Guide to managing risk in

construction: Concrete
pumping
Guidance material
NOVEMBER 2021
Disclaimer
Safe Work Australia is an Australian Government statutory agency established in 2009. Safe Work Australia includes Members
from the Commonwealth, and each state and territory, Members representing the interests of workers and Members
representing the interests of employers.
Safe Work Australia works with the Commonwealth, state and territory governments to improve work health and safety and
workers’ compensation arrangements. Safe Work Australia is a national policy body, not a regulator of work health and safety.
The Commonwealth, states and territories have responsibility for regulating and enforcing work health and safety laws in their
jurisdiction.
ISBN 978-1-76114-217-8 (word)
ISBN 978-1-76114-992-4 (PDF)
Creative Commons
With the exception of the Safe Work Australia logo, this copyright work is licensed under a Creative Commons Attribution-
Noncommercial 4.0 International licence. To view a copy of this licence, visit creativecommons.org/licenses In essence, you are
free to copy, communicate and adapt the work for non-commercial purposes, as long as you attribute the work to Safe Work
Australia and abide by the other licence terms.
Contact information
Safe Work Australia | mailto:[email protected] | www.swa.gov.au
Contents
Contents...................................................................................................................................3
1. Introduction.......................................................................................................................5
1.1. What is concrete pumping?....................................................................................5
1.2. Who should use this guide?....................................................................................5
1.3. How to use this guide..............................................................................................5
2. Who has health and safety duties?.................................................................................7
2.1. Persons conducting a business or undertaking......................................................7
2.2. Principal contractors................................................................................................7
2.3. Designers, manufacturers, importers, suppliers and installers...............................8
2.4. Officers....................................................................................................................9
2.5. Workers...................................................................................................................9
2.6. Other persons at the workplace..............................................................................9
2.7. WHS laws in your state or territory.......................................................................10
3. Managing health and safety risks..................................................................................11
3.1. Consultation..........................................................................................................11
3.2. The risk management process..............................................................................12
3.2.1. Identify the hazards...............................................................................................12
3.2.2. Assess the risks....................................................................................................13
3.2.3. Take action to control the risks.............................................................................13
3.2.4. Maintain and review control measures.................................................................15
3.3. Information, training, instruction and supervision..................................................15
3.4. Relevant competencies.........................................................................................16
3.5. Licensing requirements.........................................................................................17
3.6. Emergency plans..................................................................................................17
4. Planning and preparation for concrete pumping operations.....................................18
4.1. Registering a concrete placing boom....................................................................18
4.2. Pumping operation planning.................................................................................18
4.3. Safe work method statements..............................................................................19
4.4. Concrete pumping equipment owner....................................................................20
4.5. Concrete pumping equipment operator................................................................21
5. Safe operation of concrete pumping equipment.........................................................22
5.1. Setting up on site..................................................................................................22
5.2. Maintaining stability of concrete placing equipment..............................................22
5.3. Role of a spotter....................................................................................................23
5.4. Concrete delivery..................................................................................................23
5.5. Concrete pumping.................................................................................................23
 5.6. Traffic control........................................................................................................25
5.7. Preparation for road travel....................................................................................25
5.8. Noise.....................................................................................................................25
5.9. Fumes...................................................................................................................25
6. Working near overhead powerlines..............................................................................26
6.1. Electrical safety laws.............................................................................................26
6.2. Planning for work near overhead powerlines........................................................26
6.3. Approach distances...............................................................................................27
6.4. The safety observer zone.....................................................................................27
6.5. Safety observer.....................................................................................................28
6.6. Controlling risks.....................................................................................................29
6.7. Contact with power lines.......................................................................................29
7. Inspection and maintenance..........................................................................................31
7.1. Concrete placing booms.......................................................................................31
7.2. General.................................................................................................................31
7.3. Pre-operational inspections..................................................................................31
7.4. Routine inspections...............................................................................................31
7.5. Periodic inspections..............................................................................................32
7.6. Inspection report...................................................................................................32
7.7. Repair following an incident..................................................................................32
7.8. Log books and inspection record sheets..............................................................33
Appendix A – Concrete delivery..........................................................................................34
Appendix B – Concrete pumping........................................................................................36
Appendix C – Minimising the risk of hose whip................................................................37
Appendix D – Blockages......................................................................................................39
Appendix E – Cleaning.........................................................................................................41

Concrete pumping
Guidance material Page 4 of 43
1. Introduction
1.1. What is concrete pumping?
Concrete pumping is the transportation of a freshly mixed batch of concrete via a system of
pipes to a specific location on a construction site. Concrete pumping is a widely used
process in the construction industry. It can be used to manufacture pre-cast and tilt up
concrete panels, concrete formwork, slab construction, concrete paving and concrete
spraying.

Equipment used in concrete pumping includes the following:

Line Pump: Use of a fixed or mobile pump that pumps concrete through pipes and/or
flexible hoses that run along the ground
Mobile Concrete Placing Boom: Use of a truck-mounted pump to pump concrete through
pipework that is supported by a multi-staged boom
Satellite Concrete Placing Boom: Use of a fixed or trailer-mounted pump to pump concrete
through pipework to a concrete placing boom fixed to the structure being built
Concrete is normally delivered to the concrete pump using a concrete truck that dispenses
concrete into the hopper on the pump, which is then pushed through pipework to the location
of the concrete pour. Concrete pumping is generally a more efficient means of delivering
concrete in comparison to the use of a wheelbarrow or crane-lifted concrete kibble.
However, due to the high pressure involved and the pulsating motion of the pump, there can
be significant safety risks associated with pumping concrete.
Generally, concrete pumping work is defined as construction work. It may also be
considered high risk construction work under the Work Health and Safety (WHS)
Regulations. A safe work method statement (SWMS) must be prepared before high risk
construction work starts.

1.2. Who should use this guide?

This guide provides practical guidance to assist duty holders, primarily a person conducting
a business or undertaking (PCBU), to manage risks to health and safety associated with
concrete pumping in construction work. You should use this guide if you own, hire, lease,
handle, store, transport, maintain or use concrete pumping equipment in the workplace.

1.3. How to use this guide

This Guide is intended to supplement other information produced by Safe Work Australia to
assist you to meet your duties and obligations under WHS laws. It should be read in
conjunction with the following:
 Model Code of Practice: How to manage work health and safety risks
 Model Code of Practice: Managing the risks of plant in the workplace, and
 Model Code of Practice: Construction work.

Guidance material
Concrete pumping Page 5 of 43
This Guide includes references to the legal requirements under the WHS Act and WHS
Regulations. These are included for convenience only and should not be relied on in place of
the full text of the WHS Act or WHS Regulations.
In this Guide, the word ‘must’ indicates a legal requirement that must be complied with. The
word ‘should’ indicates a recommended course of action.

Concrete pumping
Guidance material Page 6 of 43
2. Who has health and safety duties?
Everyone at the workplace involved in concrete pumping has health and safety duties. A
person can have more than one duty and more than one person can have the same duty at
the same time.

2.1. Persons conducting a business or undertaking

WHS Act section 19
Primary duty of care
WHS Act section 21
Duty of persons conducting businesses or undertakings involving management or control of
fixtures, fittings or plant at workplaces

PCBUs have the primary duty of care for the health and safety of their workers and others at
the workplace.
A PCBU can be a:
 company
 unincorporated body or association
 sole trader, or
 self-employed person.
Individuals who are in a partnership that is conducting a business or undertaking will
individually and collectively be a PCBU.
A PCBU must ensure, so far as is reasonably practicable, that workers and other people are
not exposed to health and safety risks arising from the business or undertaking.
This duty requires the person to manage risks by eliminating health and safety risks so far as
reasonably practicable, and if it is not reasonably practicable to eliminate the risks, by
minimising those risks so far as is reasonably practicable.
It also includes ensuring so far as is reasonably practicable the:
 provision and maintenance of safe plant, including concrete pumping equipment, and
 safe use, handling, storage and transport of plant.

A PCBU also has a number of more specific obligations, which are set out in the WHS
Regulations.

2.2. Principal contractors

WHS Regulations 308-315
Duties of principal contractors

Concrete pumping
Guidance material Page 7 of 43
 Projects involving construction work that costs $250,000 or more are classified as
‘construction projects’ under the model WHS laws. Each construction project has a ‘principal
contractor’. A principal contractor is also a PCBU. The principal contractor for a construction
project is:
 the PCBU that commissions a construction project
 if the PCBU that commissions the project engages another PCBU to be the principal
contractor and authorises the person to have management or control of the workplace
and to discharge the duties of the principal contractor, the PCBU so engaged, or
 if the owner of residential premises is an individual who directly or indirectly engaged
a PCBU to undertake a construction project in relation to the premises, the PCBU so
engaged, provided the PCBU has management or control of the workplace.

A construction project only has one principal contractor at any specific time.
In addition to the duties imposed on a principal contractor as a PCBU, the principal
contractor has duties relating to WHS management plans, ensuring general compliance, and
managing specific risks.

2.3. Designers, manufacturers, importers, suppliers

and installers
WHS Act section 22
Duties of persons conducting businesses or undertakings that design plant, substances or
structures
WHS Act section 23
Duties of persons conducting businesses or undertakings that manufacture plant,
substances or structures
WHS Act section 24
Duties of persons conducting businesses or undertakings that import plant, substances or
structures
WHS Act section 25
Duties of persons conducting businesses or undertakings that supply plant, substances or
structures
WHS Act section 26
Duties of persons conducting businesses or undertakings that install, construct or
commission plant or structures
WHS Regulation 295
Designers must give safety report to person who commissions design

A designer, manufacturer, importer, supplier or installer of concrete pumping equipment

must ensure, so far as is reasonably practicable, that the concrete pumping equipment they
design, manufacture, import, supply or install is without risks to health and safety. This
includes undertaking necessary associated testing and providing adequate information about
the concrete pumping equipment.

Concrete pumping
Guidance material Page 8 of 43
Suppliers must provide a purchaser of concrete placing booms with the design registration
number.
When hiring or leasing concrete pumping equipment, the person who owns the equipment
must be consulted about potential hazards, as there is a shared responsibility for ensuring,
so far as is reasonably practicable, that the equipment is safe to use and without risk to
health and safety.
Anyone hiring or leasing concrete pumping equipment to others has duties as both a
supplier of the equipment and as a person with management or control of the equipment at
the workplace. They must check the equipment is safe to use and properly maintained and
provide specific information including safe operation instructions.

2.4. Officers
WHS Act section 27
Duties of officers

An officer (for example a company director) must exercise due diligence to ensure the PCBU
complies with the WHS Act and WHS Regulations. This includes taking reasonable steps to
ensure the PCBU has and uses appropriate resources and processes to eliminate or
minimise risks to health and safety.

2.5. Workers
WHS Act section 28
Duties of workers

If not used correctly, concrete pumping equipment can be dangerous to workers and others.
Workers have a duty to take reasonable care for their own health and safety, and to take
reasonable care to not adversely affect the health and safety of other persons.
Workers must also:
 comply as far as they are reasonably able with any reasonable WHS instructions from
the PCBU such as wearing relevant personal protective equipment (PPE), and
 co-operate with any reasonable policy or procedure relating to WHS at the workplace
that has been provided to them.
The PCBU must make workers aware of the hazards associated with the use of concrete
pumping equipment, including the process for reporting safety incidents.
When discussing health and safety matters with workers, a consultative approach should be
taken to allow workers a reasonable opportunity to express views before any decision is
made.

Concrete pumping
Guidance material Page 9 of 43
 2.6. Other persons at the workplace
WHS Act section 29
Duties of other persons at the workplace

Other persons at the workplace, such as visitors, must take reasonable care for their own
health and safety and must take reasonable care not to adversely affect other people’s
health and safety. They must comply, so far as they are reasonably able, with reasonable
instructions given by the PCBU to allow that person to comply with the WHS Act. If PPE is
provided by the business or undertaking, other persons at the workplace must, so far as they
are reasonably able, use or wear it in accordance with the information, instruction and
training provided.

2.7. WHS laws in your state or territory

The Commonwealth, state and territory WHS regulators are responsible for enforcing WHS
laws. They make decisions about whether you are in compliance with the requirements.
WHS laws are not the same across Australia. If you need help understanding your WHS
requirements, please contact your WHS regulator.
Further information on work health and safety duties is in the model Code of Practice:
Managing the risks of plant in the workplace and the model Code of Practice: How to
manage work health and safety risks.

Concrete pumping
Guidance material Page 10 of 43
3. Managing health and safety risks
As a PCBU, you must manage the health and safety risks associated with concrete pumping
in the workplace. In concrete pumping operations, risks may arise from known hazards
including, but not limited to:
 Plant and equipment, including:
o concrete placing booms
o pump gauges
o concrete pipelines
o pipe clamps
o anchor brackets
o pipes
o delivery hoses
o receiving hoppers
o outriggers
 Placement of plant and equipment, for example:
o proximity to traffic, members of the public, powerlines, other plant,
structures and trenches
o ground stability
 Tasks, including:
o concrete delivery
o pump and boom operation
o concrete pipeline handling, erection and dismantling
o concrete pouring
o pump relocation (internal climbing)
o line cleaning
o pump cleaning
o road travel
 By-products, such as fumes, dust and noise.

This document discusses the hazards and risks listed above, including appropriate control
measures.

3.1. Consultation
You must consult, so far as is reasonably practicable, with your workers and their elected
health and safety representatives (if any) about health and safety at your workplace.
Workers must be consulted on health and safety matters, including (but not limited to):
 identifying hazards and risks associated with the use of concrete pumping equipment
 making changes to processes or procedures
 improving controls put in place to protect workers from the identified risks
 procedures for resolving health and safety issues
 procedures for monitoring the conditions at the workplace, and

Concrete pumping
Guidance material Page 11 of 43
  procedures for providing information and training.

Participation of your workers in discussions about health and safety is important, as they are
most likely to know about the risks of their work. Joint involvement in identifying hazards and
assessing and controlling workplace risks will help build a mutual commitment to this
process and any changes that may result.
Further information on consultation requirements is in the Code of Practice: Work health and
safety consultation, co-operation and co-ordination.

3.2. The risk management process

Risk management requires you to think about what could go wrong at your workplace and
what the consequences could be. Then you must do whatever is reasonably practicable to
eliminate or minimise those risks.

Risk management involves four steps:

 Identify hazards—find out what could cause harm.
 Assess risks, if necessary—understand the nature of the harm that could be
caused by the hazard, how serious the harm could be and the likelihood of it
happening. This step may not be necessary if you are dealing with a known risk with
known control measures.
 Control risks—work through the hierarchy of risk controls to implement the most
effective control measure that is reasonably practicable in the circumstances and
ensure it remains effective over time.
 Review hazards and control measures to ensure they are working as planned.

Determining what control measures are reasonably practicable includes consideration of the
availability and suitability of control measures. Cost may also be relevant, but you must only
consider this after you have assessed the extent of the risk and the available ways to
eliminate or minimise the risk.
Further information on the risk management process is in the Code of Practice: How to
manage work health and safety risks.

3.2.1. Identify the hazards

The first step in the risk management process is to identify hazards associated with concrete
pumping. Identifying hazards involves finding things and situations that could potentially
cause harm to people.
There are many hazards associated with concrete pumping that can pose a risk to the health
and safety of workers.
The following can help you identify hazards:
 Observe the workplace. Consider the ground conditions where the pumping
equipment will operate and how it could interact with other plant, people and
structures, including overhead electric lines. Think about the layout of your workplace
and the placement of any overhead structures where the concrete placing boom may
be used.

Concrete pumping
Guidance material Page 12 of 43
  Review inspection, test and maintenance records, such as log books and incident and
injury records, including near misses.
 Consult with other PCBUs, concrete pumping operators, workers, and others about
specific hazards and any problems they encounter. This could include problems with
operation, inspection, maintenance, repair, transport and storage of concrete pumping
equipment.

Hazards can also arise from the conditions of the workplace. For example, local weather
conditions can introduce new hazards. High winds can be dangerous and cause
uncontrolled movement of a concrete placing boom. Rainfall can affect ground conditions
which may cause the machine to become unstable. Operating in storms risks lightning
strikes to booms.

3.2.2. Assess the risks

Even though the risks and related control measures will be known in many cases, you
should carry out a risk assessment. Risk assessments help determine how serious the risk
posed by the hazard is, what action is necessary to control the risk, how urgently the action
needs to be taken and who is responsible for implementing the control measure.
A risk assessment should be carried out if any of the following apply:
 there is uncertainty about how a hazard may result in an injury
 the work activity involves a number of different hazards, or
 there is any lack of understanding of how these hazards may interact with each other.
Risk assessments should consider:
 the effectiveness of existing control measures
 how work is actually undertaken in the workplace (compared to the written manuals
and procedures and infrequent or abnormal situations)
 maintenance and cleaning
 breakdowns of equipment, and
 failures of health and safety controls.
The assessment should also:
 identify the type and potential severity of the harm (Note: other factors, such as the
potential distance of a fall, may influence the severity)
 consider the number of people potentially exposed to the hazard
 work out the likelihood of harm occurring, and
 consider how frequently the task is done or how close people are to a hazard.

3.2.3. Take action to control the risks

WHS laws require you to do everything reasonably practicable to eliminate or minimise risks
to health and safety in the workplace. It is most likely you will need to use a range of control
measures to protect your workers from the risks associated with concrete pumping.
Controlling risks should involve discussing site-specific requirements, including the concrete
pump selection, concrete delivery and traffic control requirements.
The ways of controlling risks are ranked from the highest to lowest level of protection and
reliability, known as the hierarchy of risk controls. You must work through this hierarchy to
manage risks.
You must always aim to eliminate a risk where reasonably practicable. Where a risk cannot

Concrete pumping
Guidance material Page 13 of 43
be eliminated, it must be minimised, so far as is reasonably practicable, using one or more of
the following approaches:
 substitution
 isolation, and
 engineering controls.
If the risk cannot be completely managed by the above controls, the remaining risk must be
further minimised using administrative control measures, so far as is reasonably practicable.
If risk remains thereafter, personal protective equipment (PPE) should be used to control any
remaining risks. Cost may also be relevant, but you can only consider this after an effective
review of all reasonably practicable control measures. A control measure can only be
discounted where the cost of implementing the control is grossly disproportionate to the risk.
A combination of control measures may be required where a single control is not sufficient to
minimise the risks. Monitor and review all controls to ensure they remain effective.

Elimination
The first thing you must consider is whether a risk can be completely removed from the
workplace. For example, for small jobs it may be possible to move concrete using
wheelbarrows to eliminate the need to use concrete pumping equipment.
If it is not reasonably practicable to completely eliminate the risk, then risks must be
minimised, so far as is reasonably practicable, using the hierarchy of controls.

Substitution controls
Substituting the hazard for something safer can be an effective control measure. For
instance, if working in an area with overhead structures or limited space, you may be able to
substitute a concrete placing boom with a line pump to minimise risks.

Isolation controls
Isolation involves physically separating the source of harm from people.
For example, if the concrete placing boom is close to a deep excavation, use physical
barriers, such as secured fencing, to ensure persons and plant cannot access the
excavation edge or unstable ground near the excavation edge.

Engineering controls
An engineering control is a control measure that is physical in nature, including a mechanical
device or process. These are permanent or automatically applied and do not rely on human
behaviour to be effective. For example, the use of a hopper with ‘low level’ sensors to
indicate when the concrete levels are low and likely to pull air in with the mix.

Administrative controls
If risks remain after implementing all reasonably practicable substitution, isolation or
engineering controls, they should be minimised by implementing administrative control
measures, so far as is reasonably practicable. Administrative control measures include work
methods or procedures that are designed to minimise exposure to a hazard as well as the
information, training and instruction needed to ensure workers can work safely.
Administrative controls are less effective than other control measures because they do not
control the hazard at the source and instead rely on human behaviour and supervision.

Concrete pumping
Guidance material Page 14 of 43
Some administrative measures will be necessary to ensure substitution, isolation and
engineering control measures are implemented effectively, for example, following safe work
procedures when using equipment.

Personal Protective Equipment

Personal protective equipment (PPE) is the least effective method for controlling risk in
isolation, however it can be effectively used in conjunction with higher level controls to
minimise residual risk. Before beginning any pumping operation, you and the principal
contractor or person in control of the workplace should assess the conditions likely to affect
the health and safety of workers and arrange for the provision and use of appropriate PPE.
You must provide the PPE required to manage the risks and ensure workers are trained in
its correct use.
The following items of PPE may be required when pumping concrete:
 safety helmets
 eye protection
 face masks
 safety vests, and
 rubber safety boots.
The following may also be required:
 hearing protection, and
 gloves.

3.2.4. Maintain and review control measures

You should regularly review control measures to make sure they remain effective. This is
particularly important if there have been changes to the nature or duration of work.
Consulting with workers and their representatives, if any, can help determine if the control
measures are effective. You should also consider:

 if the control measures introduce any new risks

 if the workers are actively involved in identifying hazards or controls
 if incidents are occurring more or less frequently, and
 if any new information or equipment has been developed that may be effective.
If issues with the controls are found, the risk management process should be repeated to
identify additional ways to effectively manage the risks.

3.3. Information, training, instruction and

supervision
You must, so far as is reasonably practicable, provide any information, instruction, training or
supervision necessary to protect people from health and safety risks that arise from the work
carried out as part of the business or undertaking.
You must ensure that information, training or instruction provided to a worker is suitable and
adequate for:
 the nature of the work carried out by the worker

Concrete pumping
Guidance material Page 15 of 43
  the nature of the risks associated with the work at the time of the information, training
and instruction, and
 the control measures implemented.
You must also ensure, so far as is reasonably practicable, that the information, training and
instruction are provided in a way that is readily understandable for the person to whom it
is provided.
Information, training and instruction provided to workers should include:
 familiarisation with new or unfamiliar plant and work environments
 communication procedures between the concrete pump operators, ground workers
and any other relevant workers
 relevant information for operators, including how to operate the equipment correctly,
how to conduct pre-operational inspections and safe use of the pump
 the proper use, wearing, storage and maintenance of PPE
 the hazards and risks associated with the work performed
 how to follow the health and safety procedures associated with the work, including the
contents of any SWMS for high risk construction work
 emergency and rescue procedures, including how to position equipment to ensure
access to emergency controls is not obstructed
 procedures for reporting hazards and incidents, and
 control measures for other potential hazards, such as unstable ground.
Those supervising the work should also receive training. The amount and type of training
required will depend on the nature of the work and the risks involved.
You must not direct or allow a worker to carry out construction work unless the worker has
successfully completed general construction induction training and has carried out
construction work in the last two years, if the worker completed training more than two years
previously. You must also ensure the worker holds a general construction induction training
card or a general construction induction training certification issued within the preceding 60
days.
For further information on induction training, see the information sheet: Workplace induction
for construction workplaces.

3.4. Relevant competencies

Concrete pump and boom operators must be competent to safely operate the relevant
equipment. Competency is achieved through training and supervision and should be
assessed by testing both theoretical knowledge and physical operation of the equipment.
Anyone operating a concrete placing boom must hold the relevant high risk work licence.
Pump and boom operators should:
 be familiar with and operate the plant in line with manufacturer’s (or competent
person’s) advice and information contained within manuals and other documents,
including hydraulic pressure relief settings and maximum rated concrete pressure
 carry out the daily maintenance inspection, visual inspection of the pipeline and other
preoperational inspections in accordance with the manufacturer’s instructions, before
pumping commences
 ensure concrete pumping equipment is not left unattended while in operation
 pump concrete only when the hopper grate is in the closed position (grates should be
interlocked to prevent this)
 ensure pump flow rates match discharge rates of concrete delivery trucks

Concrete pumping
Guidance material Page 16 of 43
  be able to maintain a volume of concrete in the concrete pump hopper at levels that
will not allow air into the pump. The SWMS should include specifics of how this will be
achieved (e.g. automatic shut-off if level of concrete in hopper falls too low; or
additional competent person stationed at hopper to stop the pump)
 follow the directions of the line hand, and
 ensure a system of communication is maintained with the line hand.

Reporting defects
Pump operators should report defects immediately. If a defect is a hazard to safety, pumping
operations should be stopped until the defect is rectified. Details of reported defects and
subsequent action taken should be entered into a log book.

3.5. Licensing requirements

Under the WHS Regulations, a person operating a concrete placing boom must hold a high
risk work licence. Schedule 3 to the WHS Regulations identifies the classes of work that
require a high risk work licence. Operators of concrete placing booms must hold the high risk
work licence, Licence to operate a concrete placing boom.
You must not ordinarily direct or allow a worker to carry out high risk work unless you have
seen written evidence of the worker’s high risk work licence.
A person who operates a concrete placing boom is not required to be licensed if they are
undertaking training to obtain their high risk work licence and supervised by a person holding
the relevant licence. A licence is also not required if the work carried out is:
 solely for manufacturing, testing, trialling, installing, commissioning, maintaining,
servicing, repairing, altering or disposing of the concrete placing boom, or
 solely for the purpose of moving, loading or unloading the concrete placing boom in
the workplace.

3.6. Emergency plans

You must ensure an emergency plan is prepared for each workplace where concrete
pumping equipment will operate. You must ensure workers are trained and familiar with
emergency and rescue procedures. The plan must be tested in the workplace and include
emergency procedures like effective response, evacuation and notifying emergency
services.
Workers should know how to contact emergency services, with contact numbers easily
accessible. Signs displaying evacuation locations should be placed where they can be easily
seen.
Rescue equipment should be available and easily accessible. There should be processes in
place so that injured workers, including the concrete boom operator, can be rescued.

Concrete pumping
Guidance material Page 17 of 43
4. Planning and preparation for
concrete pumping operations
Planning and preparation is the first step in ensuring that work is done safely. Planning for
concrete pumping operations should start as early as possible in the development of any
work or project to help eliminate many of the associated health and safety risks. For planning
to be successful, it should involve consultation with all people engaged in the work. This may
include the principal contractor, any PCBUs, the electricity authority, designer, project
manager, road authorities and operators of the plant.

4.1. Registering a concrete placing boom

Concrete placing booms must be registered with a WHS regulator before they can be used
in the workplace. Concrete placing boom designs must be design registered before being
supplied, and the plant must also be item registered before being commissioned for use. The
concrete placing boom manufacturer or supplier must provide the design registration number
with the plant.
The concrete placing boom design registration number must be readily accessible in the
vicinity of the plant at all times. If a person modifies a concrete placing boom, they then take
on the duties of a designer under WHS laws. They must ensure the modified plant is safe
and the new design is design registered.

4.2. Pumping operation planning

Effective planning will help identify ways to protect people who are:
 directly involved in the concrete pumping work
 performing other work activities at the workplace, and
 the general public.
When planning concrete pumping operations, you should consider:
 liaising with electricity supply authorities regarding the safe supply of electricity and
control measures for working around existing power supplies
 the proximity to overhead and underground powerlines, eliminating electrical risks if
possible or using appropriate control measures to minimise risks, such as exclusion
zones. The concrete placing boom manufacturer may specify instructions for
operating near power lines which should be followed when planning concrete
pumping operations
 concrete pumping requirements, including concrete pumping equipment selection,
concrete delivery, ground conditions and site access, at the project design stage
 traffic control requirements
 ensuring that an emergency plan has been prepared for each workplace where
concrete pumping work will be undertaken
 providing additional safety observers and spotters, depending on the size and
complexity of the work
 ensuring plant is suitable for the work and minimises the risks of injury from
movements such as hose whip

Concrete pumping
Guidance material Page 18 of 43
  maintaining adequate clearances between mobile plant (such as cranes, elevating
work platforms, forklifts), mobile plant loads and concrete pumping equipment and
 ensuring you conduct negotiations between worksites, so you are able maintain
sufficient clearances when mobile plant and concrete pumping equipment operate on
adjacent worksites and share the same airspace.
Before commencing concrete pumping operations, you should ensure that:
 people not involved in concrete pumping (workers and members of the public) are
excluded from the work area
 if required, the spotter stays in view of the concrete truck driver while the truck is
moving. If the spotter is out of the view of the truck driver, the driver is to stop the
vehicle
 people in the concrete delivery area are wearing high visibility vests
 concrete trucks have audible reversing alarms and flashing amber lights
 permits have been obtained from the relevant authority where concrete pumps are set
up on, or adjacent to, public roads
 the weather conditions are suitable for the pour, and
 any necessary barriers and signage are in place, no matter how brief the occupation
of the site, for the:
o protection of workers and the public
o protection of the pipes and the pump
o provision of adequate warning of changes in surface condition, and the
presence of personnel or plant engaged in work on the road
o adequate instruction of road users and their safe guidance through, around or
past the worksite.
In addition, each pump unit should be equipped with the following items:
 first aid kit (including eye wash)
 fire extinguishers, and
 sufficient reflective traffic cones, signs (e.g. exclusion zone) and high visibility vests.

4.3. Safe work method statements

The WHS Regulations state that a SWMS is required for high risk construction work. Some
examples of high risk construction work most likely to be applicable to concrete pumping
include work carried out:
 in an area where there is any movement of mobile powered plant
 on, in or adjacent to a road, railway, shipping lane or other traffic corridor in use by
traffic other than pedestrians
 in or near a shaft or trench deeper than 1.5 m or a tunnel, and
 near energised electrical installations or services
A SWMS is a written document that must identify the high risk construction work activities to
be carried out at a workplace, the hazards and risks to health and safety arising from these
activities, the measures to be implemented to control the risks and how the control measures
are to be implemented, monitored and reviewed.
Its primary purpose is to help PCBUs, supervisors and workers implement and monitor the
control measures established at the workplace to ensure high risk construction work is
carried out safely.

Concrete pumping
Guidance material Page 19 of 43
Who is responsible for preparing a SWMS?
As a PCBU, you must prepare a SWMS—or ensure a SWMS has been prepared—before
high risk construction work starts.
The person responsible for carrying out the high risk construction work is best placed to
prepare the SWMS, in consultation with workers who will be directly engaged in the work.
If more than one PCBU has the duty to ensure a SWMS is or has been prepared, they must
consult and cooperate with each other to coordinate who will be responsible for actually
preparing it.
There may be situations where there are different types of high risk construction work
occurring at the same workplace. In these cases, one SWMS may be prepared to cover all
high risk construction work activities. Alternatively, a separate SWMS can be prepared for
each type of high risk construction work. If separate SWMS are prepared, consider how the
different work activities may impact on each other and whether this may lead to
inconsistencies between control measures.

SWMS content
The content of a SWMS should provide clear direction on the control measures to be
implemented.
SWMS must be accessible and understandable to any individual who needs to use it. It is
important that those who need to carry out work in accordance with the SWMS understand
the detail of the SWMS and what they are required to do to implement and maintain risk
controls. For example, it should consider the literacy needs and the cultural or linguistically
diverse backgrounds of workers.

Consultation
Workers and their health and safety representatives, if any, must be consulted so far as is
reasonably practicable when preparing a SWMS. If there are no workers engaged at the
planning stage, you must consult with workers when the SWMS is first made available, for
example during workplace-specific training or a toolbox talk. You must also consult with
workers and their health and safety representatives, if any, when a SWMS is reviewed.

Complying with a SWMS

If you are involved in high risk construction work, you must put in place arrangements to
ensure the work is carried out in accordance with the SWMS. The PCBU who directly
engages the workers performing the high risk construction work is best placed to implement
the SWMS and to ensure compliance.
A principal contractor must have a system in place to monitor compliance with the SWMS.
If work is not being carried out in accordance with the SWMS then the work must stop
immediately, or as soon as it is safe to do so. Work must not resume until it complies with
the SWMS. If another method is identified as being a reasonably practicable option, you
should revise the SWMS to take this into account before re-commencing work.

4.4. Concrete pumping equipment owner

The owner of concrete pumping equipment must take all reasonable steps to ensure that all
safety features and warning devices of the plant are operational and used in accordance
with the relevant instructions and training.

Concrete pumping
Guidance material Page 20 of 43
An owner who employs concrete pump operators should also ensure that operators have
undergone appropriate training and that line hands are trained and competent.
The owner must ensure that all information obtained from the manufacturer of the concrete
pumping equipment is supplied and readily available to those who need it (e.g. the concrete
pumping equipment manufacturer’s operating manual should be kept with the concrete
pump, and maintenance staff should have access to all current maintenance manuals). The
owner should ensure the design, maintenance records and all inspection reports for the plant
are available and signed off before deployment.

4.5. Concrete pumping equipment operator

A concrete pump operator must always operate the concrete pumping equipment safely.
Concrete operators are required to know:
 the model of plant to be operated, its characteristics, functions and limitations
 the information in the concrete pumping equipment’s operating manual, and
 any site conditions that may affect concrete pump operations, including the presence
of overhead powerlines and nearby structures and plant, for example cranes.
Before and during concrete pumping operations, the operator should:
 check unauthorised people are not present in the concrete pumping exclusion zone
 check each boom motion is safe and without risk
 complete the daily inspection checklist, including filling out the log book
 for mobile concrete placing booms, ensure outriggers are set according to the
manufacturer’s operating instructions for the specific type of mobile concrete pump
 monitor the safe use of the concrete pump, concrete delivery lines and boom (if fitted)
Note: In the case of satellite booms, the boom operator is responsible for the safe
operation of the boom but will not be able to monitor the hopper – a separate pump
operator located at the pump will perform this function. Likewise, the pump operator
on a satellite boom installation is not able to monitor the safe operation of the
concrete placing boom. In these cases, a reliable means of communication must be
provided between the boom operator and pump operator.
 in the case of mobile concrete placing booms, periodically check outriggers or
stabilisers for movement during operation
 be in view of the line hand and monitor the safe delivery of concrete, and
 monitor the concrete hopper.
Operators of concrete placing booms must hold the high risk work licence, Licence to
operate a concrete placing boom. Where the discharge hose needs to be moved, directed or
held during the pour, the concrete pump operator is not to carry out the task of the line hand
located at the end of the concrete delivery line.

Concrete pumping
Guidance material Page 21 of 43
5. Safe operation of concrete pumping
equipment
5.1. Setting up on site
When setting up a concrete pump, the area should be level, capable of supporting the load
and free of obstructions. If it is not possible to set up the pump on level ground, ensure that
the incline or angle of the machine does not exceed the manufacturer’s recommendations.
If outriggers are required, you should ensure:
 adequate outrigger pads (e.g. timbers) for packing the base plate are supplied
 the outrigger pads are clear of excavations, soft or filled ground, or other obstacles
 the outrigger pads have sufficient bearing area to support the machine
 the outriggers are regularly checked to ensure stability, and
 the outriggers are adequately protected from inadvertent impact (e.g. from passing
traffic).
Short legging is a practice that should be avoided wherever possible, due to the increased
risk of overturning the pump.
Take particular care when a concrete pump is used in the vicinity of an excavation. The
weight of the concrete pump, vibration and the load can affect the stability of the excavation
wall and cause the excavation wall to collapse, which may lead to the concrete pump
overturning. Do not position the pump over or adjacent to:
 previously disturbed ground that has been backfilled
 excavations, trenches or holes in the ground
 cellars, basements or pits, or
 inadequately compacted or soft ground.
The operator should immediately refer any concerns over the placement of the concrete
pumping equipment (i.e. if it is on unstable ground or near an excavation) to the principal
contractor.
Ensure unauthorised persons are kept away from the plant. Authorised persons working in
the concrete pumping exclusion zone should wear high visibility vests.
The area should be clearly marked and made safe from other traffic, ensuring there is clear
access for the safe movement of materials, equipment and persons. If concrete pumping
activity is taking place on or near the access way, put in place a second access way.
Setup areas should also be provided with clear access and adequate lighting at all times
during operation. Clearly post signage stating that the area is for authorised persons only.

Concrete pumping
Guidance material Page 22 of 43
 5.2. Maintaining stability of concrete placing
equipment
Ground factors
Ground conditions can vary dramatically from one workplace to another, and even within the
one workplace. Ground conditions can affect the stability of concrete pumping equipment
and may cause it to overturn and result in serious injury.
The following may affect ground stability:
 slope/gradient
 water (including mud and underground sources)
 the type of ground (e.g. clay, sand, rock)
 back-filled ground
 cavities or penetrations in the ground
 continued operation of the concrete pump in one location
 clearances to other services.

Wind loading
Do not operate mobile and satellite concrete placing booms in winds exceeding
manufacturer’s specifications. This information should be either on the manufacturer’s
identification plate on the unit or in the operating manual for the unit.

5.3. Role of a spotter

A spotter is a person who is trained and competent to observe and advise the pump/vehicle
operators, if the vehicle or the pump is likely to contact a person, structure or moving plant
on site.
The spotter should:
 have knowledge about working safely around moving plant, including the
understanding of escape routes and maintaining visibility
 understand the relevant traffic management guidelines for the site, including any site-
specific traffic management plan and SWMS
 understand exclusion zones, how the concrete pump operates and the limits of its
range of movement, and
 understand the potential of the equipment to encroach on exclusion zones or contact
people, structures, or plant.

5.4. Concrete delivery

The concrete delivery process poses risks to the concrete delivery truck driver, the concrete
pump operator, the allocated spotter, other workers working in and around the concrete
pumping exclusion zone and members of the public.
These risks include being hit or run-over by a delivery truck, or being trapped between the
delivery truck and hopper or between delivery trucks. Risks also include entanglement,
crushing and amputation from the concrete hopper and being struck by plant and other
material.

Concrete pumping
Guidance material Page 23 of 43
A checklist for safely receiving concrete delivery and delivering it to the pump hopper is
included in Appendix A.

5.5. Concrete pumping

When pumping concrete, there may be a risk of concrete lines bursting, lines becoming
unrestrained and pipe clamps being dislodged. Damage to delivery hose or the inappropriate
selection of the delivery hose may also cause the discharge of concrete under pressure.

A checklist for minimising health and safety risks when pumping concrete is given in
Appendix B.

Minimising the risk of hose whip

Hose whip is the term used to describe uncontrolled and rapid motion of the flexible rubber
hose on the end of a concrete placing boom or other concrete delivery line. Hose whip is
extremely dangerous and can occur during the concrete pumping operation itself or when
the line is being cleaned out.
People can be seriously injured or killed by being struck directly by the whipping hose itself,
being knocked over and hitting the ground or an object or being hit by ejected material.

A checklist for minimising the likelihood of injury from hose whip when operating concrete
pumping equipment is given in Appendix C.

Avoiding blockages
Concrete line blockages can be caused by mix design deficiencies, pipeline and joint
deficiencies and excessive component wear in parts of the concrete pump. This is
dangerous as blockages can cause segregation of the concrete mix, meaning components
of the mix do not bind together and start to separate.
A checklist for minimising risks associated with concrete line blockages is provided in
Appendix D.

Clearing blockages
The operator may be able to break an aggregate jam loose by alternately reversing the
pump and resuming pumping a few times. Though a minor blockage can be cleared in this
way, no amount of pressure will clear a major blockage. Do not continue the reversing
process for more than a few attempts because it can make the blockage even tighter.
If reversing the pump does not work, an alternative method needs to be carried out to locate
the blockage.
When attempting to clear a blocked concrete delivery line, follow the checklist provided
Appendix D to minimise risks to health and safety.

On-site line cleaning

Dislodged concrete and plugs used for cleaning can act as a high-velocity projectile,
potentially striking both workers doing cleaning and others nearby. You should undertake
and document risk assessments to effectively control the risks of line cleaning.
When performing line cleaning, follow the checklist given in Appendix E.

Concrete pumping
Guidance material Page 24 of 43
On-site pump cleaning
Entanglement, crushing, and amputation hazards exist in a concrete hopper and pumping
device.

To minimise risks to health and safety when cleaning a pump on-site, follow the checklist
provided in Appendix E.

5.6. Traffic control

Concrete pumping is often carried out in busy, trafficable areas. Motorists, cyclists,
pedestrians, delivery truck drivers and workers may interact with concrete pumping
equipment as it arrives and is set up in the designated concrete pumping area.
There are numerous ways to control the risks associated with working on roads or road-
related areas. Examples of traffic control measures that may be considered include:
 road closures
 footpath closures
 detours
 protective barriers, and
 traffic controllers.
Where concrete pumping involves multiple truck deliveries, there should be a spotter,
separate from any traffic controllers in place, who is responsible for controlling the delivery of
the concrete trucks.
Further information can be found in the Workplace traffic management guidance material.

5.7. Preparation for road travel

The manufacturer’s instructions must always be followed. Where appropriate:
 secure outriggers (both hydraulic and manual), with a locking device specified by the
manufacturer and stow in a travelling position to prevent lateral movement
 stow loose components (such as pipes, couplings and tools etc) in appropriate
storage areas in accordance with manufacturer or other any relevant published
guidelines
 disengage all drives to hydraulic pumps (for operating the concrete pump), boom
and/or outriggers, and put the controls in the off position, and
 restrain booms in accordance with any manufacturers’ instructions to ensure there is
no unintended movement.

5.8. Noise
Operators of concrete placing equipment should be provided with suitable hearing protection
and relevant training. The operator should remain aware of changes in noise levels during
operation which may be an indicator of an unsafe condition.

Concrete pumping
Guidance material Page 25 of 43
 5.9. Fumes
If possible, place the truck in a position that will eliminate or reduce the build-up of exhaust
fumes.
If it is necessary to place the truck in an enclosed area, ensure that an adequate level of
ventilation is maintained to prevent the build-up of hazardous exhaust fumes or that exhaust
fumes are vented to open air.
You should ensure fumes are dispersed if the concentration level is likely to exceed safe
levels, particularly when working in enclosed spaces.

Concrete pumping
Guidance material Page 26 of 43
6. Working near overhead powerlines
Electric lines can have significant risks including electrocution, arcing, explosion or fire
causing burns, unpredictable cable whiplash and other objects being electrified like signs,
poles, trees or branches. Contact with energised overhead or underground electric lines can
be fatal regardless of the voltage they carry. It is not necessary to touch an overhead electric
line to be electrocuted. A ‘flashover’ or ‘arc’ can electrocute people when close to a line
conductor.
Ensure, so far as is reasonably practicable, no person or concrete pumping equipment at the
workplace comes within an unsafe distance of an overhead or underground electric line.
If this is not reasonably practicable, carry out a risk assessment and implement control
measures to manage the risks. The control measures must be consistent with requirements
of the relevant electricity supply authority.
A safety observer should be used when the concrete pumping equipment is in motion and
likely to enter a restricted work zone established around electric lines.
Most risks can be controlled by observing safe working distances for people and concrete
pumping equipment working near electric lines. Safe working distances will depend on the
type of work and the voltage of the electric lines. Contact the relevant electricity supply
authority to determine the type of control measures required. This may include isolating the
electric line for the duration of the work.
Contact with energised overhead electric lines may have an impact on parts of the concrete
pumping equipment. If contact occurs, the concrete pumping equipment should be
immediately placed out-of-service until it has been inspected by a competent person and
proven to be safe to use.
Further information can be found in the General guide for working in the vicinity of overhead
and underground electric lines.

6.1. Electrical safety laws

Information about requirements for working near overhead powerlines can be provided by
your local electrical safety regulator.
Contact details for your local electricity safety regulator can be found on the Safe Work
Australia website.

6.2. Planning for work near overhead

powerlines
Contact with overhead powerlines can pose a risk of electric shock or electrocution when
operating a concrete placing boom. Do not operate concrete placing booms over the top of
energised powerlines for the following reasons:
 the shape and height of the boom does not allow for a large separation distance from
the powerlines
 boom movement may occur due to pumping motions, wind and ‘bounce’ as the boom
is handled, and

Concrete pumping
Guidance material Page 27 of 43
  it can be extremely difficult for safety observers observing from the ground to judge
distances and determine clearance from the powerlines.
Before setting up a concrete placing boom near overhead powerlines, you should conduct
an inspection to identify the presence of overhead powerlines that may pose a risk.
The most effective way to eliminate any risk of electric shock is by turning off the power. You
should discuss options for de-energising or re-routing the electricity supply with the relevant
electrical network operator (electricity supplier).

6.3. Approach distances

Prior to starting work, you should determine what approach distances and work zones (see
Figure 1) are required for the safe operation of the concrete pumping equipment and the
safety of the operator and other workers.
The approach distance for each work zone will vary depending on the voltage of the
overhead electric line and the level of authorisation of each person doing the work. As the
risk increases, a greater approach distance is required.
There are three work zones (see Figure 1 below):
 Zone C is a No Go Zone closest to and surrounding the electric line where Electricity
Supply Authority approval is required. A ‘permit to work’ may be required.
 Zone B surrounds the electric line and is further away than Zone C. It is for authorised
people. Authorised people are workers who have successfully completed a recognised
training course in overhead line electrical hazards so are permitted to work in Zone B.
 Zone A is furthest away from the electric line and is for unauthorised people.
Unauthorised people are workers who have not received training in overhead line
electrical hazards and do not have sufficient training or experience to enable them to
avoid the dangers from overhead electric lines and associated electrical equipment.
Figure 1 Work zones in the vicinity of overhead electric lines

Refer to the relevant electrical safety authority for further advice. Australian standard
AS2550.15:2019 Cranes, hoists and winches – safe use – concrete placing equipment
provides additional guidance.

6.4. The safety observer zone

Concrete pumping equipment is in a safety observer zone when it is possible that a

Concrete pumping
Guidance material Page 28 of 43
 part of the plant or a person, equipment or tools could enter zone B operations.
A concrete pump is not operating in a safety observer zone when:
 high voltage electric lines have been de-energised, isolated or earthed
 limiting devices are used to warn the operator or prevent any part of the plant from
entering Zone B—as long as the limiting device is effective under stress conditions
and is regularly inspected by a competent person, or
 physical barriers stop any part of the plant entering Zone B.
Figure 2 Safety observer zone for overhead electric lines on poles and towers

6.5. Safety observer

A safety observer should be used when the concrete boom is in motion and is likely to enter
Zone B. The safety observer should:
 mark the border of Zone B with suitable markers e.g. red warning tape easily seen by
the operator
 warn the operator if a part of the concrete pumping equipment is about to enter Zone
B
 stop unauthorised people entering Zone B
 communicate effectively at all times with the operator and warn them about an
approach to Zone B
 be provided with specialist communication equipment where there is a barrier to
communication
 be trained to perform the role, and
 have the authority to stop the work at any time.
A safety observer is used to observe and advise the pump operator if the line or any part of
the pump is likely to come within an exclusion zone of an overhead powerline.
Authorised people who work closer than Zone B and safety observers who observe the work
should successfully complete a relevant training course provided by a registered training
authority. They should be assessed as competent to carry out their work tasks in the vicinity
of energised electric lines and exposed parts, and written certification should be verified.
Safety observers must be competent to implement control measures in an emergency and to
rescue and resuscitate a worker if necessary. Authorised people and safety observers must
be re-assessed annually to ensure their ongoing competency to rescue and resuscitate and
should also be re-assessed to ensure their competency to work in the vicinity of overhead
electric lines.

Concrete pumping
Guidance material Page 29 of 43
The safety observer should encourage concrete pumps to be located away from the
exclusion zone to prevent possible contact. When that is not possible, adopt other suitable
precautions to prevent encroachment.

6.6. Controlling risks

Where it is reasonably practicable, the hazard must be eliminated, for example by
removing energised electric lines from work areas. Consider:
 de-energising the electric line, or
 isolating and earthing the line for the duration of the work, or
 re-routing the electric line away from the work area.
Where elimination is not reasonably practicable, the risks must be minimised.
Consider substituting the hazard or work practice with something safer, for example
by using alternative plant that cannot enter an unsafe zone.
You must ensure, so far as is reasonably practicable, that any person, part of the
concrete placing boom and/or the drop hose does not enter Zone B.
There are many ways this could be achieved, such as:
 setting up the concrete placing boom in a position that keeps it outside the restricted
work zone
 erecting a physical barrier, made of non-conductive materials, to prevent any part of
the concrete placing boom or person entering an unsafe distance. This may require
isolating the electricity supply while the barrier is installed.
When implementing a system to maintain the exclusion zone, consider factors including:
 identifying the minimum clearance distance from the closest part of the concrete
placing boom to the powerline
 allowing for sway or sag of the powerlines (sway is usually caused by wind, while sag
may vary as the temperature of the line varies)
 ensuring that persons, plant and vehicles always stay outside the restricted work
zone, and
 using a safety observer who observes the operation of the concrete placing boom.
The identified minimum clearance distance may need to be greater than the prescribed
distance to ensure there is no breach of the restricted work zone.
There are devices available that assist in increasing protection from a hazard, including:
 warning signs to indicate the location of overhead powerlines
 tiger tails or line markers on overhead powerlines to act as a visual aid to highlight the
location of the powerline.
Unloading and setting up of concrete pumping pipes also poses a risk of contact with
overhead powerlines. Keep pipes parallel to the ground when setting up near overhead
powerlines.

6.7. Contact with power lines

If contact with power lines is made:
 stay calm
 do not attempt to touch the concrete pumping equipment until a competent person
says it is safe to do, in case the plant is ‘live’

Concrete pumping
Guidance material Page 30 of 43
  if you must leave the concrete pumping equipment, for example in the event of an
imminent hazard such as fire, jump clear to the ground with both feet together. Do not
remain in contact with the concrete pumping equipment when you land on the ground.
Shuffle or jump with both feet together away from the plant as the ground may be
charged. Jump or shuffle until you are at least eight metres clear of the vehicle,
powerlines or anything in contact with them
 keep the area clear of people, including workers and pedestrians
 notify the site manager/supervisor and call the relevant authorities immediately
 if possible, follow a competent person’s advice and attempt to break contact with the
powerline
 if a competent person says it is safe to do so, exit the machine. The machine should
be checked for arcing and other damage. Inform the local power authority so they can
check and repair the power lines, and
 keep a safe distance from the concrete pumping equipment and the powerlines until
help arrives.

See the Working in vicinity of underground and overhead electricals lines guidance material
for further information.

Concrete pumping
Guidance material Page 31 of 43
7. Inspection and maintenance
7.1. Concrete placing booms
You should ensure that concrete placing booms are regularly maintained in accordance with
manufacturer’s instructions to prevent structural or mechanical failure. Due to the pulsating
nature of concrete pumping operation, equipment is prone to fatigue cracks and also rust
from water ingress.
When inspecting concrete placing booms, consider:
 all functions and their controls for speeds, smoothness of operation and limits of
motion
 all emergency and safety devices
 lubrication of all moving parts, inspection of filter elements, hydraulic oil, and coolant,
as specified by the manufacturer, and
 visual inspection of structural components and other critical components such as
fasteners, pins, shafts, welds and locking devices.
The erection and dismantling of concrete placing booms should be conducted in accordance
with the manufacturer’s instructions. Refer to Australian Standard AS2550.15:2019 Cranes,
hoists and winches – safe use – concrete placing equipment for further guidance.

7.2. General
Appropriate planned inspections and preventative maintenance programs are essential for
safe operation of concrete placing equipment. The inspections and maintenance should be
carried out at intervals as specified by the manufacturer.
You should also ensure that all warning and safety signs/stickers are in good condition,
legible and positioned on all equipment (after being inspected and found to be serviceable).

7.3. Pre-operational inspections

Before the start of each work period, all concrete pumping/placing equipment should be
given a visual inspection and function test. You should follow the manufacturer’s instructions
and recommendations.

7.4. Routine inspections

You should establish an appropriate program of monthly inspections of all equipment to
identify if preventative maintenance is required, in accordance with the manufacturer’s
recommendations. You should consider the equipment’s working environment and its
frequency of use. Keep details of these inspections in the appropriate log book, and a copy
kept in the unit.

Concrete pumping
Guidance material Page 32 of 43
 7.5. Periodic inspections
All concrete pumping equipment should be inspected by a competent person in accordance
with the manufacturer’s specifications, or at least annually.
Where not specified by the manufacturer, inspection intervals should be based on actual
hours of use (as recorded by the operating-hours meter), increasing in frequency as the
plant ages.
The periodic safety inspection includes a comprehensive inspection of the plant, its support
structure, and outriggers (where fitted).

7.6. Inspection report

A comprehensive inspection report should be completed prior to the plant re-entering
service. The report should include:
 a summary of the history of the concrete pumping equipment prior to the periodic
inspection being carried out, unless this is unavailable (if unavailable, the periodic
inspection is likely to be more comprehensive)
 where provided, a copy of the inspection criteria specified by the manufacturer
 extracts of the manufacturer’s maintenance manual detailing wear tolerances, bolt
torques, and other relevant instructions followed during the inspection process
 a list of work carried out on the boom
 photographs of the unit during the inspection process including photos of damage,
wear or cracking
 a list of competent persons carrying out work on the unit as part of the inspection
 signed statements from persons involved in the assembly process in relation to:
o slew ring bolts being installed correctly (taking into consideration bolt type,
lubricant if used, and bolting sequence)
o pin and pin retainers installed correctly
o hydraulics components installed correctly including a statement that replaced
hydraulics components meet the manufacturer’s specifications and that fittings
have all been tightened to the correct torque
 confirmation that hydraulic cylinders have been creep tested and are satisfactory, and
 a summary of parts replaced with copies of receipts for parts provided in the report
appendices.
Where some of the work has been contracted to external parties, provide a description of
this work and copies of invoices in the appendices.
Where the competent person has made the decision not to dismantle the plant, or parts of
the plant, they should document a comprehensive rationale for their decision.

7.7. Repair following an incident

In the event of an incident where structural failure has occurred or the plant has overturned,
ensure the plant is assessed by the boom manufacturer or a competent person. Analyse the
circumstances of the incident to determine the main contributing factors and possible
reasons for the failure (i.e. soft ground, design abnormalities, normal wear, collision with
other plant, etc).
Where the plant is to re-enter service, the manufacturer or competent person may oversee
the following additional measures:

Concrete pumping
Guidance material Page 33 of 43
  determine the components that may have been damaged that will need to be
inspected
 dismantle the plant, if needed, to enable the inspection of potentially damaged
components
 replace damaged components with new components that meet the design
specifications of the manufacturer
 function test the re-assembled boom, including through load testing, and
 prepare a detailed report on the repair of the boom that includes a statement that the
concrete placing boom is safe to operate.

7.8. Log books and inspection record sheets

Records of tests, inspections, maintenance, commissioning, decommissions, dismantling,
and alterations must be kept for registered concrete placing booms and made available for
examination as required.
Records must be kept for the period the concrete pumping equipment is used, or until control
is transferred to another person. The following should also be adhered to:
 keep instruction manuals (with sufficient instructions for operation, maintenance and
repairs) with the pump unit and/or boom
 keep all manuals up-to-date with any additional information from the manufacturer
 keep maintenance and repair manuals in a safe place at the registered premises,
including a parts catalogue
 keep maintenance log books up-to-date, on the pump, and available on request at the
workplace, and
 ensure all log books and inspection record sheets show complete details of all
inspections, tests, repairs, replacements and modifications carried out.
Keep evidence that the pump and associated equipment have been inspected and certified
as ‘suitable for continued service’ (i.e. in a safe working condition) with the unit. They should
be available to the principal contractor or person in control of the workplace for inspection
(on request) before the unit is allowed to operate on site.

Concrete pumping
Guidance material Page 34 of 43
Appendix A – Concrete delivery
This table provides useful information on managing health and safety risks when receiving
concrete delivery and delivering concrete to the pump hopper. This list is not exhaustive.

When receiving concrete delivery:

Do the concrete delivery trucks have clear and safe access to approach
and leave the receiving hopper of the pump?

If necessary, is a spotter or traffic controller being used to safely direct the

movement of the trucks?

Are all concrete delivery trucks fitted with flashing hazard lights and audible
reversing lights that are activated when the truck is in reverse?

Have you ensured no worker is standing between the reversing concrete

delivery truck and the hopper?

Have you ensured concrete delivery trucks do not reverse into the exclusion
zone if they cannot see the spotter or traffic controller?

Have you ensured the concrete chute on concrete trucks is only moved
when the truck is stationary?

It is preferable that for the truck driver to perform this task. If another worker
carries out the task, first obtain permission from the driver

Is the concrete receiving hopper at a height that allows a gravity flow of

concrete into the hopper?

Where low slump concrete is to be used and additional ramping is available

for the concrete delivery truck, are the ramps specifically designed to
ensure the truck cannot back off the ramps, ensure the truck remains stable
and have a non-slip surface?

When delivering concrete to the pump hopper:

Is the receiving hopper positioned so it can receive a concrete flow readily?

Have you provided a grate to prevent access to dangerous moving parts

such as agitator mechanisms and valve gear?

Are the hopper grates functioning and designed for opening fitted with an
interlock system that de-activates both the paddles and the valve gear?

Concrete pumping
Guidance material Page 35 of 43
 Is the emergency stop button accessible to the concrete pump operator?

Is the grate constructed of parallel bars which are spaced so that it is not
possible for a person’s hand to reach the danger area of the agitator and
valve gear?

Concrete pumping
Guidance material Page 36 of 43
Appendix B – Concrete pumping
This table provides useful information on managing health and safety risks when pumping
concrete. This list is not exhaustive.

Is only the line hand located directly under the boom?

This is needed to effectively move the concrete placing boom’s drop hose. Only
the line hand can be directly under the concrete placing boom. However, the time
spent under the raised boom can often be reduced by manoeuvring the hose
from the side to avoid working directly under a raised boom.

Have you checked the delivery hose for damage prior to it being fitted?

Where the delivery hose is positioned over or above any working or public area,
has it been fitted with a suitable stop at the outlet end?

Have you avoided damage to the hose during use?

Have you ensured the delivery hose fitting on the boom pump is secured in
position by a safety chain, sling or other retaining device?

Are you using a delivery hose that has a pressure rating to accommodate the
pumping concrete pressure?

Have you followed manufacturer’s requirements on the maximum size and length
of hose that may be suspended?

Are reducers being used as per the manufacturer’s recommendations to avoid

overload of the delivery hose or other parts of the unit?

Is the line hand wearing suitable eye protection (i.e. complying with AS/NZS 1336
Eye and face protection guidelines)?

Concrete pumping
Guidance material Page 37 of 43
Appendix C – Minimising the risk of
hose whip
This table provides useful information on managing health and safety risks of concrete
pumping through minimising the likelihood of hose whip. This list is not exhaustive.

Have you ensured you only pump concrete that is a pumpable mix as specified
by the concrete supplier?

Other types of concrete can block the line and cause hose whip

Have you ensured that concrete has not solidified in the line?

Are you using appropriately trained operators?

Have you started the pump up slowly?

Have you ensured you are not using a rubber delivery hose with metal fittings
attached to the free end?

Have you set up an exclusion zone?

Have you ensured you do not stretch the delivery hose to reach the pouring
location?

Are flexible hoses on line pumps secured in place when priming or clearing
blockages?
Are workers wearing the appropriate PPE, including safety helmets?

Are you maintaining good housekeeping around the work area to reduce the
likelihood of tripping?

Have you ensured you do not let more hose hang from the boom than that
allowed by the plant manufacturer?

Have you ensured you do not allow concrete to drop out of the hose when
pumping is stopped, as this can allow air to enter the system?

Have you blown out or sucked in the mix in the lines before moving the boom?

Have you sought verification from the concrete delivery truck owner of when the
bowl was last descaled/debagged?

Concrete pumping
Guidance material Page 38 of 43
 Have you maintained an adequate level of concrete in the hopper to prevent air
ingress?
Have you kept watch of the consistency of the mix and advised the operator of
any issues?

Have you used the emergency stop if lumps or objects are identified?

Concrete pumping
Guidance material Page 39 of 43
Appendix D – Blockages
This table provides useful information on managing health and safety risks through avoiding
blockages when pumping concrete and safely clearing them when they occur. This list is not
exhaustive.

To avoid blockages:
Have you ensured the concrete mix is not too stiff or too wet?

A mix that is too stiff can’t be pumped because it will not fill the pumping cylinders
and the pumping pressures will be excessive. A mix that is too wet can cause the
mix components to segregate by allowing heavier materials to settle.

Where recycled or remanufactured aggregate is used, have you checked whether

an additive may be required to assist with binding the mix together?

Is the system sized or designed properly for the pump capacity to ensure the
pumping pressure is sufficient to move the concrete over the full length of the
pipeline?

Have you adequately primed and lubricated the pipeline prior to commencing the
concrete pumping operation?

Have you minimised the number of bends and short bends in the pipe or hose, as
these will increase the concrete pumping pressure?

If the reducer connecting the concrete pump to the pipeline system is too abrupt,
the pumping pressure can increase and cause a blockage.

Have you cleaned pipelines and hoses properly to avoid blockages caused by the
setting of old concrete?

Have you replaced damaged or defective couplings, gaskets, or weld collars?

Excessive component wear in parts of the concrete pump can cause segregation
of the concrete mix and lead to blockages.

When clearing blockages:

Have all people been excluded from the pipeline area, except for workers
involved in clearing the line?

After locating a blockage or rock jam, have you ensured the line is no longer
under pressure before attempting to clear it?

Reverse the pump to reduce the pressure.

Concrete pumping
Guidance material Page 40 of 43
 Have you ensured you do not straddle a horizontal line when opening a coupling?

You should stand to one side and lift the line so that free-flowing concrete runs
out. Bend the hose or tap on the pipeline near the jam and shake out loose
particles

If pressurisation of the line is used to clear the blockage, have you taken
particular care to exclude all people from the line vicinity and, in particular, the
delivery hose, in case of hose whip?

Restrain the hose from movement and attach a catchment device or properly
designed receptacle to the discharge end of the pipeline to safely catch any
projectiles, while still allowing concrete to flow. Workers should not try to restrain
the hose by hand.

Concrete pumping
Guidance material Page 41 of 43
Appendix E – Cleaning
This table provides useful information on managing health and safety risks when cleaning
the concrete delivery line. This list is not exhaustive.

When cleaning the concrete delivery line:

Have you ensured only competent persons carry out line cleaning?

Have you followed manufacturer’s instructions?

Have you used water in preference to air to minimise the risk of projectiles?

Have you ensured there is always a connection to atmosphere (air relief valve)
as well as the air entry point to the pipeline?

This allows the system to be depressurised before removing any pipeline. Do

not attempt to take a line apart to clean out a blockage or to dismantle it until
after the pressure has been relieved.

Have you ensured no pipeline connection or fitting is disconnected unless it is

free of internal pressure?

Have you ensured the pump operator remains at the pump controls while the
pipeline is pressurised?

Have you ensured you always remove the rubber delivery hose at the end of the
pipeline, so that the hose cannot whip if the line is blown out?

Are all parts of the pipeline secured to prevent movement during purging?

Is a positive catchment device or properly designed receptacle attached to the

discharge end of the pipeline to safely catch the cleaning device?

Have you restrained concrete lines from moving (if using a properly designed
receptacle, such as a concrete truck bowl)?

Restraint by attachment to the concrete truck’s ladder is not an adequate

control.

Have you ensured all workers are kept away from the discharge end while the
concrete is under pressure?

Are all workers involved wearing adequate PPE?

Concrete pumping
Guidance material Page 42 of 43
 When cleaning the concrete pump:
Have you fitted and maintained a physical barrier at all times during operation to
prevent a person contacting moving parts in a hopper?

Where cleaning or dislodgement of material requires a worker to enter the

hopper, have you shut down the equipment and exhaust any accumulated
hydraulic or air pressures that may allow the elements to move or rotate, even
with the engine stopped?

Have you ensured that cleaning is not undertaken alone?

Concrete pumping
Guidance material Page 43 of 43