Heavy Lifting News
Case Studies on Innovative Problem Solving
Massive Pipe Rack, Multiple Challenges
Inside the First 8-Leg JS250 Lift in the USA
02/06/2026
By Greg Bogdanski
Sales Representative
When a contractor needed to lift a massive pipe rack during construction of a manufacturing plant in North Carolina, Engineered Rigging’s team understood this project would not be a standard rigging job. The lift would require us to push the limits of synchronized lifting technology—and ultimately make history in the process.
The Challenge:
Limited Headroom, Massive Load
This project presented several unique challenges. First, the sheer size of the load required special consideration. The pipe rack weighed 245,000 pounds, was 110 feet long and nearly 18 feet wide. It needed lifted 22 feet into the air while being absolutely level to avoid deflection during the lift. The alignment of 56 bolt holes in the pipe rack with matching holes in the structure would require a precise vertical lift without any horizontal movement. The pipe rack had only a half inch of clearance to the building structure (see adjacent photo). Consequently, there was no room for an overhead crane or hydraulic gantry. An innovative rigging alternative was needed to safely lift and hold the load while it was bolted into place.
Engineering the Solution
The Enerpac JS250 jack-up system was the clear choice for this application, but the scale was unprecedented. Typically, a jack-up system utilizes two or four units to support a heavy load (see the Waccamaw River Bridge case study for an example). To lift the massive pipe rack, eight legs were required, a configuration that had never been deployed in the United States.
Each of the legs would be loaded with eight adjustable top barrels to achieve the required elevation of 22 feet. The computer controls, which included a smart box and a laptop, would deliver precise synchronization of the eight legs and provide Center of Gravity calculations in real time to ensure the pipe rack remained level and stable throughout the lift. The control system’s load and stroke alarms and emergency stop switches would optimize safety.
Precise Execution
The project unfolded over approximately one week, with each phase carefully orchestrated in a safe and controlled manner by following the carefully engineered lift plan. An Engineered Rigging technician was on-site to provide technical support throughout the process from initial setup until equipment teardown.
“Having expert onsite technical support provides our customers with peace of mind. It allows us to optimize equipment performance and safety while also troubleshooting any challenges in real-time,” explained Mike Beres, Vice President of Engineered Rigging.
Setup
The pipe rack was rolled into position using hydraulic platform trailers and staged on steel load stools. Meanwhile, eight JS250 units were placed at predetermined locations per the lift plan. Ten barrels were positioned near each unit to streamline the barrel loading process.
Initial Lift
Hydraulic cylinders integrated inside of the top barrels of the JS250 units were connected to split-flow pumps to lift the pipe rack off the temporary load stools. The cylinders were then secured with a locking collar to ensure level, synchronized lifting throughout the operation. These adjustable top barrel cylinders helped account for any floor variation or elevation change prior to lifting.
Barrel Loading and Ascent
With all data cables and power connected to the control system, the lifting sequence was initiated. Using a forklift, the crew manually loaded each barrel into the insertion tray of each JS250 unit. Next, a technician managed the incremental lifting sequence using the smart box control system. The process was repeated until all ten barrels were loaded into each unit and the pipe rack reached its final 22-foot elevation.
As expected with precision work of this scale, minor adjustments on individual legs were necessary to facilitate the alignment of the bolt holes. The JS250 system’s smart control box made it easy to manage the fine-tuning.
Holding the Load
Once the pipe rack was lifted to the required height, the JS250 lifting system securely held it in position while crew members inserted 56 bolts into the aligned holes. Once the pipe rack was secured, the crew quickly demobilized the jacking system using the automatic lowering cycle. The equipment was removed from the site so that construction of the plant could continue on schedule.
Setting a New Standard
By deploying eight JS250 legs simultaneously, this project represents a milestone in synchronized lifting capability in the U.S.A. Engineered Rigging demonstrated that even the most challenging lifting scenario, one with limited headroom and a heavy load of extreme length, can be managed safely and efficiently with the right equipment and expertise.
