How to Lift Vertical Concrete Cylinders Safely and Precisely

[MikePhua]

The Challenge of Vertical Pipe Placement
Installing large concrete cylinders vertically into confined spaces—such as manhole shafts or sewer trenches—poses a unique lifting challenge. Unlike horizontal pipe placement, vertical orientation demands precise control, minimal tilt, and secure gripping mechanisms. The difficulty increases when the pipe must be lowered directly onto a concrete base without clearance for slings or bottom supports. In many cases, the pipes weigh over a ton and lack lifting eyes, brackets, or internal holes, making conventional rigging methods unsuitable.
This scenario is common in utility infrastructure projects where reinforced concrete pipes are used as vertical shafts. The lack of internal access and the need for water-tight seals further restrict lifting options, especially when vacuum testing is required post-installation.
Terminology and Lifting Concepts
- Manhole Shafting: Vertical concrete pipe sections used to form access points in sewer or drainage systems.
- Spreader Bar: A horizontal lifting beam that distributes load evenly across multiple lifting points, reducing stress and tilt.
- Internal Lifting Clamp: A mechanical device inserted into the pipe’s interior that expands to grip the walls from within, allowing vertical lifting without external contact.
- Swift Lift Anchors: Embedded lifting points cast into concrete during manufacturing, designed to accept specialized lifting dogs or pins.
- Pick Holes: Pre-drilled holes in concrete pipe walls used for inserting lifting pins or bolts.
Solutions for Lifting Without External Slings
When slings are not viable due to space constraints or the need to maintain vertical orientation, several alternative methods can be employed:
- Use of internal lifting clamps designed for manhole shafting. These clamps expand inside the pipe and grip the inner wall, allowing for vertical lift with minimal tilt. Hydraulic pad spreaders are often used for larger diameters exceeding 1200 mm.
- Installation of lifting eyes or threaded inserts during manufacturing. These can accept bolts or lifting dogs and are sealed post-installation to maintain water-tight integrity.
- Drilling temporary holes near the top rim and inserting rebar or lifting pins. Though time-consuming, this method allows for custom rigging and can be patched afterward.
- Custom spreader bars with chain wraps. A steel bar is placed across the top of the pipe, with chains wrapped around the exterior and hooked to each other. A central D-ring on the bar serves as the lift point. This method is commonly used for septic tanks and concrete inlets.
Safety Considerations and Load Dynamics
Lifting heavy concrete vertically requires careful attention to load balance, sling tension, and ground personnel safety. The heavier the object, the tighter the sling or clamp will grip—assuming proper application. Nylon straps are preferred over wire rope or chain due to their flexibility and reduced risk of surface damage.
Operators must ensure:
- Straps or clamps are rated above the pipe’s weight
- No lateral movement occurs during lift
- Ground crew maintains safe distance during lowering
- Backhoe or loader used for lifting has sufficient hydraulic capacity and boom reach
In one case, a backhoe loader was used to maneuver 40-inch diameter concrete shafts nearly 6 feet long. The operator opted for a custom spreader mechanism fabricated by an engineer, as the pipes lacked any embedded lifting hardware. The spreader was designed to grip the top rim internally and distribute force evenly, allowing for safe lowering onto the concrete base.
Field Anecdotes and Practical Adaptations
In regions where manufacturers do not embed lifting anchors, contractors often fabricate their own lifting devices. One crew in Indiana used a steel bar with dual chains wrapped around the pipe, secured with slip hooks. The system was simple but effective, allowing for controlled vertical placement without damaging the pipe.
In Western Australia, well liners are commonly lifted using Swift Lift anchors or D-rings cast into the concrete. If these are absent, operators drill holes and insert rebar for temporary lifting points. Larger contractors use hydraulic spreaders rented from concrete suppliers, though setup on smaller machines like backhoes can be complex.
Recommendations for Future Projects
To streamline vertical pipe installation:
- Request embedded lifting anchors during manufacturing
- Invest in adjustable internal clamps for varying diameters
- Use spreader bars with certified lifting chains and central lift points
- Train operators on vertical load dynamics and sling behavior
- Coordinate with suppliers to borrow lifting gear when possible
Vacuum testing requirements are becoming more stringent, especially in urban sewer systems. Any lifting method must preserve the integrity of the pipe and avoid introducing holes or cracks that could compromise water-tightness. Threaded plugs and bolt-in lifting points are increasingly favored over traditional pick holes.
Conclusion
Vertical lifting of concrete cylinders demands a blend of mechanical ingenuity, safety awareness, and site-specific adaptation. Whether using internal clamps, custom spreaders, or embedded anchors, the goal remains the same: precise, secure placement with minimal risk. As infrastructure standards evolve, so too must the tools and techniques used to handle these massive components. With the right approach, even the most awkward pipe can be set down smoothly—standing tall and sealed tight.