07 Dec How a Major Steel Manufacturer Eliminated Injuries & Reduced Costs by Switching to Cordstrap Lashing
How a Major Steel Manufacturer Eliminated Injuries & Reduced Costs by Switching to Cordstrap Lashing
A DunLash take on a Case Study for Safer, Stronger, and More Efficient Cargo Securing for Steel Coils
For over 15 years, one of the world’s leading steel manufacturers relied on steel banding to secure heavy steel coils inside ship holds. It was the traditional method — sharp, rigid, labour-intensive — and for many years, it went unquestioned.
But the company faced growing challenges:
- Employees and contractors were sustaining injuries from sharp edges and recoil.
- Time spent securing each load was high.
- Costs were rising.
- Productivity suffered.
- Customer satisfaction was being impacted.
Their goal was clear: find a safer, stronger, and more efficient alternative.
What they discovered would reshape their entire approach to cargo securing: a shift to Cordstrap engineered lashing, delivered and supported by the certified regional distributor — DunLash.
This blog explores how Cordstrap transformed their steel-securing process, reduced costs, eliminated injuries, and modernised an outdated method — with verified results.
The Challenge: Outdated Steel Banding Was Causing Hurt and Harming Productivity
Steel coils are among the most difficult cargo types to secure safely.
They’re extremely heavy, highly dynamic, and unforgiving if they shift even slightly during transport.
According to the original case study document:
“Steel banding had been used for 15 years… However, this method was causing injuries to employees and contractors. They wanted a safer solution… and to reduce costs and increase productivity.”
The main issues they faced:
- Sharp steel edges were causing cuts, injuries, and PPE damage.
- Recoil from steel banding created a serious safety risk.
- High physical effort required to tension steel straps increased fatigue and slowed operations.
- Inconsistent securing quality led to load failures and customer complaints.
- Labour time was significantly longer than necessary.
- Cost per shipment continued to climb.
It became clear that steel banding — the industry’s “default” method — was no longer suitable for modern shipping environments.
The Approach: Demonstration, Training & Breaking Old Habits
Cordstrap’s technical specialists worked directly with the steel manufacturer’s teams to prove that high-tenacity polyester lashing — composite and woven — could outperform steel.
From the case study:
“The team worked collaboratively to break down barriers to change… and demonstrate that Cordstrap lashing was a real alternative to steel.”
Key steps included:
- Hands-on demonstrations of Cordstrap lashing solutions.
- Education sessions explaining the dangers of steel banding and the safety advantages of polyester systems.
- Training operators to apply Cordstrap consistently and efficiently.
- Building trust through testing, certification, and repeatable results.
What made this approach successful was changing behaviour — helping teams replace 15 years of muscle memory and routine with a safer, more advanced method.
This change-management element reflects what DunLash also provides to South African industries:
- Cargo Lashing Equipment Africa
- Steel & Metal Industry Securing Solutions
- Cordstrap Distributor South Africa
The Solution: Cordstrap Lashing + Dynablock for Heavy Steel Cargo
Cordstrap introduced a system designed specifically for heavy, dynamic steel loads:
✔ Cordstrap Composite Lashing (“Synthetic Steel”)
Made from high-tenacity polyester yarns, composite lashing delivers extreme strength with exceptional shock absorption — outperforming traditional steel in dynamic environments.
✔ Dynablock® Dynamic Load Buckle
The most advanced buckle in the polyester lashing industry, engineered to maintain tension on loads prone to shifting.
From the case study:
“Dynablock – designed for heavy duty dynamic loads… the highest degree of strength and security available in the polyester lashing industry.”
✔ Individually GL-Certified Systems
Every Cordstrap lashing + buckle combination is individually tested and certified by Germanischer Lloyd — a globally trusted cargo inspection authority.
This certification is the same standard used in DunLash’s South African applications for securing:
- Steel coils
- Machinery & heavy equipment
- Timber bundles
- Mining cargo
- Industrial freight
- Automotive components
The Results: Immediate, Measurable Improvements
According to the case study document:
25% Reduction in Cost per Shipment
Lower material usage + faster application + fewer failures = measurable savings.
10% Increase in Productivity
Cordstrap lashing is quicker and easier to apply than steel banding, reducing labour time.
100% Elimination of Injuries
No sharp edges.
No recoil.
No steel-related hazards.
The switch dramatically improved on-site safety.
Improved Customer Relationships
With properly secured cargo, customers received steel coils in better condition, with no shifting or damage.
Reduced Wastage
Longer-lasting lashing materials + fewer damaged coils.
This transformation illustrates the true value of modern cargo securing:
Safety + Efficiency + Compliance + Cost Reduction.
Why This Story Matters for South African Industries
Steel manufacturers in South Africa — especially in KZN, Gauteng, Eastern Cape, and the Western Cape — face the same challenges as the company in this case study:
- Heavy coil handling
- High-risk securing environments
- Long-distance freight
- Port operations (Durban, Richards Bay, PE, Ngqura)
- Corrosion from coastal moisture
- Labour safety concerns
DunLash is already working with steel mills, engineering companies, mining suppliers, and logistics firms across South Africa to modernise their securing systems using Cordstrap.
Cargo Lashing Equipment Durban / KZN / Eastern Cape / etc.
Why Cordstrap Outperforms Traditional Steel Banding
Based on both the case study and DunLash’s broader expertise:
1. Greater Safety
No sharp edges.
No whipping recoil.
No rust.
No broken tools.
2. Higher Strength-to-Weight Ratio
Composite lashing retains tension better under vibration.
3. Faster Application
Battery tensioners + lightweight lashing = faster workflows.
4. Lower Total Cost of Ownership
Fewer injuries + faster securing + less wastage.
5. Maintains Tension During Movement
Critical for steel, mining cargo, and machinery.
6. GL-Certified
A requirement for global maritime and container inspections.
What This Means for South African Exporters and Logistics Companies
Whether you’re securing:
- Steel coils
- Metal sheets
- Fabricated steel
- Mining equipment
- Industrial machinery
- Construction materials
- Automotive components
Cordstrap systems provide unmatched benefits.
DunLash’s engineering support ensures:
- Correct product selection
- Correct application methods
- Correct tensioning
- Correct compliance
This combination is why companies across South Africa, Namibia, Zambia, Botswana, and Mozambique rely on DunLash for safe cargo movement.
Key Learning for Industry (From the PDF)
According to the case study:
“Working closely with partners to ensure new applications and solutions are fully trained ensures adoption and trust.”
This reflects DunLash’s own philosophy:
Training + Demonstration + Engineering Support = Successful Adoption
No product can transform a business unless people understand how to use it. DunLash ensures:
- Teams are trained
- Supervisors are confident
- Operators are supported
- Compliance is maintained
Conclusion: Steel Securing Has Evolved — And DunLash Leads the Way in Africa
The shift from dangerous steel banding to Cordstrap engineered lashing is not merely a change in materials — it is a transformation in safety, efficiency, and global compliance.
The results speak for themselves:
- 100% injury reduction
- 25% cost savings per shipment
- 10% productivity improvement
- Better customer satisfaction
- Less wastage
- Stronger compliance with global standards
If your company is still using steel banding, rope, chains, or outdated methods, this case study proves it’s time to modernize — and DunLash is here to guide the transition.
