“Think Safety Before You

Place Concrete”
Presented By:
Brundage-Bone Concrete Pumping, Inc.
Safety Department

Concrete Pump Trucks…

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Concrete Pump Trucks…

Concrete Pump Trucks…

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Concrete Pump Trucks…
¾ Hydraulic reciprocating pumps.

¾ Components: Two cylinders (differential

cylinders), two materials cylinders, a
water box, and a concrete valve. (Rock
valve, S valve, Gate valve, etc.)

Cycling the Pump…

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High Pressure Hydraulic Lines…

Concrete Pump Hopper…

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Rear Transition Cover…

Rear Transition Cover…

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Grate (covers the agitator and concrete valve)…

Augers (agitator) and Concrete Valve…

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Concrete Pump Trucks...
¾ Concrete pressure during pumping
operations generally from 600 psi to 1233
p.s.i.

¾ Concrete can be pumped up to 213 yards

per hour.

¾ Operator controls the pump functions

through wireless radio remote or hardwire
remote.

Radio Remote Control Box….

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Wired Remote Control Box…

Job-Site Conditions Checklist…

¾ Before any concrete pour begins, the
following items should be checked off to
ensure a safe start to your concrete
placement operations.

¾ Person-In-Charge (PIC) has been

identified.
identified

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Job-Site Conditions Checklist…

Job-Site Conditions Checklist…

¾Pump operators must have 17’ clearance
away from all energized power lines
before operations can begin or,

¾Power lines have been de-energized or

relocated to prevent accidental contact.

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How Close Are They?...

Overhead lines - The Three Types…

¾ Transmission lines

¾ Distribution lines
¾ 7,200 volts, phase to ground, is most common
¾ Service drops
¾ 220 volts average; 440 in some industrial
settings

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Service Drop – 220-440 Volts…

Distribution Lines – 7,200 to 100,000 Volts…

¾ The most hazardous to

concrete pumpers!
¾ Familiarity breeds
complacency
¾ May be as low as 18 feet

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Transmission Line 50,000 to 1,000,000 Volts…

Paths to Ground…

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An Example of “Path-To-Ground”…

An Example of “Path-To-Ground”…

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An Example of “Path-To-Ground”…

Electrical Burn…
¾ Most Common Exit Wound

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Why/How Contact With Lines Occurs…
¾ Working in area below lines - pump
operator tries to reach over lines

Why/How Contact With Lines Occurs…

¾ Wires behind work area, but contacted
when boom is moved

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Look Up and Live!!!…
¾ Florida, January 2006
¾ 1 Fatality

Look Up and Live!!!…

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Look Up and Live!!!…

Look Up and Live!!!…

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Look Up and Live!!!…

Look Up and Live!!!…

17 Feet!

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Control Measures…
¾ Site survey ahead of time

¾ Positioning the Pump to avoid power lines

Control Measures…
¾ De-energize lines

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Electrical Awareness Barrier (Cone Policy)…

If Contact With Lines Occurs…

¾ Stay away until you know for certain the
power is off
¾ If you’re in the vehicle, stay put if you can
¾ If you have to get out, jump!
¾Never step down or touch the ground and
vehicle at the same time.
time

¾ If you’re standing near by, shuffle away -

taking very small steps

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Job-Site Conditions Checklist…
¾ Adequate access and egress routes for
Ready Mix trucks have been established.
Ready-Mix established

Job-Site Conditions Checklist…

¾ Adequate Access and Egress

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Job-Site Conditions Checklist…
¾ A staging area has been established for
ready mix trucks.
ready-mix trucks

Job-Site Conditions Checklist…

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Job-Site Conditions Checklist…
¾A clean out area for the ready-mix and
pump truck has been established.
established

Job-Site Conditions Checklist…

¾ Adequate lighting has been provided.

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Job-Site Conditions Checklist…
¾ Ground Stability has been considered:
¾ Soils Condition - Will the ground support the
weight of a pump truck and ready- mix truck?

¾ Compaction - Has the ground been properly

prepared?

¾ Rain & Weather - Has the weather affected the

ground conditions?

Ground Stability…

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Ground Stability…
¾ Example of virgin soil w/ inadequate
cribbing

Ground Stability…
¾ Virgin soil ALWAYS needs extra cribbing

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Ground Stability…
52m Outrigger
¾ Exerts 60
60,000
000 lbs of downward force

60,000 lbs ÷ 14” x 14” pad = 306 p.s.i.

60,000 lbs ÷ 24” x 24” Pad = 104 p.s.i.

60,000 lbs ÷ 5ft x 5ft Steel Plate = 16.7 p.s.i.

60,000 lbs ÷ 8ft. X 10ft Steel Plate = 5.2 p.s.i

200 lb man standing on one foot with a size 10

shoe = 5.5 p.s.i

Ground Stability…

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Ground Stability…

Ground Stability…

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Ground Stability…

Ground Stability…

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Ground Stability…

Job-Site Conditions Checklist…

¾ Effects of adverse weather conditions on
personnel and operations.
operations

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Communication…
¾ Pre-task planning sessions for the up-
coming pour should include
representatives from the contractor,
concrete pumping company, and redi-mix
company.

Communication…
¾ Between the Redi-mix company and
concrete pumping company regarding the
delivery and status of trucks.

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Communication…
¾ Between the redi-mix driver and pump
operator/hopper watch to ensure
personnel safety while trucks are pulling
up, backing in, and pulling out.

Communication…

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Communication…

Communication…

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Communication…

Communication…

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Communication…
¾ Between the redi-mix driver and pump
operator/hopper watch to maintain the
proper level of concrete in the hopper.
¾ How to locate and activate the horn on
the truck.
g y stop
¾ The location of the emergency p
switches.

Communication…
¾ Full Hopper

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Communication…
¾ Emergency Stop & Horn

Communication…
¾ Emergency Stop (E-Stop)

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Communication…
¾ Between Pump Operator and Placing Crew

Communication…
¾ Between Pump Operator and Placing Crew

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Communication…
¾ Between Pump Operator and Placing Crew
¾ To keep hose moving smoothly and at the proper height
over the concrete…not in it.

Hose/Pipe – Size & Selection…

¾ Determined by:
¾ The speed (in yards per hour) of the pour.

¾ Size of the aggregate/mix design.

¾ Weight of the delivery hose.

¾ Ease of use for the operator.

operator

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Hose/Pipe – Size & Selection…
¾ Mix Design

Hose/Pipe – Size & Selection…

¾ How many yards/hr will travel through
system?

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Hose/Pipe – Size & Selection…
¾ Ease of Use

Hose/Pipe – Size & Selection…

¾ Tip Hose = 1 End Coupled

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Hose/Pipe – Size & Selection…
¾ Double-Ended Tip Hose….Never!

Air In The System…

¾ Air in the system results from (among
other things) allowing the level of
concrete in the hopper to fall below its
safe operating level of the pump.

¾ Communication between the redi-mix

operator/ hopper watch person and the
pump operator is critical.
critical

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Air In The System…

Blockages In The System…

¾ Thorough cleaning is essential. A hose or
pipe that has not been properly cleaned
will reduce the ability of the concrete to
flow smoothly and may cause a blockage.

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Blockages In The System…
¾ Dirty Hoses

Blockages In The System…

¾ Dirty Hoses

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Blockages In The System…
¾ Foreign objects from concrete mixer
trucks (barrel chips,
trucks…(barrel chips oversized aggregate,
aggregate
etc.) can get into the system and cause a
blockage that results in the concrete
plugging.

Blockages In The System…

¾ Foreign Objects

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Blockages In The System…
¾ Long delays on the jobsite can allow the
concrete to set up and cause a blockage.
blockage

Blockages In The System…

¾ Release of a temporary blockage

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Blockages In The System…
¾ Extreme caution must be taken whenever
a blockage occurs.
occurs The operator must get
all personnel must get back beyond the
reach of the tip hose before he can
attempt to free the blockage.

¾ If the clamp is removed before the

operator backs off the pressure there can
be a violent release of concrete.
Communication is critical!

Blockages In The System…

¾ Do NOT remove clamps before directed to
by the operator

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Clamp Opened Under Pressure

Blockages In The System…

¾ Kinking the hose prevents continuous flow
of concrete and INSTANTLY creates
maximum pump pressure

¾ This can cause a violent reaction.

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Blockages In The System…
¾ Kinked Hoses…Will Straighten!

Thanks….and Have a Safe Pour!

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