South Africa’s largest manufacturer of copper, …

1 South africa s largest manufacturer of copper , brass & alloy solutionscopalcor group catalogueJan 2013 Metallurgical Tes ng ServicesMESSAGE 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 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 are maintained throughout each process, from validation of raw material to the final semi-manufactured product.

2 This is achieved by adherence to ISO 9001 GrantManaging DirectorMetallurgical Tes ng ServicesCOPALCOR HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: GroupHead Office & WorksPhone:+27(0)11 821 Trading -PretoriaPhone:+27(0)12 379 Trading -Port ElizabethPhone:+27(0)41 451 Trading -DurbanPhone:+27(0)31 482 Trading -Cape TownPhone:+27(0)21 982 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: Website: HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: , Manufacture and ImplementationPROJECTSC opalcor offers clients a complete solution from design to manufacture, through to installation and the operations ofcasting, rolling and busbar fabrication are all fully integrated.

3 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 Insulation Slab CastingElectro PlatingSupervised Installation Hot Rolling Copalcor owns the total value chain COPALCOR HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: ExamplesPROJECTS6 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).

4 220 (120 tonnes) copper Cooling Blocks used in a Titanium Oxide Smelter (Richards Bay Minerals, 2003).Antimicrobial copper touch surface products for the medical Switch ConnectionCOPALCOR HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: 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 size range:Length (max) in excess of 10 000 mmThickness 6 mm up to 50 mmWidth 80 mm up to 615 mmMajor customers: Chemical corporations ( 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 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 services Copalcor offers the following on-site services.

5 Painting Electroplating Hot dip solder plating Aluminium busbarsProducts, Projects and Turnkey SolutionsBUSBARS teel Support StructuresCopper SlabInstallationSilver Plated and InsulatedBusbar Fabrication COPALCOR HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: - - thickness:> 3mmRoundOD: - thickness: > 5mmHexagonAF: - thickness: > 5mmOctagonAF: - thickness: > 5 - - thickness:> 3 - - thickness - - thickness:> 3mmBrass wire in coilsDiameter: - bar profiles available on request. All tolerances comply to BS EN standardsLarge HollowExtruded HollowExtruded SolidCustomised ExtrusionsEXTRUDED PRODUCTSC opalcor 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 limitations:Profile to fit in a radius of mmThickness of extrusion to be not less than 3,20 mmCOPALCOR HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: PRODUCTSR elated specifications - Low fuming bronze:ASTM/AWS R Cu Zn C BS 1453 C4 UNS C68100 SABS 392BS 1845 CZ7 DIN 1733 S-Cu Zn 39 Sn Wn and mechanical properties.

6 Tensile strength - 63,500 psi / 420 mpa Elongation - Brinell hardness - Melting point - 1625 F / 887 C Solidification - 1590 F / 868 CLengths: 450mm to 1000mmPacking and labelling:Tied in 10kg cardboard tubes marked copflo Packed in 500kg wooden RangeA (mm)Mass (kg/m)A (mm)Mass (kg/m) Non-standard sizes available on requestLow Fuming Bronze - Brazing Rod - C681 COPALCOR HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: PRODUCTSMass Calculation FormulaeCOPALCOR HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: RangeWidthThicknessCopper foil in to to strip in to to flat strip cut to length (length < 2000mm) to to sheet (length < 2000mm) to to to to to to to platingOptionalOptionalSize RangeWidthThicknessBrass foil in to to narrow strip in to to wide strip in to to wide strip cut to length (length < 2000mm) to to sheet (length < 2000mm) to to Plate (length < 2000mm)(Black as rolled - unscalped) to to to mould plate,cooling blocks &contact shoesHot rolled, forged, ultrasonically tested, inter annealed, cold rolled, black, unsculped, unpickledWidth: to mm, and widerThickness: to mmLength.

7 Please copper And BrassROLLED PRODUCTSF reedom Park, Pretoria COPALCOR HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: BARL eaded machining brass for casting 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 coloursHanger bar for the electrowinning plantsCOPALCOR HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: & Earthing Protection ServicesEARTHING PRODUCTSW elcome to Earthcor, the earthing and lightning protection division of Copalcor (Pty) Earthing Rage121.

8 3 Pointed brass finial mounted on rod and flat parapit mounting bracket2. 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 rods8. 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)

9 C Crimpits/CrimpetsJB Clamp for Earth Matsin copper or BrassConductive 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 SolutionsCOPALCOR HEAD OFFICE Telephone +27 (0)11 821 0700 Fax +27 (0)11 827 8750 Email: Website: WELDINGS afety Equipment Apron Glasses Gloves Chain Clamp Steel disc SC45 Connection Handle clamp1.

10 Mould cover2. Starting powder3. Weldmetal powder 4. Steel disk5. Tap hole6. Weld Chamber7. Cable (conductor)The EARTHCOR exothermic welding process - simple & effectiveexothermic 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 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 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 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)