PLT/Specific Plant/TBT-PLT-007

Concrete Pump Safety

Plant & Equipment › Specific Plant › Concrete Pump Safety

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Concrete pumps deliver wet concrete through a pipeline under high pressure to the placement location via a boom or static line.
The pump boom must be treated as a mobile crane — outriggers must be fully extended on spreader plates before use.
Pipeline blockages cause dangerous pressure build-up — never look into or stand in front of a blocked delivery line.
The discharge hose at the end of the boom whips violently as concrete flows — it must be controlled by a trained operative.
Concrete pump operators must hold a valid CPCS or equivalent card for the specific pump category being operated.
Setup location must account for ground bearing capacity, overhead power lines, and proximity to excavation edges.
Boom movement creates an exclusion zone beneath and around the operating radius where no unauthorised persons may enter.
Pump pipelines routed across the site create trip hazards and must be clearly marked and protected at crossing points.
Communication between the pump operator, boom controller, and placing gang must be continuous throughout the pour.
After pumping, the pipeline must be cleaned using water or sponge balls under controlled conditions to prevent blockages.

Pipeline pressure	A blocked pipeline under pump pressure stores enormous energy — sudden release propels concrete and fittings with lethal force.
Hose whip	The discharge hose moves with extreme force as concrete flows — an uncontrolled hose has struck and killed workers at the pour.
Boom setup	The boom and outrigger system behaves like a crane — incorrect setup on soft ground or slopes causes catastrophic overturn.

Don't

Set up the pump on firm ground with outriggers fully extended on spreader plates.
Check for overhead power lines before positioning the pump and extending the boom.
Establish exclusion zones beneath and around the operating boom radius.
Control the discharge hose at all times using a trained operative at the end.
Maintain continuous communication between pump operator and placing gang.
Hold a valid CPCS concrete pump card before operating the equipment.
Mark and protect pipeline routes across the site to prevent trip hazards.
Stop pumping and relieve pressure safely if a pipeline blockage is suspected.
Clean the pipeline under controlled conditions after the pour is complete.
Brief the team on exclusion zones, communication signals, and emergency stops.

DON'T set up the pump on soft ground or slopes without full outrigger deployment.
DON'T position the pump boom near overhead power lines without a risk assessment.
DON'T allow anyone beneath the boom or within the exclusion zone during pumping.
DON'T let the discharge hose operate without a trained person controlling it.
DON'T pump without clear communication between the operator and placing gang.
DON'T operate a concrete pump without the required CPCS competency card.
DON'T leave pipeline routes unmarked where people could trip over them.
DON'T look into or stand in front of a blocked pipeline under pressure.
DON'T rush the pipeline cleanout — it involves pressurised water and residual concrete.
DON'T begin pumping without briefing the team on exclusion zones and emergency stops.

See also: Concrete Pour Safety | Concrete Pump and Skip Safety

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