Macalloy is the leader in the design, manufacture and supply of threaded tension rod systems since 1948. Macalloy supply a range of high strength bar and cable systems to world-wide markets. Macalloy's unsurpassed quality and high-level of service makes them the manufacturer of choice for all rod and cable systems.
The variety of the Macalloy range reflects its position as a respected designer and service provider to architects, engineers and contractors.
Buildings are all different, each requiring an individual approach to its design. Decon engineers are experienced at recognising the opportunities to stretch the design envelope to provide an individual solution for your project. Please call the technical department to discuss your requirements.
Decon Inc. is proud to be the sole North American distributor for Macalloy products
Macalloy 460 Carbon Steel Tendons
Macalloy 460 is a fine grain steel with an exceptional blend of mechanical properties; combined with rolled threads this provides a material with superior fatigue performance. Macalloy 460 is a weldable steel with a maximum carbon equivalent of 0.55%.
All fittings are designed and tested to provide a tensile capacity equal or superior to that of the theoretical strength of the bar. The standard left hand–right hand tendon will provide adjustment to accommodate site and manufacturing tolerances:
Cutting tolerance for rods: up to M76 (3") +/- 6 mm (1/4")
Cutting tolerance for rods: over M76 (3") +/- 25mm (1")
Adjustment for rods M12 (1/2") to M56 (2-1/4") +/- 12mm (1/2") each end
Adjustment for rods M64 (2-1/2") to M100 (4") +/- 25mm (1") each end
Macalloy 460 can be provided with any practical coating system in accordance with your specification; such as galvanizing, priming or painting. Please discuss your exact requirements with the Decon engineers.
Architectural fittings are finished to provide a smooth transition from the bar to the fork. This aesthetic appearance is provided by the use of threaded lock covers, which combine the function of a lock nut and a blending thread cover.
The connection to the structure should be made by utilising a connection plate with the same thickness and edge distance as the Macalloy spade shown in the product catalogue. All connections should be made using standard grade 50 material.
Macalloy 460 Stainless Rod System
In keeping with Macalloy's position as the international leader for tension structure supplies, Stainless Macalloy S460 has now been developed.
Macalloy Grade S460 provides a unique opportunity to present the same shape and profile for all bar systems. Many more structures are moving to stainless steel tension support systems.
Buildings and their facades are all different and each requires an individual approach. Decon engineers are experienced at recognising the opportunities to stretch the design envelope, to provide a truly individual solution for your project.
Macalloy S460 is selected from high strength stainless steel to provide the optimum balance of strength, ductility and appearance.
The standard left hand–right hand tendon will provide adjustment to accommodate site tolerances:
Cutting tolerance for rods up to M56 (2-1/4") +/- 6 mm (1/4")
Adjustment for rods up to M10 (3/8") +/- 12 mm (1/2") each end
Adjustment for rods M12 (1/2") to M56 (2-1/4") +/- 1/2 diameter each end
Adjustment for all rods with a turnbuckle +/- 50 mm (2")
All standard Macalloy S460 rods are finished with a light satin finish approximately equal to an N3 finish. Should you require any other finish please contact Decon to select from the wide range of optional surface treatments.
Architectural fittings are finished to provide a smooth transition from the bar to the fork connection, this aesthetic appearance is enhanced by the use of Lock Covers, which combine the function of a lock nut, and a blending thread cover.
The connection to the structure should be made by utilising a connection plate with the same thickness and edge distance as the Macalloy spade shown in the tensile structure catalogue. All connections should be made using standard grade 50 material or stainless equivalent.
If connecting stainless steel to carbon steel, measures should be taken to prevent bimetallic corrosion. Isolation bushes and washers are available from Decon. The Macalloy tension structure design data book shows detailed edge distance and hole diameter.
Macalloy SC460 Stainless Cable Systems
After the success of the Macalloy 460 and S460 systems, and the meet the ever increasing needs of its customers, the Macalloy SC460 Stainless Cable system has been introduced. This specially designed incorporates cable adapters, which allow standard imperial threaded swaged cables to be connected to the standard Macalloy S460 range of forks. By using the standard Macalloy S460 forks on the cable ends, continuity of design remains in projects where Standard Macalloy 460 & S460 rod systems have been used alongside the Macalloy SC460 Stainless Cable Systems.
Macalloy SC460 Stainless Cable The cable used in the system undergoes both a conventional elastic stretch as well as an initial stretch. The initial stretch can be between 0.10 and 0.75% of the cable length, depending on the magnitude and frequency of loading, and should always be considered in the design of the structure.
Macalloy offers 3 cable types
1x19 spiral strand, has moderate initial stretch properties.All the cable adapter fittings are designed to match the minimum break load of the 1x19 cable.
Compact Strand has a higher breaking load along with a lower initial stretch than the 1x19 strand cable and is available in most diameters
7x19 strand is the most flexible cable and is ideal where this property is paramount.
Standard Components SC460 Tendons
The fork and pin components of the system are all made from austenitic/duplex* stainless steel. The swaged fittings are factoryswaged to either end of the cable, and the strength of the connection exceeds the break load of the cable
*Pin set bodies above SPA24 nay be in martensitic stainless steel.
The system is designed to match the minimum bvreak load of the 1x19 strand cable.If fittings are required to match the minimum break load of the compact strand, please seek advice from the Decon technical department with regard to component sizes.
Connection Plates
All forks may be connected to either carbon steel or stainless steel connection plates with an equivalent strength to ASTM A-572, grade 50 or grade 316.
Where carbon steel plates are used, isolation sleeves and washers may be required to prevent bi-metallic corrosion, in which case the dimensions of gusset plate B reference should be used. For more details on other connection plates please see the brochure.
Macalloy 520 Rod Systems
Once more, Macalloy leads the way with the launch of a new tensile structure system, the Macalloy 520 system. The system is an extension to the already established Macalloy 460 system and is available in carbon steel from M10 (3/8”) to M100 (4”).
The fittings are designed to take the increased capacity of the system, allowing approximately 13% higher load to be carried for the same diameter, when compared with the Macalloy 460 system or 45% when compared with the more common Grade 50 steel.
Mechanical Properties
Macalloy 520 rod has the following mechanical properties:
Minimum Yield Stress 75,400 psi
Minimum Breaking Stress95,700 psi
Minimum Elongation 19%
Minimum Charpy Impact Value 20 ft-lbs @ 4°F
Young’s Modulus 29,700 ksl
Corrosion Protection
As with the Macalloy 460 system, corrosion protection can be achieved through hot dip galvanizing. Should an aesthetic solution be required, then Macalloy can also offer a paint protection.
Stressing
Stressing is still possible by means of the Macalloy TechnoTensioner.
Compression Strut
Macalloy Architectural Compression Struts have benefited the Tension structures market by providing an aesthetic pin-ended compression member that allows for adjustment of the overall length of the member.
To compliment the already existing Macalloy Compression Strut range, Macalloy now offers the Macalloy Standard Compression Strut range.
The Macalloy Standard Compression Strut provides the same compressive capacities as the architectural system, however the formal appearance of this strut, has a shorter taper cone and no locking collar.
Macalloy Compression Struts utilize standard Macalloy 520 fork ends and pin sets. These are connected to the CHS (circular hollow section) by a taper cone and threaded stud. That in turn is welded onto each end of the CHS.
Macalloy Architectural Compression Struts are available in diameters M12 to M100 in carbon or galvanized steel.The product is also supplied in diameters of M12 to M30 in stainless steel. For larger diameter stainless please contact Decon’s technical department to discuss your requirements.
The Standard Compression Strut range is available in diameters of M12 to M100 in carbon or galvanized steel.
Tolerances and adjustments:
The cutting tolerance for a CHS is +/- 3mm.
Adjustment within each fork is:
M12 to M56 +/- ½ thread diameter
M64 to M100 +/- 1”
Design and Specification:
Select the required CHS diameter from Macalloy’s standard sizes in the table.The diameter selected will depend on the required compressive load and the length of the tendon.
Check that the fork end capacity is greater than the compressive load required. Specify either the Macalloy Architectural Compression Strut or the Standard Compression Strut.In the specification ensure that the thread size, the strut diameter and the pin-to-pin length are given.
TechnoTensioner
Stressing using the Macalloy TechnoTensioner
Macalloy has always been at the leading edge of technology in the field of tension structures and has pioneered the method of stressing such tendons. We have long recognized the need for controlling the amount of load in a tendon. Therefore, for specific applications, we have developed the patented Macalloy TechoTensioner.
The hydraulic stressing unit is placed over the standard turnbuckle joint and is clamped onto the lock covers either side of the turnbuckle. The live load is induced into the tendon through the TechnoTensioner and can be measured with a degree of accuracy of +/-2.5%.
We have several units available for rent from our site stressing department for the full range of diameters and can provide the specialist supervision required on site to operate such equipment.
Further details can be requested from our Site Services or Technical Departments. Please note that the TechnoTensioner should only be used with the Stainless systems under advice from Macalloy.
Macalloy Facade Engineering and Structures
Macalloy Facade Structures section is dedicated to providing an integrated service for the design, manufacture and erection of all types of light weight glass facade support structures.
Macalloy's all encompassing approach relating to the structural design and material guarantees peace of mind. By developing the relationship with the architect, structural engineer and the glass supplier, Macalloy have been the catalyst permitting the exciting completion of many facade projects.
The Korean World Trade Centre has one of the largest catenary cable supported glass wall structures. The design concept to site erection service, provided by Macalloy engineers and our own independent consultant structural engineers, culminated in an elegant solution which was not only aesthetically attractive but engineered for efficient manufacture.
The list of facade and facade related structures is growing daily. Each project offers an opportunity to resolve an engineering problem such as:
Tensioning 330 feet long cables.
Attaching structural fittings mid length of a cable.
Designing for thermal variation caused by severe climatic change.
Creating articulated joints which can accommodate continuous change in wall profile.
Decon Site Services
Decon's substantial site services experience is at your disposal, provided by engineers and technicians who have been responsible for a wide range of stressing and erection projects around the world.
The service provided runs from renting calibrated torque wrenches, to the development of special stressing equipment and supervision of erection processes.
Macalloy have provided site services to the civil and construction industry from the very beginning of post tensioning, this continues with the services listed below.
Concrete post tensioning stressing and (or) supervision:
Post tensioning jacks
Tension structure load and levelling service:
Hydraulic Torque Wrench
Stressing pin ended structures using the patented Techno Tensioner:
Hollow Load cells
Site swaging of cable tendons:
Swaging Machines
Technical supervision of installation and erection:
