Concrete pumps deliver large volumes of concrete at high pressure through pipelines and boom arms to locations that mixer trucks cannot reach. The pressures involved are extreme, and a pipeline failure or boom contact with overhead structures can cause fatal injuries. This talk covers the hazards of concrete pump operations and the controls required for every pour involving pumped concrete on site.
Key Hazards
High-pressure pipeline burst causing severe impact injuries to nearby workers
Pump boom contacting overhead power lines during positioning or operation
Pump overturning from incorrect outrigger setup on soft or sloping ground
Concrete surge or blockage causing uncontrolled pipeline whip and release
Control Measures
Set up the pump on firm, level ground with all outriggers fully extended onto adequate pads.
Ensure the boom operating radius does not approach overhead power lines or other obstructions.
Check all pipeline clamps, couplings, and seals before pumping starts each shift.
Establish an exclusion zone around the pump boom swing radius during all pumping operations.
Ensure the pump operator holds a current CPCS card for concrete pump operation.
Brief the pour team on the pump position, pipeline route, and emergency stop procedure before starting.
Use a banksman to guide the boom operator when working near structures or restricted areas.
Flush pipelines using the correct procedure with end caps secured and personnel kept clear.
Never attempt to clear a pipeline blockage while the pump is under pressure.
Emergency / Rescue
If a pipeline bursts, activate the emergency stop immediately and evacuate the exclusion zone. Treat concrete burns by flooding with clean water for at least 20 minutes. Call for first aid and report the incident.
Remember
All outriggers must be fully extended onto adequate pads on firm level ground before pumping
Check the boom will not approach overhead power lines at any point during the operation
Pipeline clamps, couplings, and seals must be inspected before every pumping shift
An exclusion zone must be maintained around the boom swing radius throughout pumping
Never attempt to clear a pipeline blockage while the system remains under pressure
Applicable Legislation: PUWER 1998 · CDM Regulations 2015 · Electricity at Work Regulations 1989 · Health and Safety at Work etc. Act 1974