Project Overview

In October 2024, Next Level  was appointed by Kopano Ke Matla Construction Joint Venture to execute the proof load testing of a 200-ton gantry crane at the Polihali Transfer Tunnel site — part of the Lesotho Highlands Water Project Phase II.

This critical test formed part of the commissioning process for the tunnel’s heavy-lifting and assembly infrastructure, ensuring that the gantry crane met operational and safety standards before full deployment.

Scope of Work

Our team mobilised to the Polihali site with calibrated load testing equipment and executed a complete verification of the crane’s lifting capacity and safety systems under controlled conditions.

Services Performed:

• Pre-test inspection and risk assessment
• Setup of certified water bag load system and digital load cell monitoring
• Incremental proof load application up to 200 tonnes
• Verification of brake holding, hoist function, and structural deflection
• Recording of test data and preparation of compliance documentation
• Issuance of final Load Test Certificate and client acceptance report

Technical Summary

• Crane Type: Double-girder electric gantry crane
• Rated Capacity: 200 tonnes
• Testing Equipment: Calibrated load cells and water weight bags
• Load Application Method: Incremental proof load with hold intervals for stability verification
• Compliance: SANS 10375, MHSA, and OEM specifications

Challenges & Achievements

The project site presented complex logistical and environmental conditions due to its high-altitude location and restricted access within the tunnel precinct.
Despite these challenges, Next Level IMS successfully completed the operation on schedule and without incident, demonstrating our capacity to deliver large-scale, high-risk load testing in demanding environments.

Key Achievements:

• 100% HSE compliance — no incidents or downtime
• Successful verification of lifting system integrity
• Seamless coordination with client engineers and OEM representatives
• Completion within client’s commissioning window

Outcome

The successful completion of the Polihali Dam gantry crane test reaffirmed the reliability of the tunnel’s lifting infrastructure and contributed to the safe commencement of excavation and support works under the Lesotho Highlands Water Project.

This project further demonstrated Next Level IMS’s expertise in heavy lifting verification, HSE management, and technical execution for major infrastructure projects across Southern Africa.