CON/General/TBT-CON-003

Concrete Pump and Skip Safety

Concrete & Formwork › General › Concrete Pump and Skip Safety

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Concrete pumps deliver concrete through a pipeline and articulated boom, while skips are lifted by crane to the pour location.
Pump booms operate under high pressure and must be treated as mobile cranes during setup, operation, and folding.
The pump must be set up on firm, level ground with outriggers fully extended on spreader plates before pumping begins.
Pipeline blockages create dangerous pressure build-up — never attempt to clear a blocked pipeline by looking into the end.
Concrete skips carried by crane require a lift plan, exclusion zone, and trained slinger and signaller for every pour.
Pump hose whip at the discharge end can strike workers with lethal force — the hose must be controlled at all times.
Concrete delivery wagons accessing the pump must be guided by a banksman to prevent collisions and overruns.
Pump pipeline routing must avoid overhead power lines, public areas, and occupied buildings wherever possible.
Communication between the pump operator, boom controller, and placing gang must be maintained throughout the pour.
After pumping, the pipeline and hopper must be cleaned out safely — high-pressure washout creates splash and slurry hazards.

Pipeline pressure	Blocked pipelines build extreme pressure that releases explosively — standing near a blocked line risks fatal impact injuries.
Hose whip	The discharge hose moves with great force as concrete flows — uncontrolled hose whip has killed workers at the pour location.
Skip and crane	Concrete skips suspended from cranes weigh several tonnes — a dropped or swinging skip in a congested pour area is lethal.

Don't

Set up the concrete pump on firm ground with outriggers fully extended on plates.
Establish exclusion zones beneath the pump boom and around the discharge area.
Maintain communication between the pump operator and the placing gang throughout.
Control the discharge hose at all times — never let it move unrestrained.
Follow the lift plan for all crane-placed concrete skip operations on site.
Use a banksman to guide concrete wagons approaching and leaving the pump.
Route pump pipelines away from overhead power lines and public access areas.
Stop pumping and relieve pressure safely if a pipeline blockage is suspected.
Wear full PPE including waterproof gloves and eye protection during the pour.
Clean out the pump and pipeline safely after the pour using controlled methods.

DON'T set up the pump on soft or sloping ground without fully extending outriggers.
DON'T stand beneath the boom or within the exclusion zone during pumping operations.
DON'T let the discharge hose operate uncontrolled — hold it firmly or secure it.
DON'T look into a blocked pipeline — pressure release can propel concrete with fatal force.
DON'T lift concrete skips by crane without a completed lift plan and exclusion zone.
DON'T allow concrete wagons to approach the pump without banksman guidance.
DON'T route pipelines under overhead power lines or across public footpaths.
DON'T attempt to clear a pipeline blockage by increasing pump pressure.
DON'T handle wet concrete without waterproof gloves and eye protection.
DON'T rush the washout procedure — high-pressure cleaning creates dangerous splash.

See also: Concrete Pour Safety | Crane Safety and Signals

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