Boom pump safety basics

Why boom pumps need their own safety approach

A boom pump combines a heavy truck, a long articulated arm and a high-pressure concrete line. When something goes wrong, the energy involved is large: a tipping machine, a falling boom section, a line failure or a whipping hose can all cause serious injury.

Most incidents can be traced to a small number of causes, which is good news, because they are preventable with a consistent routine.

Site assessment before arrival

Safe pumping starts before the truck leaves the yard. Find out about the ground where the machine will stand, access for the truck, overhead lines, underground services, nearby people and the area where the boom will swing.

A site walk with the builder or supervisor should confirm:

• Where the pump will stand and whether the ground is firm and level enough
• Where overhead power lines run, and the required clearance distances
• Where the boom will travel and where concrete will be placed
• Where trucks will queue and discharge
• Who will be in the placing area, and where the exclusion zone will be

Setting up on the outriggers

Outriggers must be extended as the manufacturer specifies, because boom limits are based on a fully supported machine. Place each foot on a spreader pad or equivalent so the load spreads over a bigger area.

Watch for soft ground, recent fill, trenches, drains and basements. Ground bearing pressure under a loaded outrigger can be much higher than people expect, and a leg that sinks can lead to a tip-over. If the ground is uncertain, stop and get it assessed or reinforce it before unfolding the boom.

Level the machine, check the leg locks and confirm the setup before the boom comes off its rest.

Power lines

Contact between a boom, a hose or a stream of concrete and a live line can be fatal, and the danger extends beyond physical contact because electricity can arc across a gap. Regulations set minimum clearance distances that depend on voltage and location.

If lines are near the work, the safest plan is to avoid working under or near them. Where that is not possible, contact the line owner about making the lines safe, use spotters, and set up so that the boom cannot reach the restricted zone. Never assume a line is dead.

People, communication and the exclusion zone

Keep everyone who is not needed out of the work area. The placing crew must stay clear of the boom path and use agreed hand or radio signals. Anyone near the end hose should be aware of hose whip, which can happen suddenly when flow surges or air passes through the line.

The operator should stand where they can see the boom tip and the pour, or use a spotter when they cannot. Use the remote control correctly and keep the emergency stop in reach. Make sure the crew knows what an emergency stop signal looks like.

Operating within limits

Do not exceed the boom's rated reach, do not use the boom to drag or lift, do not pull on the end hose and do not bend the boom beyond its allowed angles. Follow the manufacturer's rules on end hose length and on adding extensions.

Wind matters. Strong gusts add load to the boom and make the end hose harder to control. Know the machine's wind limits and stop when conditions go beyond them.

Blockages and pressure

A blockage is a pressurised hazard. Never open a coupling on a line you think might be blocked until the pressure has been relieved, and keep people clear of the line while you do it. Use the correct clearing procedure for the machine, including reverse pumping where appropriate.

Remember that trapped air stores energy, so a plug that moves can release it suddenly.

Shutdown and travel

At the end of the pour, clean out the boom and line properly and send the cleanout material to the correct place. Fold the boom fully, engage the locks, retract and stow the outriggers and walk around the machine before moving.

Treat the pre-pour inspection as a routine part of every job, and record faults so they get fixed.

Terms in this article

• Boom pump
• Outrigger
• Spreader pad
• Ground bearing pressure
• Overhead power lines
• Exclusion zone
• Hose whip
• End hose
• Remote control
• Emergency stop
• Tip-over

Keep reading

• A short history of concrete pumping
• Line pump safety basics
• Pre-pour boom inspection checklist