Projects and Case Studies
Projects and Case Studies
Real projects from Toco Lifting
When the job needs more than a catalogue product, Toco designs, manufactures and tests the solution. These are real projects across mining, construction, agriculture and testing, each one supplied, engineered and certified in house, across South Africa and SADC.
Toco Lifting designs, manufactures and tests custom lifting, rigging and lashing solutions for mining, construction, agriculture and marine work across South Africa and SADC, and certifies them in its own SANAS backed testing facility.
Toco has supplied lifting, lashing and rigging equipment since 2002 and is a registered Lifting Machinery Entity, LME No. 008. Where a standard product does not exist, Toco engineers one: from a run of 156 purpose-built rigging screws for a mining reinforcement job, to a 65.2 metre suspension bridge fabricated in the factory and shipped in numbered pieces for assembly on site. Every project below is a real job, with the equipment supplied and the compliance outcome stated. Client names are withheld by policy.
Mining
Custom mining rigging for rock reinforcement
A mining client in Africa needed a rock support and reinforcement rigging set across eight mining tips. The rigging screws the application called for were not commercially available at the size and rating required, so an off the shelf solution was not an option.
Toco designed and manufactured 156 custom rigging screws for the job, supplied with 20mm alloy chain, 20mm connecting links and 38mm high-tension turnbuckles rated to a safe working load of 100 tonnes. All equipment was designed to meet the requirements of DMR 18(10)(a) and DMR 18(10)(c).
Outcome. A complete, purpose-built reinforcement rigging set delivered for all eight tips, engineered and manufactured in-house where no commercial product existed.
| Equipment supplied | |
|---|---|
| Alloy chain | 20mm |
| Connecting links | 20mm |
| Turnbuckles | 38mm high-tension, SWL 100 tonnes |
| Rigging screws | 156, custom manufactured |
| Application | Rock reinforcement, 8 mining tips |
| Compliance | DMR 18(10)(a) and (10)(c) |
Construction and infrastructure, SADC
A 65.2 metre suspension bridge for Eswatini
A project sponsored by the King of Eswatini set out to give schoolchildren a safe river crossing on their route to school. It called for a 65.2 metre suspension bridge, fabricated to specification and delivered ready to assemble on a remote site.
Toco Lifting manufactured the 65.2 metre suspension bridge using steel cable and dropper cables, fabricated in-house at Toco’s factory. The bridge was built and trial assembled in the factory first, then shipped in labelled, numbered pieces so it could be reassembled cleanly on site. Toco’s technical team carried the quality assurance through fabrication and delivery, working alongside a civil contractor for transport and on-site implementation.
Outcome. The bridge was completed and unveiled, giving children a safe crossing to school. The label and number method for structural fabrication, design through manufacture, shipping and site support, is a repeatable Toco capability for complex projects.
| From the general arrangement drawing | |
|---|---|
| Main span | 65.2 metres, pillar to pillar |
| Backstays | 23.7 m and 23.1 m |
| Handrail cable | 13.5 mm diameter |
| Structure | New main cable, varying-height suspenders |
| Pillar steel | 60 x 60 x 5 mm angle, 5.2 m lengths |
Numbered-piece method
Assembled in factory, shipped labelled, reassembled on site.
Testing and certification
Destruction test of a 20mm steel wire rope
A certificate is only as good as the facility behind it. Toco runs its own fully stocked testing and repair facility, carrying out inspection, testing, repair and certification to the applicable regulations, standards and engineering practice.
In one destruction test, a 20mm steel wire rope was pulled to failure. The minimum required breaking load was 25 tonnes. The rope broke at 30 tonnes, meeting the requirements of SANS 7531. The test was run on SANAS accredited load cells on Toco’s 200 tonne hydraulic proof loading bed.
Outcome. In-house proof and destruction testing, backed by SANAS accredited load cells, so Toco verifies and certifies what it supplies rather than relying on a supplier claim.
| Testing facility | |
|---|---|
| Load cells | SANAS accredited, calibrated to 100 tonnes |
| Proof bench | 200 tonne hydraulic, Germiston |
| SWR slings tested | Up to 8 metres |
| Example result | 20mm SWR, 25t minimum, broke at 30t, SANS 7531 |
See Testing and Certification for Toco’s full inspection and certification service.
Custom fabrication
Steel wire rope grommet grid, a custom build
A customer needed a grid structure that no standard product covered, built from individually rated components that could be linked into a larger net.
Toco manufactured steel wire rope grommets fitted with carabiner hooks rated to a safe working load of 500kg per hook, then linked the individual grommets to form a net or grid structure. The grommets are available in galvanised or stainless steel, with custom diameters produced by splice.
Outcome. A made-to-order grid built from certified components, for barricades, fishing and sorting sieves, agricultural sorting nets and decorative structures, where no catalogue product fit.
| Build detail | |
|---|---|
| Component | SWR grommets with carabiner hooks |
| Rating | SWL 500kg per hook |
| Material | Galvanised or stainless steel |
| Sizing | Custom diameters by splice |
Related product: Cable Laid Grommet.
Agriculture
Pivot irrigation gearbox lifting clamp
Removing and refitting a centre pivot irrigation gearbox safely needs a lifting clamp matched to the gearbox shaft, not a general purpose sling looped around it.
Toco supplies a purpose-designed pivot irrigation gearbox lifting clamp, proof loaded to 200kg with a safe working load of 70kg, sized to fit a 58mm shaft, with wing nut fastening for quick setup and release. It is supplied with a load test certificate.
Outcome. A safe, quick and repeatable way to lift pivot gearboxes for irrigation maintenance, certified and ready to use.
| Specification | |
|---|---|
| Proof load | 200kg |
| Safe working load | 70kg |
| Fits shaft | 58mm |
| Fastening | Wing nuts, quick setup and release |
| Supplied with | Load test certificate |
Transport and export
Engineered here, shipped across borders
A client needed to lift and move a 13.5 tonne drilling machine, and to get the lifting solution to a site in West Africa.
Toco’s Cape Town team engineered a 20 tonne lifting beam paired with adjustable chain slings, sized to hoist the machine safely and evenly. The complete custom application was packed and shipped to Guinea, ready to use on arrival.
Outcome. A purpose-built below-the-hook lifting solution, engineered in Cape Town and exported to Guinea, delivered ready to lift.
| Project detail | |
|---|---|
| Load | 13.5 tonne drilling machine |
| Solution | 20 tonne lifting beam, adjustable chain slings |
| Branch | Cape Town |
| Destination | Guinea, West Africa |
Export reach and project highlights
Sectors
Sectors Toco Lifting supplies
Mining and reinforcement
Custom rigging, chain, turnbuckles and reinforcement sets for mining operations.
Construction and infrastructure
Structural fabrication and rigging, from bridges to site lifting tackle.
Agriculture
Purpose-built clamps and rigging for irrigation and farm equipment maintenance.
Marine and fishery
Steel wire rope, grommets and grid structures for harbour and fishery use.
Transport and lashing
Lashing and securement equipment for heavy haulage and cargo.
Heavy engineering
In-house testing, certification and custom manufacture for engineering projects.
Questions
Frequently asked questions
Does Toco Lifting manufacture custom lifting and rigging equipment?
Toco Lifting designs and manufactures custom lifting, rigging and lashing equipment when a standard product does not exist. Recent examples include 156 purpose-built rigging screws for a mining rock reinforcement job and a 65.2 metre suspension bridge fabricated in-house from steel cable.
Can Toco Lifting fabricate large structural steelwork?
Toco Lifting fabricates large structural steelwork in-house, including a 65.2 metre suspension bridge built and assembled at its factory, then shipped in labelled, numbered pieces for reassembly on site. This design through manufacture and site support approach suits complex structural projects.
Does Toco Lifting load test and certify to South African standards?
Toco Lifting is a registered Lifting Machinery Entity, LME No. 008, and runs an in-house testing facility with SANAS accredited load cells and a 200 tonne proof loading bed. Equipment is inspected, tested and certified to the OHS Act, DMR 18 and the applicable SANS standards.
What is Toco Lifting’s in-house testing capacity?
Toco Lifting runs an in-house 200 tonne proof bench at Germiston with load cells SANAS calibrated to 100 tonnes, and tests steel wire rope slings up to 8 metres. In one destruction test a 20mm steel wire rope broke at 30 tonnes against a 25 tonne minimum, meeting SANS 7531.
Which sectors does Toco Lifting supply?
Toco Lifting supplies mining, construction and infrastructure, agriculture, marine and fishery, transport and heavy engineering across South Africa and SADC, from its branches in Germiston and Cape Town.
Are Toco Lifting projects compliant with DMR 18?
Toco Lifting engineers regulated lifting and rigging equipment to the Driven Machinery Regulations. The custom mining rigging set, for example, was designed to meet DMR 18(10)(a) and DMR 18(10)(c). Certification is issued under Toco’s LME No. 008 registration where the equipment falls within that scope.
How often must lifting equipment be inspected and load tested in South Africa?
Toco Lifting inspects and load tests lifting equipment on the intervals set by the OHS Act and Driven Machinery Regulation 18: a visual examination every 3 months, a thorough examination every 6 months and a performance load test every 12 months. Chain blocks and lever hoists are tested to SANS 500 and certified under Toco’s LME No. 008 registration.
