Construction
Concrete Pumping Risk Assessment: Practical Steps, Hazards, and Controls
Nov
Why a risk assessment matters
A proper assessment sets out the people at risk, foreseeable hazards, and controls tied to site-specific methods (pump selection, pipeline routing, work area, emergency plans). The source document outlines supervision structure, working conditions/shifts, equipment lists, and step-by-step responses to blockages, bursting, and pump failure—making it an ideal template for live jobs.
Core hazards & controls (from the site RA table)
The Risk Assessment table for cleaning out delivery lines of a static pump lists hazards, who may be harmed, and controls. Key items include:
- Bursting pipes / high-pressure discharge → Major injury or death risk to workers and anyone near inlet/discharge.
Controls: Blow-out only under a qualified operator’s supervision; two-person control; fit a catching basket at outlet; use shut-off valves; cordon danger zones; never dismantle lines until fully depressurised. (See Annex 4 table.) - Concrete burns / cement dermatitis → Skin/eye hazards to all cleaning crew.
Controls: Gloves, long sleeves, goggles/face protection, washing facilities. (Annex 4.) - Falling materials/tools at discharge point → Major injury risk to operators and nearby workers.
Controls: Keep tools tethered; protect workers below; enforce exclusion zones; good lighting and housekeeping. (Annex 4.) - Flying particles during blow-out → Major injury risk to anyone nearby.
Controls: Barriers and spotters; clear warnings before blow-out; confirm line is connected to catching device before air; controlled, stepwise pressurisation; only trained staff in zone. (Annex 4.) - Slips, trips, and falls → Reportable injuries during hose handling and cleaning.
Controls: Cable and hose management, non-slip surfaces, housekeeping, supervision. (Annex 4.)
The Risk Rating Matrix (R/R) defines severity vs. likelihood and classifies outcomes (Low → High risk), guiding which tasks require additional controls or re-planning before work. (See “Risk Rating (R/R)” sheet.)
Supervision, crews, and working conditions
The document prescribes a named manager, pump and placing boom operators, and assistants, with relief periods to manage fatigue. It also permits extended pours with shift planning (including double shifts for >14-hour operations), all tied to the contractor’s requirements and start times. (See “Supervision,” “Working Crews & Shifts,” and “Working Conditions”.)
Equipment & work environment
Typical plant includes static pumps (e.g., Schwing BP series), placing booms (up to ~50 floors), steel line (e.g., 125 mm, bends, clamps), reducers, and shut-off valves. The work area must be barriered with clear access/egress, safe zones around the hopper and boom, and danger zones marked per the layout sketch in the annex. (See “Equipment” and “Annex 2: Danger Zones”.)
Safe procedures you must document
- Pipeline lubrication (start-up & line change)
- Use Prime-a-Pump slurry at the specified ratio (e.g., ~454 g per 30 L water per 50 m line).
- Wear PPE (dust mask, gloves, eye protection) and manage spill risks—the product is extremely slippery. (See “Instruction for lubricating the pipeline” + Annex 3 MSDS.)
- Cleaning the line (post-pour)
- Clean from top down on high-rise pours, using a catching basket, sponge balls, and a compressor (~8 bar minimum); blow-out only by a qualified pump operator. (See “Instruction for cleaning the pipeline”.)
- Blockages & bursting – decision trees
- Blockage: Reverse pump briefly; if small, clean and lubricate; otherwise change to spare line and then clear original.
- Bursting: Change to spare line, lubricate, and repair damaged pipeline before resuming. (See flowcharts.)
- Pump failure contingency
- Short-term: Crane concrete in skips while repairs are arranged; if downtime exceeds limits, replace the pump to resume. (See “Instruction in case of pump failure”.)
- Changing pipeline
- Close gate valve, depressurise, disconnect before reducer, install pre-cut bends/lengths, and reconnect between core wall and boom as shown in the diagrams. (See “Instruction for changing the pipeline” + Figures.)
- Danger zones & exclusion areas
- The annex sketch shows no-go zones around hopper, boom sweep, and discharge. Post signage, barriers, and a banksman to control entries—particularly during blow-out. (See Annex 2.)
Pre-pour checklist (use/adapt on your jobs)
- Method statement approved; named supervisor and competent pump crew briefed.
- Pipeline layout fixed and supported; general layout drawing reviewed with team.
- Prime-a-Pump materials, PPE, catching basket, sponge balls, compressor, valves, and reducers on site.
- Exclusion zones set, barriers/signage in place; communication plan for blow-out.
- Emergency actions briefed: blockage, bursting, pump failure, and manual shut-off points.