South Africa’s largest manufacturer of copper, brass ... · PDF fileSouth Africa’s largest manufacturer of copper, brass & alloy solutions copalcor group catalogue Jan 2013 Metallurgical

South Africa’s largest manufacturer of copper, brass & alloy solutions

copalcor group catalogueJan 2013

Metallurgical Tes�ng Services

MESSAGE FROM THE MANAGING DIRECTOR

“Copalcor is one company that can service and deliver to the

growing electrical sector. We aim to focus on niche markets and

to develop an international footprint, leveraging off our total

value chain offering.”

Copalcor (Pty) Ltd is South Africa’s largest manufacturer of copper, brass and alloy-based, semi-finished productsand turnkey busbar solutions. Established in the Johannesburg area in 1948, the company has undergone various name changes from McKechnie Brothers, Brass Extruders (BESA) and Copalcor Rolled Metals (CRM) to the current Copalcor Group. Copalcor offers solutions incorporating a wide range of our rolled, extruded and forged non-ferrous metal products for the local and international market.

Through ongoing development and expansion the company maintains its position as a leader in the field of service to South African strategic industries and continues to grow as an exporter worldwide.

Standards are maintained throughout each process, from validation of raw material to the final semi-manufactured product. This is achieved by adherence to ISO 9001:2008.

Gordon GrantManaging Director


COPALCOR HEAD OFFICE • Telephone +27 (0)11 821 0700 • Fax +27 (0)11 827 8750 • Email: [email protected] • Website: www.copalcor.co.za2

CONTENTS

Copalcor GroupHead Office & WorksPhone:+27(0)11 821 0700Email:[email protected]

Copalcor Trading -PretoriaPhone:+27(0)12 379 6043Email:[email protected]

Copalcor Trading -Port ElizabethPhone:+27(0)41 451 2355Email:[email protected]

Copalcor Trading -DurbanPhone:+27(0)31 482 2300Email:[email protected]

Copalcor Trading -Cape TownPhone:+27(0)21 982 1155/6Email:[email protected]

PROJECTS 3

BUSBAR 5

EXTRUDED PRODUCTS 6

ROLLED PRODUCTS 9

FORGINGS 10

INGOTS 10

HANGER BAR 10

EARTHING PRODUCTS 11

EXOTHERMIC WELDING 12

ANTIMICROBIAL PRODUCTS 14

COPALCOR TRADING PRODUCTS 15

USEFUL DATA 16

COPALCOR HEAD OFFICE • Telephone +27 (0)11 821 0700 • Fax +27 (0)11 827 8750 • Email: [email protected] • Website: www.copalcor.co.zaCOPALCOR HEAD OFFICE • Telephone +27 (0)11 821 0700 • Fax +27 (0)11 827 8750 • Email: [email protected] • Website: www.copalcor.co.za3

Design, Manufacture and Implementation

PROJECTS

Copalcor offers clients a complete solution from design to manufacture, through to installation and the operations ofcasting, rolling and busbar fabrication are all fully integrated.

• Complete scope of work in design, manufacture and installation of earthing and busbar systems.

• Design and supply of all steelwork and insulation material for supporting busbar systems.

• Shipment and installation supervision, including installation manuals and drawings.

Drilling

Smelting

Insulation

Slab Casting

Electro Plating Supervised Installation

Hot Rolling

“Copalcor owns the total value chain”


Project Examples

PROJECTS

6 line, 600 tonne, 60 000 Amp/line DC (high current) turnkey busbar installation project for copper foil platingplant (Nan Ya Plastics Corporation, Taiwan, 2007).

16 line, 200 tonne, 17 600 Amp/line DC turnkey busbar installation project for NaOH Chlor-Alkali plant(Formosa Plastics Corporation, Taiwan, 2006).

220 (120 tonnes) Copper Cooling Blocks used in a Titanium Oxide Smelter (Richards Bay Minerals, 2003).

Antimicrobial copper touch surface products for the medical industry.

60ka Switch Connection


Logistics

Copalcor is the leading manufacturer of busbar systems in Southern Africa. The operations of casting, rolling and busbar fabrication are all fully integrated. We offer clients a complete solution from design to manufacture, through to installation. Copalcor has extensive experience in managing the shipment and installation of busbar systems worldwide.

Busbar size range:Length (max) in excess of 10 000 mmThickness 6 mm up to 50 mmWidth 80 mm up to 615 mm

Major customers:• Chemical corporations (e.g. Chlor-alkali plants)• Electroplating copper foil plants• Mining and mineral beneficiation companies involved in the electro-winning of minerals such as zinc and copper (SX-EW)• Companies involved in the metals furnace and smelting industries.

Copalcor is often contracted to coordinate and manage the design and supply of all other hardware associated with busbar systems, including:

• Flexible connectors, insulation, steel support structures.

Additional services Copalcor offers the following on-site services:

• Painting• Electroplating• Hot dip solder plating• Aluminium busbars

Products, Projects and Turnkey Solutions

BUSBAR

Steel Support Structures

Copper Slab

InstallationSilver Plated and Insulated

Busbar Fabrication


RoundDiameter:3.0mm - 127.0mm

RoundOD:20.5mm - 59.0mmWall thickness:> 3mm

RoundOD: 60.0mm - 127.0mmWall thickness: > 5mm

HexagonAF: 55.0mm - 110.0mmWall thickness: > 5mm

OctagonAF: 55.0mm - 111.0mmWall thickness: > 5mm

SquareWidth:5.0mm - 90.0mm

HexagonAF:20.5mm - 54.0mmWall thickness:> 3mm

OctagonAF:38.0mm - 82.5mm

FlatWidth:8.0mm - 127.0mmStandard thickness’savailable

HexagonAF:5.0mm - 90.0mm

OctagonAF:22.0mm - 54.0mmWall thickness:> 3mm

Brass wire in coilsDiameter: 1.6mm - 12.0mm

Hollow bar profiles available on request. All tolerances comply to BS EN standards

Large HollowExtruded HollowExtruded Solid

Customised Extrusions

EXTRUDED PRODUCTS

Copalcor can supply you with any custom shapes, sections, edging, railing lock body, electrical contact, and profiles that you might need, in various grades of copper or brass.

Size limitations:Profile to fit in a radius of 120.00 mmThickness of extrusion to be not less than 3,20 mm


EXTRUDED PRODUCTS

Related specifications - Low fuming bronze:ASTM/AWS R Cu Zn C BS 1453 C4UNS C68100 SABS 392BS 1845 CZ7DIN 1733 S-Cu Zn 39 Sn Wn 2.0532

Physical and mechanical properties:• Tensile strength - 63,500 psi / 420 mpa• Elongation - 25.5%• Brinell hardness - 95.5• Melting point - 1625°F / 887°C• Solidification - 1590°F / 868°C

Lengths: 450mm to 1000mm

Packing and labelling:Tied in 10kg cardboard tubes marked ‘copflo’ Packed in 500kg wooden crates.

Size Range

A (mm) Mass (kg/m) A (mm) Mass (kg/m)1.60 0.0170 4.00 0.10642.00 0.0266 5.00 0.16632.40 0.0383 6.00 0.23953.20 0.0681 10.00 0.6552

• Non-standard sizes available on request

Low Fuming Bronze - Brazing Rod - C681


EXTRUDED PRODUCTS

Mass Calculation Formulae


Size Range

Width ThicknessCopper foil in coil 16.00 to 360.00mm 0.05 to 0.39mmCopper strip in coil 6.36 to 630.00mm 0.40 to 3.00mmCopper flat strip cut to length (length < 2000mm) 6.35 to 610.00mm 0.40 to 6.00mmCopper sheet (length < 2000mm) 300.00 to 1200.00mm 0.56 to 10.00mmRoofing copper 600.00mm 0.50 to 0.70mmCopper busbar 60.00 to 620.00mm 6.35 to 50.00mmCopper circles 50.80 to 600.00mm 0.50 to 2.00mmTin plating Optional Optional

Size Range

Width ThicknessBrass foil in coil 6.35 to 310.00mm 0.07 to 0.39mmBrass narrow strip in coil 6.36 to 630.00mm 0.075 to 3.00mmBrass wide strip in coil 361.00 to 620.00mm 0.40 to 3.00mmBrass wide strip cut to length (length < 2000mm) 20.00 to 600.00mm 0.45 to 3.00mmBrass sheet (length < 2000mm) 300.00 to 610.00mm 3.18 to 8.00mmBrass Plate (length < 2000mm)(Black as rolled - unscalped) 600.00 Max 8.10 to 50.00mm

Brass Circles 50.80 to 600.00mm 0.50 to 2.65mm

Copper mould plate,cooling blocks &contact shoes

Hot rolled, forged, ultrasonically tested, inter annealed, cold rolled, black, unsculped, unpickled

Width: 80.00 to 695.00 mm, and widerThickness: 30.00 to 150.00 mmLength: Please request.

Rolled Copper And Brass

ROLLED PRODUCTS

Freedom Park, Pretoria


FORGINGS

INGOTS HANGER BAR

Leaded machining brass for casting purposes.

Advantages of forging:

Forgings of copper and brass offer a number of outstanding advantages over parts produced by other manufacturing pro-cesses. These advantages result from the inherent properties of copper and copper alloys plus additional improvements in mechanical and physical properties imparted by the forging process. Our design team will work with you to explain the entire process, with all the advantages in cost and time clearly explained.

• High electrical and thermal conductivity• Superior corrosion resistance• Outstanding machinability• Excellent joining and plating characteristics• Superior polishing and finishing characteristics• Non-magnetic properties• Non-sparking characteristics• Attractive solid colours

Hanger bar for the electrowinning plants


Lightning & Earthing Protection Services

EARTHING PRODUCTS

Welcome to Earthcor, the earthing and lightning protection division of Copalcor (Pty) Ltd.

General Earthing Rage

12

1. 3 Pointed brass finial mounted on rod and flat parapit mounting bracket

2. Aluminium conductor3. Push in clips for mounting

8mm aluminium conductor4. Test clamp5. Inspection box6. Buried earth conductor7. Crows foot earth

installation consisting of 3 earth rods

8. Earth rods9. Lattice copper earth mat10. Solid earth plate11. Universal clamp used for

multiple earth connections12. Brass earth rod clamp

Lightning & Earthing Protection ServicesAs a manufacturer of electrical earthing and lightning protection equipment we also offer a complete

design and installation service that will cover SANS Code or Practice 10313 and 62305

• PLEASE NOTE: Aluminium conductors and down conductors to be installed above ground level only.

Square Tape Clamp (Junction Clamp)

“C” Crimpits/CrimpetsJB Clamp for Earth Matsin Copper or Brass

Conductive Concrete

• Earth Rods• Couplings & Drill Tips• PVC Insulated & Bare Copper Earth Wire• Earth Rod Clamps• Exothermic Welding• Fence Earthtail Clamp• Transformer Type Connectors• Conductive Concrete• Earth Bar Termination Assembly

• Cable Crimping Lugs• Fasteners & Nail-in Anchors• Copper Rod• Copper Tapes & Busbars• Copper Tape Clips• Flexible Plain & Tinned Copper Braid• “C” Crimpits• Line Taps• Earth Plate &

Lattice Earth Mats• Lightning Protection• Electrical Earth Inspection Box• Sacrificial Earth Anodes• Special Tapes & Putties• Static Earthing Solutions• Test Connectors• ... Custom Solutions


EXOTHERMIC WELDING

Safety Equipment• Apron• Glasses • Gloves

• Chain Clamp

• Steel disc

• SC45° Connection

• Handle clamp

1. Mould cover2. Starting powder3. Weldmetal powder 4. Steel disk5. Tap hole6. Weld Chamber7. Cable (conductor)

The EARTHCOR exothermic welding process - simple & effective

exothermic welding makes strong and low resistant electrical connections of various metals like; copper to copper, copper to steel and steel to steel. Without an external heat or power source.

The weld metal powder, consisting of powdered aluminium and copper oxide. The powder is poured into a graphite mould (as shown right) fol-lowed by the ignition powder. Nothing more than a spark is required to ignite the powder.

The heat from the resultant exothermic reaction produces moulten cop-per and aluminium oxide slag.

In a matter of seconds the molten copper melts the metal disc and flows down the tap hole and over the conductors in the weld chamber, melting them and welding them into a solid mass.

Benefits

• A greater current capacity than the conductors• Lower electrical resistance than a mechanical joint• Will not corrode - lasting indefinitely• Lends itself to field work since it requires no external heat source• Time saving (entire process takes only a few seconds)• No special skills required, only minimal training• Superior to all known mechanical or pressure connectors

General tool kit • Mould scrapers• Flint igniters • Spare flints• Conductor cleaning

brush• Mould cleaning brush

• Weldmetal powder

• Mould


EXOTHERMIC WELDING

• SCC

• CER 900

• SC 450 • SCH • SCHT • SCV • SSTV

• SBBV• CBH

• TBBV

• CKP • TCHRV • TCHRH • TCHRV • CPRP

• TBBH

• XBBH• TBCH • SBBH

• SSTH

• CERH • CBER 900

• TCC • XCC • HCC • VCC

Cable to Cable / Rod to Rod

Cable or Rod to Earth Rod

Cable or Rod to Steel, Vertical or Horizontal

Copper Bar to Cable or Rod Connection

Re-Bar Connections

Flat Copper Bar to Earth Rod

Studs to Steel, Vertical or Horizontal

Copper Bar to Bar Connections

• CBERH


• Copalcor product installed for dental practitioner in February 2013

ANTIMICROBIAL PRODUCTS

Copalcor has embraced the Antimicrobial properties of copper and now offers custom-made products for use in those sectors that require them the most.

In 2008 the U.S. Environmental Protection Agency (EPA) registered 275 copper alloys as antimicrobial materials, meaning that when uncoated, these alloys kill more than 99.9% of disease-causing bacteria*, including MRSA.

Consider Antimicrobial copper from Copalcor for use in hospitals, public, commercial and residential buildings forapproved non-food contact surfaces.

All reference material obtained from “The Copper Advantage - A Guide to Working With Copper and Copper Alloys”

www.antimicrobialcopper.com


COPALCOR TRADING (NATIONWIDE)

Products

All copper-based ingots(Bronze, brass etc.)

Cut plateCopper, brass, aluminium

Aluminium rods &profiles Earthing productsEarth rod/spike, earth mat, accessories

Aluminium plates Industrial copper tubing

Brass extrusionsRod, hexagon, square, octagon, flat, hollow bar, sections

Machined bushes(Flange bushes etc.)

Brass forgings Oilite(Oilite bronze)Solid and hollow bar

Brass tubing Rolled copper & brassSheets, strip, foil, roofing copper, cut plate, shimstock

Bronze(Continuous cast)General purpose bronze, Pb1

Special steelsBMS,EN8,EN19T,EN24 and EN36B

Bronze, brass & copper castings(Of any dimensions)

Stainless steel bars304 and 316 round bar

Continuous cast iron bar(BS 1452 Grade 17)Square and rectangular, also available: SG and ductile

ZincIngot; rolled zinc anodes, marine anodes, kirksite,AZIM 5, AZIM 3, sheets

Copper extrusionsRod, hexagon, square, flat (busbar)

Zinc Marine Anode

Copalcor Trading - Cape TownTel: +27(0)21 982 1155/6Fax: +27(0)21 982 115823 Wessel Geldenhuys Street Brackenfell, Industria

Copalcor Trading - DurbanTel: +27(0)31 482 2300Fax: +27(0)31 467 2671212 Bluff Road, Jacobs

Copalcor Trading - PretoriaTel: +27(0)12 379 6043Fax: +27(0)12 379 5259Unit F 5 & 6 Old Mutual Industrial Park, MootStreet, Hermanstad

Copalcor Trading - Port ElizabethTel: +27(0)41 451 2355Fax: +27(0)41 451 297730 Sidwell Road, Sidwell

Contact Us


Copper Rolled Alloys & Equivalent SpecificationsCopalcor

AlloyDescription

German(DIN)

American(ASTM / UNS

Japanese(JIS)

International (ISO)

European BS EN

Q004Electrolitic Touch Pitch -

Electrical Applications and Busbar, Furnace Cooling Blocks and Contact Shoes

E - Cu C11000 C1100 Cu ETP CW004

Q005Phosphorus Deoxidized DHP -

Ornamental, Cladding, Building, Hot Water Geysers

SF - Cu C12200 C1220 Cu DHP CW024

Q008 Phosphorus Deoxidized DLP - Furnace Cooling Blocks SW - Cu C1200 C1201 Cu DLP CW023

Q010 Copper Zinc Phos 99,0% Cu - Radiator Foil and Heat Exchangers

Q020 Copper Zinc Phos 99,0% Cu - Mould Plate

Brass Rolled Alloys & Equivalent SpecificationsCopalcor

AlloyDescription

German(DIN)

American(ASTM / UNS

Japanese(JIS)

International (ISO)

European BS EN

Q312 Gilding Metal (90/10) CuZn10 C22000 C2200 CuZn10 CW501

Q319 Rolled Brass Strip and Foil (Cartridge Brass) CuZn30 C26000 C26000 CuZn30 CW505

USEFUL DATA

Copper Flat Bar Conductor RatingsConductor

W x TCross

sectionkA for1 sec

kA for3 sec

ConductorW x T

Cross section

kA for1 sec

kA for3 sec

12.5 x 3 37.5mm2 6.6 3.8 38 x 5 190mm2 33.4 19.320 x 1.5 30mm2 5.3 3.0 38 x 6 228mm2 40.1 23.220 x 3 60mm2 10.6 6.1 40 x 3 120mm2 21.1 12.2

25 x 1.5 37.5mm2 6.6 3.8 40 x 6 240mm2 42.2 24.425 x 3 75mm2 13.2 7.6 50 x 3 150mm2 26.4 15.225 x 6 150mm2 26.4 15.2 50 x 4 200mm2 35.2 20.330 x 3 90mm2 15.8 9.1 50 x 5 250mm2 44.0 25.430 x 5 150mm2 26.4 15.2 50 x 6 300mm2 52.8 30.538 x 3 114mm2 20.1 11.6 50 x 6.3 315mm2 55.4 32.0


Brass Extrusion Alloys & Equivalent SpecificationsCopalcor

Alloy Description German(DIN)

American(ASTM / UNS

Japanese(JIS)

International (ISO)

European BS EN

Q101 High Speed Machining Brass CuZn39Pb3 C38500 C3606 CuZn39Pb3 CW601

Q103 USA High Speed Machining Brass CuZn36Pb3 C36000 C3601 CuZn36Pb3 CW603

Q202 Machining Brass for Sections C38000 CuZn43Pb2 CW623

Q207 Ductile Machining Brass CuZn-36Pb1.5 C35000 CuZn37Pb2 CW606

Q210/213 Machining Brass - Dezincification Resistant C35330 CW602

Q218 European Hot Stamping Brass CuZn40Pb2 C37710 C3603 CuZn40Pb2 CW617

Q303 Cold Headed Brass CuZn37 C27400 C2700 CuZn37 CW508

Q501 (Low Mn)

High Tensile Brass (Low Manganese) C67600

Q508 (Med Mn)

High Tensile Brass (Medium Manganese) C68600 CuZn39Al-

FeMnQ514

(High Mn)High Tensile Brass (High Manganese) CuZn40Al2 C67410

Q804 Low Fuming Bronze L-CuZn39Sn C68100

USEFUL DATA

Mass Calculation Formulae

Profile Shape Aluminium Brass Bronze Copper Steel Stainless

Density 2.70 g/cm3 8.48 g/cm3 8.58 g/cm3 8.93 g/cm3 7.80 g/cm3 7.80 g/cm3

Round Bar (Diameter)2 in

mm x 0.002132 = mass in kg/m

(Diameter)2 in mm x 0.006675 =

mass in kg/m


mass in kg/m


mass in kg/m


mass in kg/m


mass in kg/m

Square Bar

(Width across flats)2 in mm x

0.002712 = mass in kg/m


0.00848 = mass in kg/m









Rectangular Bar

(Width x Thick-ness) in mm x

0.002712 = mass in kg/m











Hexagon Rod




0.007344 = mass in kg/m


0.007638 = mass in kg/m






0.006963 = mass in kg/m

Round Tube

Wall Thickness x (Outer Diameter

minus Wall Thickness)

in mm x 0.0085 = mass in kg/m








minus Wall Thickness) in mm x 0.028 =

mass in kg/m







Irregular Shapes

Cross-sectional area in mm2 x

0.002712 = mass in kg/m












NOTES


Copalcor Trading - Cape TownTel: +27(0)21 982 1155/6Fax: +27(0)21 982 115823 Wessel Geldenhuys Street Brackenfell, Industria

Copalcor Trading - DurbanTel: +27(0)31 482 2300Fax: +27(0)31 467 2671212 Bluff Road, Jacobs

Copalcor Trading - PretoriaTel: +27(0)12 379 6043Fax: +27(0)12 379 5259Unit F 5 & 6 Old Mutual Industrial Park, MootStreet, Hermanstad

Copalcor Trading - Port ElizabethTel: +27(0)41 451 2355Fax: +27(0)41 451 297730 Sidwell Road, Sidwell

Tel: +27(0)11 821 0700 Fax: +27(0)11 827 8750E-mail: [email protected]: www.copalcor.co.za

42 Rendell RoadWadeville, Germiston1407South Africa

Private Bag X030Wadeville, Germiston1422South Africa

Documents

South Africa’s largest manufacturer of copper, brass ... · PDF fileSouth Africa’s largest manufacturer of copper, brass & alloy solutions copalcor group catalogue Jan 2013 Metallurgical