M42 M48 M56 M64 M76 M85 M90 M100 M105
Nominal Bar Diameter mm 39 45 52 60 72 82 87 97 102
Yield Load kN 566 746 1031 1361 1985 2531 2863 3586 3978
Ultimate Load kN 719 947 1309 1727 2519 3212 3634 4551 5049
Permanent Working Load (0.5*Py) kN 283 373 516 681 993 1266 1432 1793 1989
Tension Resistance EN1993-5 Kt=0.6 kN 361 475 656 867 1265 1633 1823 2284 2534
Tension Resistance EN1993-5 Kt=0.9 kN 541 713 985 1300 1897 2449 2735 3426 3801
Weight per Metre kg/m 9.4 12.5 16.7 22.2 32 41.5 46.7 58 64.1
Macalloy TB520 System Minimum Yield Stress: 520 N/mm2 may be considered a weldable
Available in diameters M42 to Minimum Break Stress: 690 N/mm 2 steel. The maximum carbon
M105, the system has a yield Minimum Elongation: 19% equivalent is 0.55%, although
stress of 520 N/mm2, making the typically the carbon equivalent of
system 13% stronger than the For diameters up to M90, the the steel comes in at less than
Macalloy’s TB460 grade system, maximum standard length of bar is 0.47%. Arc Welding may be carried
allowing thereby the use of smaller 11.80m. out using standard techniques and
diameters to take the same load. low hydrogen rods.
All fittings are designed to carry the
The Macalloy TB520 bar has the full capacity of the bar. The system
following mechanical properties:
Table 3: Plate Dimensions - Macalloy TB460 & Macalloy TB520
Bearing Plate Units BP42 BP48 BP56 BP64 BP76 BP85 BP90 BP100 BP105
Width x Length mm 180 x 180 180 x 180 180 x 180 180 x 180 200 x 200 200 x 200 200 x 200 220 x 220 250 x 250
Thickness mm 30 30 30 30 40 40 50 50 50
Anchor Plate Units AP42 AP48 AP56 AP64 AP76 AP85 AP90 AP100 AP105
Width x Length mm 225 x 225 275 x 275 300 x 300 350 x 350 425 x 425 500 x 500 525 x 525 575 x 575 600 x 600
Thickness mm 25 25 30 35 40 45 50 55 55
Above dimensions based on TB520 capacity
3
Macalloy TB590 and Macalloy TB700 System
Table 4 – Tendon Capacities for Macalloy TB590 System
Thread Diameter Units M42 M48 M56 M64 M76 M85 M90 M100 M105
Nominal Bar Diameter mm 39 45 52 60 72 82 87 97 102
Yield Load kN 643 847 1170 1544 2252 2872 3249 4068 4514
Ultimate Load kN 871 1148 1586 2094 3054 3894 4405 5517 6120
Permanent Working Load (0.5*Py) kN 322 424 585 772 1126 1436 1625 2034 2257
Tension Resistance EN1993-5 Kt=0.6 kN 419 551 761 1005 1466 1893 2114 2648 2938
Tension Resistance EN1993-5 Kt=0.9 kN 628 826 1142 1507 2199 2839 3171 3972 4407
Tension Resistance to EAU2004 kN 582 775 1035 1378 1985 2575 2898 3603 3984
Weight per Metre kg/m 9.4 12.5 16.7 22.2 32 41.5 46.7 58 64.1
Macalloy TB590 System The Macalloy TB590 bar has the All fittings are designed to carry the
Available in diameters M42 to following mechanical properties: full capacity of the bar.
M105, the system has a yield
stress of 590 N/mm2, making Minimum Yield Stress: 590 N/mm2
the system 28% stronger than Minimum Break Stress: 800 N/mm2
Macalloy’s standard 460 grade Minimum Elongation: 12%
system, allowing the use of smaller
diameters to take the same load. The maximum standard length of
bar is 10m.
Table 5 – Tendon Capacities for Macalloy TB700 System
Thread Diameter Units M42 M48 M56 M64 M76 M85 M90 M100 M105
Nominal Bar Diameter mm 39 45 52 60 72 82 87 97 102
Yield Load kN 762 1004 1388 1832 2672 3407 3855 4827 5355
Ultimate Load kN 871 1148 1586 2094 3054 3894 4405 5517 6120
Permanent Working Load (0.5*Py) kN 381 502 694 916 1336 1704 1928 2414 2678
Tension Resistance EN1993-5 Kt=0.6 kN 471 620 856 1131 1649 2130 2378 2979 3305
Tension Resistance EN1993-5 KT=0.9 kN 706 930 1284 1696 2474 3194 3568 4468 4958
Tension Resistance to EAU2004 kN 634 834 1153 1522 2221 2868 3203 4012 4451
Weight per Metre kg/m 9.4 12.5 16.7 22.2 32 41.5 46.7 58 64.1
Macalloy TB700 System The Macalloy TB700 bar has the All fittings are designed to carry the
Available in diameters M42 to following mechanical properties: full capacity of the bar.
M105, the system has a yield
stress of 700 N/mm2, making Minimum Yield Stress: 700 N/mm 2
the system 52% stronger than Minimum Break Stress: 900 N/mm2
Macalloy’s standard 460 grade Minimum Elongation: 12%
system, allowing the use of smaller
diameters to take the same load. The maximum standard length of
bar is 10m.
Table 6: Plate Dimensions - Macalloy TB590 & Macalloy TB700
Bearing Plate Units BP42 BP48 BP56 BP64 BP76 BP85 BP90 BP100 BP105
Width x Length mm 180 x 180 180 x 180 180 x 180 180 x 180 200 x 200 200 x 200 200 x 200 220 x 220 250 x 250
Thickness mm 30 30 30 40 40 50 50 60 60
Anchor Plate Units AP42 AP48 AP56 AP64 AP76 AP85 AP90 AP100 AP105
Width x Length mm 225 x 225 275 x 275 300 x 300 350 x 350 425 x 425 500 x 500 525 x 525 575 x 575 600 x 600
Thickness mm 25 30 35 40 45 50 55 60 65
Above dimensions based on TB700 capacity.
4
Macalloy Corrosion Protection and Waling Bolts
Corrosion Protection scavengers, such as the Denso temperature range. It is non-
Steel sheet piling is used in many range of products. Please refer to hardening and non-cracking. It is
aggressive environments and table 7. highly resistant to mineral acids,
consequently factors affecting alkalis, salts and micro-organisms
The exposed end can be and highly impermeable to water,
the life of the tie bar must be
protected with an anchor head water vapour and gases.
considered.
cap, which is filled with Denso
Void Filler. An outer layer of PVC Tape
Several options are available,
is then used to complete the
including painting and galvanising, The most common form of
corrosion protection. The tape is
but the most common form is to protection is denso tape with PVC. a plasticised PVC sheeting that is
wrap the bar with a protective The Denso Tape is cold applied coated on one side with a rubber
barrier containing oxygen and remains plastic over a wide resin pressure sensitive adhesive.
Protection of Anchor Head
Sleeve
The process is carried out quickly stressing as the friction generated is
negligible
5. There is no need for use of ducting
machine. The advantages of using and grouting.
6. It saves cost and time on site as it
1. It is a very quick and easy process reduces the installation time.
2. It does not affect the structural
performance of the bar in any way
3. There is no loss in load during
Table 7: Recommended Levels of Tape Protection for a given environment
Type of Protection Recommended Application
Denso tape with 15mm overlap For non marine area or to debond in concrete
Denso tape with 55% overlap For marine environment
Denso tape with 55% overlap % pvc overlap For marine environment: also provides for handling. For medium life structures
Denso tape with 55% overlap & Densotherm overwrap For aggressive and marine environments, exposed to wave action. For medium to long life structures
Macalloy tape system For aggressive and marine environments, especially for long life structures
Sacrificial Protection Galvanising
Alternatively, if design of the superior mechanical Galvanising of tie bars to the Euro
calculations are completed using properties of the steel. These Norm BS EN ISO 1461:2009 can
stress levels appropriate to calculations should be in be done by double dipping the bar
BS EN 10025 S355JR, by using accordance with Sacrificial and brushing the threaded ends.
the higher grade Macalloy 460, it Corrosion Calcs - accordance with
is permissible to allow sacrificial EN1997-5.
corrosion to take place because
5
Macalloy Plates
Rocker Plates
To suit individual
Taper Plates requirements please
For angles >10° please contact Macalloy contact Macalloy
Macalloy End Termination
Fork Termination
For sheet pile connection or
circular pile conection please
contact Macalloy
Spherical Nut
Spherical Washer Taper Washer
Offering misalignment of up to +/- 3° please contact Macalloy For angles >10° please contact Macalloy
Macalloy Joints
Fork and Spade Articulated Joint
Please contact Macalloy
6
Table 8: Component Dimensions - Macalloy TB460 & Macalloy TB520
Thread Units M42 M48 M56 M64 M76 M85 M90 M100 M105
Nut Ref. NM42 NM48 NM56 NM64 NM76 NM85 MNM90 NM100 NM105
A/F mm 65 75 85 95 110 120 130 145 150
L mm 34 38 45 51 61 68 72 80 85
Washer Ref. WM42 WM48 WM56 WM64 WM76 WM85 WM90 WM100 WM105
O/D mm 78 92 105 115 135 145 160 175 180
T mm 7 8 9 9 10 12 12 14 15
Turnbuckle Ref. TE42 TE48 TE56 TE64 TE76 TE85 TE90 TE100 TE105
O/D mm 63 71 80 95 112 125 132 148 152
L mm 184 196 212 228 252 270 280 300 310
K mm 100 100 100 100 100 100 100 100 100
Coupler Ref. CE42 CE48 CE56 CE64 CE76 CE85 CE90 CE100 CE105
O/D mm 63 71 80 95 112 125 132 148 152
L mm 89 101 117 133 157 175 185 205 215
Table 9: Component Dimensions - Macalloy TB590 & Macalloy TB700
Thread Units M42 M48 M56 M64 M76 M85 M90 M100 M105
Nut Ref. NM42 NM48 NM56 NM64 NM76 NM85 MNM90 NM100 NM105
A/F mm 65 75 85 95 110 120 130 145 150
L mm 34 38 45 51 61 68 72 80 85
Washer Ref. WM42 WM48 WM56 WM64 WM76 WM85 WM90 WM100 WM105
O/D mm 78 92 105 115 135 145 160 175 180
T mm 7 8 9 9 10 12 12 14 15
Turnbuckle Ref. TE42 TE48 TE56 TE64 TE76 TE85 TE90 TE100 TE105
O/D mm 66 75 88 100 120 135 142 157 165
L mm 184 196 212 228 252 270 280 300 310
K mm 100 100 100 100 100 100 100 100 100
Coupler Ref. CE42 CE48 CE56 CE64 CE76 CE85 CE90 CE100 CE105
O/D mm 66 75 88 100 120 135 142 157 165
L mm 89 101 117 133 157 175 185 205 215
Macalloy Waling Bolts
Macalloy can supply end threaded
waling bolts to complement its tie
bars in various grades. The most
cost effective bolt is to use the
standard 460-grade material.
7
Macalloy Sheet Piling Projects
Port Bronka Expansion, St Petersburg, Russia
Reykjavik Haven, Iceland
Uyeasound, Shetland United Kingdom
Belfast Harbor, United Kingdom
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: sales@macalloy.com technical@macalloy.com and siteservice@macalloy.com
is a Registered Trade Mark of McCalls Special Products Ltd.
