The ABCs of Concrete Pump Safety: Everything You Need to Know

concrete pump safety


Concrete pumping is an efficient method of placing concrete, allowing large volumes to be poured quickly with minimal labor. However, operating concrete pumps requires proper training and adherence to safety protocols to avoid accidents and injuries. This blog post will provide a comprehensive overview of concrete pump safety, covering various hazards, risk mitigation strategies, and best practices to keep workers safe. Whether you are an equipment operator, site supervisor, or worker in the vicinity of concrete pumping, understanding the ABCs of concrete pump safety is crucial.

Hazards and Risks

concrete pump safety

Using concrete pumps presents several potential hazards that require hazard awareness and preventative measures. Some key risks include:

  • Pipe burst hazards – Concrete pumping uses high pressure to move concrete through pipes. Worn pipes or improper pipe setup can cause dangerous bursts, spraying concrete.
  • Overhead powerline contact – Concrete pump booms must maintain safe distance from overhead powerlines to prevent electrocution risks.
  • Tip over – Pump stability on uneven or soft ground, steep slopes, or excessive boom reach can lead to tip overs.
  • Struck by piping – Workers can be struck by piping if pipe connections come loose or break.
  • Noise – Concrete pump operation generates very high noise levels that require hearing protection.
  • Confined spaces – Working in confined spaces like tunnels introduces risks like poor ventilation and limited exit points.
  • Falls – Climbing on pump set up creates fall hazards.
  • Struck by concrete pump – Workers on foot can get struck by mobile pump trucks.

Thorough hazard assessment and implementing control measures are vital to mitigating these risks and preventing incidents.

Safe Work Practices

concrete pump safety

Following safe work practices and operating procedures is the foundation of concrete pump safety. Key safe practices include:

Inspections and Maintenance

  • Inspect concrete pumps and accessories like hoses and booms prior to each use. Check for wear, leaks, damage and defects.
  • Follow manufacturer maintenance schedules and repair or replace defective components.
  • Lubricate and clean components as required.

Setup Precautions

  • Position pump on firm, level ground and use outriggers to stabilize.
  • Do not exceed safe boom reach limits.
  • Check for obstructions in swing radius.
  • Secure pipe connections; use retaining lines on pipes.
  • Establish safe exclusion zone around pump.

Pumping Practices

  • Do test runs at low pressure before pumping concrete.
  • Open valves/throttles slowly to avoid pressure spikes.
  • Communicate with workers using signals.
  • Keep hoses free of tight kinks.
  • Stop pumping if a pipe or hose bursts.
  • Adhere to capacity limits.

Qualified Operators

  • Only trained, authorized workers should operate concrete pumps.
  • Operators must demonstrate competency through hands-on testing.
  • Operators should be familiar with equipment and site conditions.

Hand Signal Communication for Concrete Pumps

Arm extended, hand openStart pumping concrete
Arm extended, hand closedStop pumping concrete
Hands crossed in front of bodyEmergency stop
Arm rotatingIncrease concrete flow
Arm motion downwardReduce concrete flow
Thumb pointed upwardsRaise boom
Thumb pointed downwardsLower boom
Forearm rotatedSwing boom left or right

Personal Protective Equipment (PPE)

  • Operators and ground workers must wear approved hard hats, safety shoes, high visibility vests, gloves and eye protection. Hearing protection is mandatory.

Cleanup and Storage

  • Wash equipment after use to avoid concrete buildup. Clean up concrete spills.
  • Follow storage procedures, including pipe support and boom restraints.

Equipment Safety Features

Concrete pump manufacturers incorporate various safety features into equipment designs to aid in hazard control:

  • Boom kickout – Hydraulically prevents booms from unintentionally lowering into free fall if a hydraulic line fails.
  • Wind speed sensor – Automatically stops the pump when wind speeds exceed safe thresholds.
  • Anti-tear protection – Prevents uncontrolled retraction if a portion of hose or piping snags or fails.
  • Overflow sensor – Detects concrete overflow conditions in hopper.
  • Access platforms and ladders – Provide safe access points with guardrails and non-slip surfaces.
  • Emergency stop buttons – Allow operators or workers to immediately cut power in case of emergency.
  • Audible motion alarms – Alert workers in the area when the pump is about to move.
  • Pipe break valves – Isolate pump sections in the event of pipe or hose failure to stop concrete discharge.
  • Boom acting indicators – Alert operator when reaching unsafe boom angle.

Concrete Pump Safety Training

Formal training is essential for concrete pump operators, spotters and ground personnel. Training should include:

  • Hazard awareness and control measures
  • Operating procedures
  • Inspection and maintenance
  • Emergency response
  • Hands-on practice under supervision
  • Safety device use
  • Site communication and signal methods

Trainings should be repeated periodically as a refresher. Only personnel who have successfully completed training should work with concrete pumps.

Additional Safety Tips

Beyond formal training, the following safety tips can further reduce concrete pump hazards on the jobsite:

  • Use tag lines to control hoses and pipes when positioning.
  • Barricade or mark deep puddles/soft spots in pump paths.
  • Position spotters with line of sight on operations.
  • Do not kink hoses to stop concrete flow.
  • Establish and enforce minimum approach distances to powerlines.
  • Monitor concrete pumping pressure gauges.
  • Report any safety incidents or near misses.
  • Keep work areas clean and free of clutter.


Concrete pumps allow fast, high-volume concrete placement that would be extremely labor intensive manually. But their operation also introduces serious hazards if proper safety protocols aren’t followed. By understanding pump hazards, following safe work practices, using well-maintained equipment, and ensuring qualified personnel through training, concrete pumping can be performed safely and efficiently. Adhering to the ABCs of concrete pump safety provides the knowledge workers need to avoid incidents and complete pumping jobs successfully. Implementing these practices is an investment that pays dividends through improved productivity and worker protection.


Q: How often should concrete pump safety training be conducted?

A: Formal safety training should be provided prior to initial assignment, with refresher training at least annually thereafter. More frequent retraining may be warranted if problems are observed.

Q: What are the most common concrete pump hazards?

A: The most common hazards include pipe bursts, overhead powerline contact, tip overs, getting struck by piping, noise, and falls. Situational hazards like confined spaces may also be present.

Q: Should PPE like hard hats and safety glasses be worn around operating concrete pumps?

A: Yes, minimum PPE should include hard hats, safety glasses, high visibility vests, gloves and steel toe boots. Hearing protection is required.

Q: Can operator error be eliminated with automation features?

A: No, operator competency is still crucial even with added machine guarding and automation. Proper training and adherence to procedures is vital.

Q: What should be done if a pipe or hose bursts while pumping?

A: Immediately activate the emergency stop and isolate the burst section. Evacuate nearby workers. Do not resume operations until the burst is repaired and new hazard assessment is done.

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