Concrete Pumping — Safe Work Method Statement
Safe Work Method Statement for concrete pump setup, operation, and washout including boom pump and line pump operations, in compliance with Australian WHS legislation and AS 2550.15.
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Concrete pumping involves the use of registered plant — boom pumps and line pumps — to transport and place concrete under high pressure. This work is HRCW under Schedule 3 of the model WHS Regulations where the boom operates at height exceeding 2 metres, or where the work is associated with elevated slab construction, and requires a SWMS to be prepared before work commences. The key Australian standard governing safe use of concrete pumps is AS 2550.15 (Cranes, hoists and winches — Safe use — Concrete placing equipment).
Concrete pump operators must be trained and assessed as competent in accordance with AS 2550.15 and the manufacturer's operator manual. Boom pumps are registered plant under the WHS Regulations and must have current registration, a current design registration, and a maintenance log. In Queensland, boom pump operators may be required to hold a specific plant operator certificate; users should confirm current requirements with their state WHS regulator. The pump contractor is responsible for ensuring the plant is maintained, safe for use, and operated by a competent person.
Key hazards in concrete pumping include boom collapse or structural failure, pressurised line blockages and blowouts (capable of causing fatal injuries), being struck by the placing hose during operation, cement burns from contact with wet concrete, and traffic and plant interaction during setup on constrained urban sites. Line blockages must be cleared using safe procedures — drilling or striking a blocked line is prohibited. All pressure must be relieved from the system before any maintenance or line change is attempted.
When customising this template, document the pump type and model, boom reach and safe working load, site access route for the pump truck, slump and pump-ability of the concrete mix, pipeline layout, and the specific controls for clearing any anticipated blockages. A pre-pour pump test should be conducted and documented, and communication protocols between the pump operator and concrete placer must be established and clear.
This SWMS applies in all Australian states and territories. Victorian users should also comply with the OHS Regulations 2017 and the Equipment (Public Safety) Act 1994 regarding plant registration.
Personal Protective Equipment
High Risk Construction Work Types
- •Work at height involving the risk of falling more than 2 metres
- •Work on or near energised electrical installations or services
- •Work involving the use of explosives
Risk Assessment
1.Site assessment and pump positioning
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Boom pump contact with overhead powerlines during boom deployment | Catastrophic | Before positioning the pump, conduct a site inspection to identify all overhead powerlines within the boom's working radius. The boom pump must not be set up within a horizontal distance where the deployed boom could come within 3 metres of any overhead powerline (or greater for higher voltages per the AS 2550.15 exclusion zone table). Contact the DNSP before setup if powerlines are in proximity. Use a spotter dedicated to powerline observation during all boom deployment and retraction. Never work under or through powerlines with the boom. | Moderate | Pump Operator / Site Supervisor |
| Pump vehicle instability and outrigger collapse causing tip-over | Catastrophic | Position the boom pump truck on firm, level ground. Inspect ground conditions for voids, underground services, soft fill, or drainage structures that could fail under the point load of the outriggers. Use purpose-built outrigger pads of adequate size to distribute the load (minimum 600 mm x 600 mm x 50 mm hardwood or engineered composite pads for standard units). Deploy all outriggers fully before extending the boom. Never extend the boom beyond the manufacturer's load chart limits for the configured outrigger span. Verify ground conditions with the site engineer where ground strength is uncertain. | Moderate | Pump Operator / Site Engineer |
2.Pipeline assembly and pressure testing
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Pipeline blowout under pressure causing concrete ejection injury | High | Inspect all concrete pump hoses, steel pipes, clamps, and rubber end hoses before assembly. Remove from service any pipe or hose showing significant wear (wall thickness below manufacturer minimum), kinking, cracking, or damaged clamp ends. Ensure all pipeline clamps are fully secured with the safety clip in place — a loose clamp can become a fatal projectile under 100+ bar pressure. Keep all personnel clear of the pipeline during the initial prime and pressure-up phase. Never stand in the line of a hose end during pumping. Wear safety glasses and hard hat at all times near the active pipeline. | Moderate | Pump Operator / Labourer |
3.Concrete placement operations
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Hose whip during blockage clearing causing struck-by injury | High | In the event of a line blockage, depressurise the entire pipeline before any attempt to clear the blockage. Reverse the pump to relieve pressure before disconnecting any fitting. Never attempt to clear a pressurised hose by striking, kinking, or pulling on the hose. Use only the pump-reverse and manual push-through procedure approved in the operator's manual. Keep all non-essential personnel at least 5 metres clear of the pipeline during blockage clearing. The pump operator must maintain communication with all placement personnel via radio or hand signals. | Low | Pump Operator |
| Chemical burns from wet concrete contact during placement | Moderate | All concrete placement workers must wear rubber gumboots, chemical-resistant rubber gloves, and safety glasses during concrete placement. Change gloves if they become saturated with concrete. Wash skin immediately with water if concrete contact occurs. Wash boots at the end of each placement. Keep a first-aid kit and clean water accessible at the placement area. Do not allow workers to stand in pooled concrete for extended periods. | Low | Concretor / Site Supervisor |
| Worker falls into open excavation or slab edge during placement | High | Identify all open edges, excavations, and slab voids before commencing the pour. Install temporary edge protection or barricading at all slab edges from which a worker could fall more than 2 metres. Do not remove edge protection to facilitate placement — adapt the hose run instead. Mark and guard all penetrations and void formers in the slab. Ensure adequate lighting for early morning or evening pours. Assign a designated worker to manage hose movement near open edges. | Moderate | Site Supervisor / Concretor |
4.Pump washout and pipeline clearing
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| High-pressure water or concrete ejection during washout | High | During washout, maintain exclusion zone around the pipeline end where the pig or sponge ball is discharged. The discharge end of the pipeline must be pointed into a washout catcher (skip or bucket) and never towards personnel. Ensure all workers are clear of the pipeline end before commencing the blow-through. Use only the manufacturer's approved washout ball for the pipeline diameter. Do not exceed the water pressure specified for washout. Wear safety glasses during all washout operations. | Low | Pump Operator |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.