Concrete Pump Safety Protocols: Tips From Our Experts

09th January 2025

Concrete is one of the most used materials in construction, and with that comes the use of concrete pumps. Boom and line pumps are large pieces of equipment that, while making the concrete pouring process extremely efficient, carry some risks that always need addressing. Concrete pump safety protocols are incredibly important when working with them for the safety of our operators and your staff.

Due to the high-pressure machinery and the sheer size of the equipment, there are a number of potential risks present when these trucks are on-site and operating. Accidents can easily happen if you're not aware of risk, and can be devastating for you and your site. Accidents will also likely halt your project, no matter whether it is a small DIY project at home or a large commercial project. This is why it is important you are up to speed on the safety procedures around concrete pumping.

At 2 Brothers Concrete & Pumping, we have a combined 25+ years of experience in concrete pumping. We have been safely delivering concrete and concrete pumping services across the South Coast for new build developments and residential and commercial projects. We know our equipment like the back of our hand, and with this comes a wealth of knowledge about safety protocols.

In this blog, we share tips around concrete pump safety so you can be prepared for us when we visit your site.

Common Hazards in Concrete Pumping

There are a number of hazards that come with concrete pumping and the equipment that is used for the process.

These can include:

High-pressure lines - concrete flows through the pump at a high pressure. A leak or failure could lead to an explosive burst, posing a risk of injury.
Equipment malfunctions and failures - problems with components such as pistons, valves, or power sources can result in unexpected downtime, spills, or even equipment failure.
Worker exposure to wet concrete - direct contact with wet concrete can cause chemical burns due to its high alkalinity. Longer exposure can also lead to severe skin irritation.
Hose whip - A sudden release of pressure in the hose, caused by a blockage or improper setup can cause the hose to "whip" around at high velocity. This puts those around the hose at risk of harm.
Blockages - blockages can lead to leaks and bursts or hose whips, increasing the danger of incidents or injury.

To reduce the chance of these hazards there are several preventative steps that can be taken by our team and your team at your site.

These are:

We inspect our equipment regularly to ensure proper line connections, and we use high-quality, well-maintained hoses to reduce the risk of leaks or bursts.
The operators will also monitor the pressure within the pump to ensure there is a reduced risk of any bursts or malfunctions.
These inspections also enable us to guarantee the equipment is working as it should, in line with manufacturer guidelines.
Our team will arrive wearing the required Personal Protective Equipment (PPE), including high-vis jackets, hard hats, long sleeves and gloves. It is essential that your team are also equipped with the right PPE.
We will complete checks on the set-up of the hose and concrete design mixture before starting any pumping to avoid hose whipping.
While the pump is in operation, workers should stand clear of the hose and site to avoid injury should the hose whip.
Our operators are trained to notice signs of blockages within the pump and to clear the problem in an appropriate and safe way.

Setting Up Safe Work Zones

One of the most important concrete pump safety protocols for you and your site is to set up safe working zones.

There are three steps to this:

Barrier placement - place barriers around the site to keep unauthorised personnel out of the pump's operating area.
Site layout - plan the placement of the pump truck to avoid congestion and allow room for safe operation - this is something we can work with you on.
Clear communication - ensure there is clear communication between the pump operator, hose handlers, and site workers. You can do this by using radios or agreed hand signals.

Proper Use of Personal Protective Equipment

As we mentioned above, wearing PPE is essential to safety when pumping concrete on a project.

Here's why:

Goggles - eyewear protects your eyes against splashing and particles escaping.
Masks - wearing a mask is important as it prevents you and your team from breathing in dust and chemicals from the wet concrete.
Gloves, boots and long sleeves - making sure your skin is covered means you reduce the chance that your skin comes into contact with wet concrete, so you can avoid skin irritation.

Best Practices for Safe Hose and Line Handling

The majority of handling the hose and line will be done by our expert operators, but it never hurts to share our rules so you and your team can follow them too.

Avoid holding the hose and keep clear of the nozzle when the pumping is being started or stopped.
Our team will handle any blockages that occur (should there be any). In this situation, show patience and keep away from the machinery in case the hose whips when the blockage is released.
Keep an eye on the flow of concrete out of the pump and communicate if there is a change to our operating team. This will allow us to pick up on any blockages before they cause problems.
After every job, we complete an inspection of the equipment and sort any maintenance issues out before moving on to the next job. This way, we both can be confident that our machinery is in the right state to continue working.

Emergency Procedures for Concrete Pumping Sites

While we will do everything we can to avoid an emergency, you must have emergency procedures in place as part of your concrete pump safety protocol.

An emergency protocol will need to cover:

Emergency shut-offs - working with our operators to stop the machinery as quickly as possible, in a safe manner. Our operators will be familiar with the emergency controls on our equipment.
Evacuation plan - Have a clear evacuation plan that removes people off-site as efficiently as possible. Make sure any personnel on-site at the time of pumping are aware of this plan.
First aid training - Make sure there is at least one trained first aider on site who can attend to any common injuries, such as concrete burns or pinching injuries.

Safe Concrete Pumping with 2 Brothers

Concrete pumping has a number of hazards that pose risks of injury to those working on the site. However, with the correct concrete pump safety protocols in place, these hazards are reduced.

While safety steps such as inspections and correct set-up of the equipment are down to our team, there are a few steps you can take on-site to keep everyone safe.

These include:

Creating safe work zones
Providing staff with the correct PPE
Having an emergency plan in place
Communicating with our team clearly and efficiently, especially while concrete is pouring

At 2 Brothers Concrete & Pumping, we are experts at pumping all concrete design mixes and liquid screed with our range of pumps. Whether we are solely using a boom pump or line pump or are combining the two to extend reach, we will work efficiently, while ensuring all steps are taken to ensure everyone's safety.

Each member of our team is highly trained to work with our equipment, so no matter what the situation is, they will be able to handle it safely.

On top of this, all our equipment is regularly serviced, and the team inspect the trucks at the start and end of the day to minimise the chance of any equipment malfunctions.

If you want to learn more about our concrete pumping services and the safety protocols we have, don't hesitate to get in touch with our friendly team. Call us on 01489 552737 or complete our online contact form to request a callback from one of our experts.