CONCRETE PUMPING RISK ASSESSMENT

IMPORTANT NOTICE / HEALTH RISK WARNING

ANY PERSON AT RISK MUST BE NOTIFIED OF THE DANGERS DETAILED BELOW BEFORE STARTING ANY CONCRETE PUMPING WORK
The mobile truck mounted concrete pump is designed to convey concrete from the machines delivery hopper to a point designated by the hirer. This is achieved via a hydraulically powered pump, through pipe
sections attached to articulated boom, to a suspended flexible rubber delivery hose, solid tremmie pipe or via a steel pipeline laid on the ground or fixed vertically.
Terms of Hire - RS Concrete Pumping supplies equipment subject to CPA Model Conditions for the Hiring of Plant (2011) in conjunction with Supplementary Conditions for Concrete Pumping. Copies can be found on
the CPA website. Hirers should insure against any liabilities that might be incurred, including damage caused when the pump is being operated in confined spaces.
Data Sheets - Detailing pump dimensions, outrigger loadings / positioning, boom type / reach and pumping delivery pressures / volume outputs are available upon request.
Training - All our Concrete Pump Operators (CPOs) are fully trained and are working towards a current CPCS card for concrete pumping operations.
Safe Systems of Work RS Concrete Pumping have assessed all aspects of its operations and have developed procedures and safe systems of work that aim to reduce and control risks to safety, health and
the environment.
British Standard BS 8476:2007 Code of Practice for the Safe Use of Concrete Pumps is recommended to hirers and interested parties as a reference document
detailing the general minimum requirements in respect of the operation of concrete pumping equipment. Copies of the standard are available from www.bsi-global.com.

RISK
Hazards Identified

CONCRETE PUMP SET UP / FOLD DOWN

Collapse or settlement of pump due to ground

conditions / overturning of pump, or collapse of
boom due to insufficient sta bility

Crush or impact by boom, or struck by placing

hose, during set up or during off the boom
placement of concrete

Contact with overhead cables

Who is at Risk

CPO, Concrete Gang

Persons working
around concreting area
& Public
Concrete Gang
Persons working
around concreting area
& Public
Concrete Gang
Persons working
around concreting area
& Public

Risk of
Occurrence

Level of
Injury

Low

High

Low

High

Low

High

Vehicle Movements (reversing) crushing or

trapping of persons when moving pump to work in
position

Person backing truck

mixer onto pump
hopper

Low

High

Back injury due to moving ground pipes

CPO/Concrete Gang

Medium

Medium High

`Low

Low

Washout of pump

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CPO, Concrete Gang

Persons working
around concreting area
& Public

Control Measures
Ensure ground conditions at set up are adequate for load of pump. Provide sufficient support (timbers,
steel sheets) as required and ensure there is adequate space around the pump for the full deployment
of outriggers. CPO to ensure outriggers are extended to appropriate position. Sole plates are provided
for placement below outrigger feet to support the pump
CPO to operate via remote control unit from a position of safety.
Hirer to ensure sufficient set up space and adequate light levels to ensure safe pump set up.
Ensure personnel remain clear of area and any operative controlling the position of the placing hose
should hold it at arms length.
Person(s) shall be nominated to converse with and signal the CPO for minor boom positioning.
Industry guidance specifies the minimum safe working distance from electric cables is 6m, this includes
the fully extended boom radius. Exceptions may apply and closer distances may be permitted where
controls are provided, however, they must be managed by a Written Safe System of Work. Where set
up cannot be clear of overhead cables, consideration should be given to the provision of a ground level
pipeline.
Keep site personnel out of reversing area. A competent Traffic Marshall should direct the moving
vehicle and look out for anyone in the danger area. Vehicles fitted with reversing sirens and amber
flashing lights should have these engaged. High visibility clothing must be worn and do not back truck
on out of view of mixer driver who will be reversing using mirrors.
Use of ropes and good manual handling practices to be adopted
The hirer / site management shall provide adequate wash out facilities for concrete residues. The CPO
to only wash out in areas defined and authorised by site management. If there is no suitable area
wash out can be taken away but this is an extra charge and should be agreed at time of booking.

Collapse of placing boom due to failure of

hydraulics or structural failure of pump / boom

CONCRETE PUMP OPERATION

Contact with pump moving parts

Concrete splashing into eyes from the end hose /

Concrete burns to hands and feet
Potential injury to persons and property damage
due to concrete spillage / splatter (predominantly
from upper floors)
High pressure concrete and aggregate going into
eyes, face or any exposed skin due to standing or
working in front of end hose, or opening up pipe
joints when pumping

Broken limbs, severe injury caused by whiplash of

placing hoses.
Injury from splash due to blow back from concrete
pump hopper
Working at height (upon pump deck)
Potential blockages at start or restart if pump, use
of suspended hose off the boom resulting in
hose whipping into danger area

Bursting of pipelines / hoses under pressure

Forceful ejection of air / concrete from the end of

the pipeline. Air sucked into line and compressed

CPO, Concrete Gang

Persons working
around concreting area
& Public
CPO
Persons working
around concreting area
Concrete Gang

High

Low

High

Medium

Medium

All moving parts on the concrete pump are fully guarded, ensure the CPO has carried out his required
daily / weekly checks
No personnel other than the CPO may operate the pump or climb onto the pump deck.
Full PPE to be worn inc, helmet, goggles, gloves, safety wellingtons and barrier cream must be worn

Medium

Medium

Ensure that the pour area has adequate protection to contain any concrete spray or spillage

Concrete Gang
Persons working
around concreting area
General Public

Medium High

High

Concrete Gang

Low

High

Truck Mixer Drivers

Low

Low

CPO

Low

Medium

Concrete Gang

Medium

High

Low

Medium

Low

Medium

CPO

Medium

Medium

CPO

Medium

Medium

Persons working
around concreting area
& Public

Concrete Gang
Persons working
around concreting
area& Public
Concrete Gang
Persons working
around concreting
area& Public

Pressurised concrete release dismantling of line

Pipeline cleaning with compressed air
pressurised release / ejection of sponge ball /
concrete / water / air

All hydraulic rams are fitted with lock valves to limit movement should failure occur. All pumps undergo
a boom test (which is certificated) and are also inspected as part of the regular servicing schedule.

Low

Under no circumstances should any unauthorised personnel attempt to open the pipeline. All
unnecessary personnel including the general public should be kept well away from the concreting area
inc lower floors and staircases. Until concrete is flowing smoothly out of the end of the delivery hose, or
when a blockage occurs in the boom pipeline, all personnel should remain clear of the delivery hose
and placing boom. Concrete Gang should wear a safety helmet, safety footwear, impervious gloves /
gauntlets, high impact goggles and high visibility clothing. Also see Blockages section below
Do not kink placing hoses in the ground line. Do not attempt to pump very old concrete or concrete
other than a pump mix. . The danger zone is the area around the end hose in which it can strike out.
The diameter of the zone is twice the length of the end hose
Keep hopper full and inform mixer driver of risk
Access shall be restricted to short duration no hirer personnel shall be permitted to access the pump
deck unless express permission is given by the CPO.
Only single ended hoses shall be used double / steel collared ended hoses shall not be used off
the boom
The CPO shall request that all persons remain clear (a radial distance of at least twice the length of the
hose) of the suspended hose at each start or restart of pump and until smooth flow has been
achieved. Also see Blockages section below
Only pipes, hoses, clips of sufficient safety rating shall be used. Wear and damage shall be monitored
by the CPO and checked during scheduled services. Excessively damaged / worn components shall
be withdrawn. Also see Blockages section below
Pipe jointing seals shall be clean and in good order. Concrete level in the pump hopper must be
maintained at the required level, where the CPO is required to position himself remote of the pump
appoint a competent persons to monitor deliveries and hopper level (to ensure air is not pumped into
the pipe system)
CPO to ensure pipeline is depressurised before freeing jointing clips, hirer personnel must not
uncouple pipes without the express permission of the CPO
A demarcated and access restricted area shall be provided at the end of the pipeline that is to be air
cleansed

The above information has been provided to assist hirers, customers and site management in identifying and controlling the significant risks associated with concrete pumping operations. If you need
more help or advice please call us on 07970 424590

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BLOCKAGES
Blockages Why do they occur?

Risk Reduction / Control

(RSCP) = RS Concrete
Pumping,
(H) = Hirer
(SM) Site Management

Segregation of concrete / aggregates as it is pressurised through the pipeline with

the primer / grout

It shall be ensured that the appropriate grout mix is used

Maximum pipeline and delivery hose length shall be considered grouting may be more successful
in shorter sections

(RSCP)
(SCP) (H)

Inappropriate concrete mix design or consistency not suitable for pumping

Only concrete that is of pump mix design and appropriate quality should be specified for delivery to
the pump

(H) or (SM)

Hardening of the concrete in boom / pipeline from standing too long (usually when
awaiting delivery of fresh concrete )

CPO shall circulate or move the concrete in the hopper / boom / pipeline
Deliveries shall be time managed and planned appropriately

(RSCP)
(H) or (SM)

Flexible placing hose become kinked

The hose should never become kinked, it should be suspended vertically when used off the boom
or kept straight if used at the end of pipelines

(H) or (SM)

Foreign objects delivered from visiting mixer drums

The quality of the concrete should be monitored

All

NOTE: WHERE THE CONCRETE IS BELIVE TO BE POOR OR UN PUMPABLE, OR WHERE FRESH CONCRETE HAS NOT ARRIVED IN TIME AND THE CONCRETE IN THE BOOM / PIPELINE IS BECOMING TOO HARD, THE CPO MAY
HAVE TO REJECT THE LOAD, OR CLEAR THE CONCRETE FROM THE PUMP. THE HIRER SHALL BE INFORMED IF THIS IS LIKELY TO OCCUR

Blockages Reacting To

Where possible the CPO will stop the pump action and reverse the pumping direction (this may free the blockage). Before the CPO restarts the pumping action, he should ensure all persons retreat to a safe distance
away from the boom / pipeline. Should the blockage persist, the CPO will stop the pump, depressurise the line and investigate the location of the blockage before taking appropriate action (ie disconnecting pipework to
locate and remove the blockage).
A momentary blockage may occur that frees immediately this is often accompanied by increased engine / pump revs and noise. The CPO shall endeavour where possible to warn persons in the vicinity to stand clear.
However the release is likely to cause the delivery hose and/or boom to move or kick before the pump action can be stopped.

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