The Journey Behind the Development of the Pile Lifting Device (PLD)

On busy piling sites, it’s all about bringing tubular foundation piles and sheet piles from horizontal to vertical position in the shortest time possible.

Traditionally, Contractors usually face two challenges: firstly, they have to rely on two cranes or a crane plus an auxiliary winch to maneuver the pile and the vibro vertically in tandem, two independent lifting lines that introduce misalignment risks, collisions, and delays.

A second challenge is certification. Vibro hammers are not certified for lifting purposes. Lifting through the vibro hammer forces contractors into a grey area unless all the components in the load path are fully certified, down to the smallest fastener. That certification burden complicates operations and can limit the scenarios in which contractors can work safely and efficiently.

Moreover, increasing pile dimensions, stricter global safety regulations and a shortage of skilled operators are restricting dynamics adding to the mix. Dieseko Group’s Pile Lifting Device tackles all these problems.

Operational envelope and requirements.

Existing upending systems (MU) and earlier PLD models (10 t and 20 t) left a capability gap: heavy pipes that were too large for the PLD10/20 yet too small in diameter-to-weight ratio for MU to grip reliably. Dieseko’s engineering team therefore targeted three outcomes: enable upending of pipes >20 t; handle small diameter/weight ratios; and guarantee that only certified lifting elements are in the load path. This led to the new PLD80T model, whose resulting baseline specifications were a maximum pipe diameter 2,400 mm, maximum pipe weight 80 t, and maximum vibro hammer weight 20 t.

Design constraints and variability. The device had to work across multiple vibro hammer geometries and suspension yoke widths. Dieseko solved this with a replaceable middle section (spacer) to absorb different adapter head widths while retaining a standard bolted interface using the existing leader guided pattern. This architecture decouples the certified lifting from the vibro’s diabolo and steelwork, simplifying certification because the vibratory hammer is no longer part of the lifting path.

Hydraulics and control. The PLD uses hydraulic cylinders to set and hold the vibro relative to the pile, keeping the PLD–to–pile chains deliberately slack once the clamps engage. This avoids transmitting vibration and unintended loads into the crane line while maintaining a certified load path through the PLD. The same power pack that drives the vibro and its clamps can actuate the PLD with minor component and control adjustments, no separate power unit is required.

Sequence of operations.

1. Attach shackles to the sheet pile’s lifting eyes with the sheet pile in horizontal position;
2. Upend to a vertical position with the crane via the PLD;
3. Position the (sheet)pile lightly on the ground;
4. Lower the vibro via the cylinders and clamp onto the pile;
5. This will slacken the PLD slings between PLD and (sheet)pile;
6. Re-position if needed and start vibro-driving.

Origin and insight. The PLD concept was born from two converging realities in the field: (a) the persistent inefficiency and hazard potential of dual-line, dual-machine lifts; and (b) the certification burden of lifting through a vibro hammer. Dieseko’s engineers observed the improvised market workarounds, e.g., auxiliary spreaders on a second line with guide fixtures, but these still left misalignment risk and certification questions unresolved. The team set a clearer ambition: one crane, one certified load path, and fast, reliable alignment under the vibro.

Iterative concepting and risk thinking. Engineers sketched multiple concepts, blended the best elements, and converged on Concept 2 for robustness and simplicity, paired with the replaceable center module (spacer) for fast cross platform fit. Formal risk analysis, FEM strength checks, and a Technical Design Review (01112022) derisked the design prior to load testing and certification.

Interdisciplinary teamwork and “customer inside” mindset. The PLD matured in close cooperation between Engineering, Commercial teams, suppliers (e.g., steel cable partner), and Dieseko’s own rental fleet, treated as a surrogate customer to keep the design process ongoing. That collaboration surfaced challenges (e.g., short Cylinder stroke for very wide hammers on small diameters) and translated into incremental design tweaks before wider release.

Certification strategy and IP. By certifying the PLD as the hoisting element for the total allowable lift force (e.g., 100 t for PLD100; 40 t for PLD40) and removing the vibro from the load path, it eliminates the need to certify every vibro component in the lift chain. Dieseko also filed patent protection for the PLD principle across key growth regions (including the U.S., Australia, Middle East, and Japan) to secure a first mover window and to protect its worldwide dealer network.

Time to value. From the initial idea to a working PLD in the field took roughly a year, helped by the simplicity and reuse of known building blocks (linear guiding , bolted interfaces, and modularity).

Beyond pipes: toward sheet piles and combi walls. As the PLD gained traction, Dieseko extended the concept to sheet piles with adjustable pick points on parallel arms‑ so the clamp sits directly over the profile’s center of gravity, covering AZ‑sheet piles and H‑profiles with a common logic. This demonstrates the wider platform mindset embedded in the PLD architecture.

The PLD technology uses an approach that anticipates the industry’s shift toward integrated, modular lifting systems. It embeds certification into the design: by removing the vibro hammer from the lift path and placing all certified loadbearing through the PLD, the system resolves a longstanding ambiguity around “lifting through the vibro”.

Moreover, it enhances productivity by taking out the second crane, allowing immediate alignment between vibro hammer and pile and consequently, earlier start in vibro driving.

That’s not all. In fact, this tool is fully adaptable to any size vibro hammer, thanks to a modular center section and standard hole pattern interface which enable cross compatibility.
The PLD is more than a product, it is a case study in how engineering foresight and modular thinking can redefine operational norms. Future foundation systems will increasingly prioritize certified lifting paths, platform-based adaptability, and digital integration for monitoring and predictive maintenance. With Dieseko’s Pile Lifting Device efficiency, safety and certified lifting equipment are now an unmissable reality