CONSTRUCT Gp

CONCRETE PUMPING OPERATION PLAN

PROJECT NAME – CONTRACT No.

Tick Applicable Box

Document Reference No: CONSTRUCT 01 Document Status Draft
Live
Authorised By: Name: Signature:
Pumping Operation Manager

Batching Plant Manager

Project Manager
Pump Supervisor / Site Manager
Health & Safety Manager

Issued to: (name & company)

Response required by (date): Plan Approved/Agreed by:

Plan Approved/Agreed Status: Yes NO

(Indicate by circling relevant (Rejected, work cannot
option) commence, must be amended &
(Accepted, ready for
resubmitted.)
implementation.)

Revision Records
Version Approved/
Issue Date Pages / Section Amended Prepared by
No Agreed by
1
2
3
4
5

Distribution of Controlled Copies

Issued
Issue Date Recipient Name Company Name
Copy No
1
2
3
4
5

Note: The latest issue will be retained by the Project Manager. All signatures must be collected on a hard copy of this
document & kept in the Site Safety Files. Acceptance sheets issued by the client or principal contractor are to be
attached to the hard copy

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INDEX

1 Scope of Works Pg
2 Competency Compliance Pg
3 Pumping Equipment Details Pg
4 Associated Equipment Pg
5 Hazard Identification/Risk Assessment Pg
6 Weather Conditions Pg
7 Training, Information and Instruction Pg
8 Supervision & Resources Pg
9 Communication Pg
10 Access and Egress Pg
11 Emergency Arrangements Pg
12 P.P.E Pg
Appendices
A Thorough Examination Certificates
B Risk Assessments
C Pump Layout Plan
D General Guidance for Calculating Outrigger Pad Size
E Daily and Weekly Checks and Inspections Record.
F Copy of Concrete Mix Design

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Relevant Legislation, Standards & Guidance

The Provision and Use of Work Equipment Regulations 1998 (PUWER)

Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)
The Manual Handling Operations Regulations 1992
The Construction (Design and Management) Regulations 2015
BS 847:2007 “Code of Practice for the safe use of concrete pumps”
Safe Use of Concrete Pumps a CPA Good Practice Guide

DATE WORKS TO COMMENCE:

1. SCOPE OF WORKS

BRIEF DESCRIPTION: Pumping …… concrete with an ………………….. over a

maximum horizontal distance of ……….. and maximum vertical distance of ………….

PUMP CLASSIFICATIONS:

Tick below boxes as appropriate:

Trailer Specialised
Truck Mounted Truck Mixer
Mounted/Static

PUMPING STRATEGY:

All pumping operations will be undertaken in accordance with …………………. to

ensure that we meet our obligations under PUWER 98 & LOLER 98, as well as BS
8476:2007 Code of Practice for the safe use of concrete pumps.

APPOINTED PERSON – PUMPING OPERATION MANAGER (Concrete Pumping

Operation)

The Appointed Person, who has prepared this document, carries full responsibility for
the safe completion of all works carried out during the pumping operation(s). The
Appointed Person must ensure that the Pump Supervisor is adequately briefed on the
contents of this document.

PUMP OPERATION SUPERVISOR:

Prior to the start of any works, the Pump Supervisor must ensure that all site personnel
are adequately briefed on the contents of this document and risk assessments. They
must liaise with the Appointed Person should site circumstances require any change to
the methods employed during pumping operation(s).

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2. COMPETENCY COMPLIANCE

Competency1
Forename Surname Role Remarks
NVQ A06 A44 A72 Other

3. PUMPING EQUIPMENT DETAILS

Identify items in table below.

The Pump

Make and Model

Registration/Plant Number

12 Monthly Thorough
Examination Certificate

Details of last service

Dimension(s)

Weight

Boom Chart Attached

Boom Reach Height

Boom Radius
Unusual Features, Boom &
Other Restrictions
Mechanical or Electronic
Restrictions
Fitted Safety Device
(VECTOR etc, short rigging)
Outriggers See Guidance at Appendix D

Outrigger Loads

Max Outrigger Point Load

Type of Outrigger Mats

1
NVQ 2-Specialist Plant and Machinery Operations Concrete Pumping (QCF). A06-Truck Mounted Boom Concrete Pump. A44-Trailer
Mounted Boom Concrete Pump. A72-Static Concrete Placing Boom.
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The Pump

Mat Area Provided

Resulting Ground Pressure

Temporary Works Load
Bearing Capacity
Additional Mats Required

The Pump Lines

Type of pipe

QC Testing

Pipe dimension(s)

Maximum pump length

Maximum Elevation

Permissible Hose Attachments

Cleaning Method

Protection Required

Pipeline Couplings

4. ASSOCIATED EQUIPMENT

PLACING BOOM DELIVERY VEHICLE

Make & Type

12 Monthly Thorough
Examination Certificate

Owned by (Contact No.)

Equipment must have a current 12 monthly thorough examination certificate.

Copies of statutory test certification and inspection reports will be available for
inspection prior to any pumping taking place and are attached at Appendix A.

5. HAZARD IDENTIFICATION/RISK ASSESSMENT

Hazard Identification. The table below indicates the type of hazards usually
applicable to the operation. Where applicable there must be mitigation put in place to
reduce the risk to as low as reasonably practicable (ALARP).

Hazard Type
Applicable to Plan Risk Assessed Risk Rating
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Low Medium High

Overhead Cables

Contact with End-

Placing Hose

Contact with
pipes, hoses and
sponge balls

Obstructions

Ground Conditions
– Pump Lifting
Position

Underground
Services

Underground
Voids / Vaults

Traffic
Site and Public

Manual Handling

Delivery line route

(interaction with
TW, other
equipment and
people)

Operator/Gang
fatigue due to
over-run.

Tower/Mobile
Cranes

Vibration

Surplus Concrete/
Spillage

Noise

Equipment
Cleaning

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Enabling Works

Communication
(radio – visual)

Lighting

Wind

Fumes

Other Hazard(s)

Please see relevant risk assessments in Appendix B and the Pump Layout Plan in
Appendix C.

6. WEATHER CONDITIONS

Pumping restrictions are implemented based on guidance from the manufacturer &/or
Operators Manual and those detailed in the risk assessment.

 Operations will take place in wind speeds up to XX metres per second.

 Pumping operations must stop during storms, or when there is a risk of lightning
strikes.

The Appointed Person, Pump Supervisor or Operator may stop pumping operations
due to weather conditions at a lower wind speed than specified above or for other
weather-related safety reasons.

7. TRAINING, INFORMATION AND INSTRUCTION

Suitable and sufficient training must be provided to ensure workforce competency.

Any unusual requirements that are out of the normal parameters of the pumping
operation must be identified and if other trades are included in this work then their
competency must be verified. Information such as vehicle operating envelope charts
must be legible and checked for accuracy. The AP must provide written and verbal
instructions as to the hazard mitigation and the safe running of the operation.

8. SUPERVISION AND RESOURCES

Supervision of the operation will be required at the point of pumping and placement.
The supervisors listed at paragraph 2 should be present at all times that the pump is in
operation which includes cleaning and carry a duty of care to stop the operation at any
point.

9. COMMUNICATION

Tick below boxes as appropriate:

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Hand Signals Two-way Radios Second Banksman

The use of hand signals should be confirmed between all operatives including Traffic
Marshals that may be otherwise involved with secondary tasks within a logistics area.
Frequencies for radio use may need to be authorised in sensitive areas such as
Airports and secure areas.

There should be sufficient information provided to others working in the area that are
not directly involved with the pumping operation. The supporting plan drawings within
this document should be placed in an area for others to see. Out of bounds areas
must be conveyed during morning safe start briefings.

A method statement / pumping operation plan briefing session will take place prior to
starting any work.

10. ACCESS AND EGRESS

Access and egress planning must cover the traffic route to/from the site and all internal
vehicle manoeuvring areas in addition to pedestrian walkways. The installation of
pumping equipment should not interfere with safe access for others to conduct their
daily work but if this cannot be averted then suitable control measures must be put in
place and risk assessed.

11. EMERGENCY ARRANGEMENTS

The emergency arrangements should be no different from those identified in the

Construction Phase Plan. Emergency arrangements are to be conveyed to the
workforce and should be exercised periodically. There will be a requirement to
produce a rescue plan to deal with the safe transport of an injured/incapacitated
person from the place of incident to the emergency vehicle. This could include the use
of a crane and suitable personal transport. This operation must be exercised
periodically under the control of the AP.

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 APPENDIX A -

THOROUGH EXAMINATION CERTIFICATES

To be held in this section.

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 APPENDIX B - RISK ASSESSMENTS

Hazard Relevant Activity Population at Control Measures Risk Rating

to Task Risk
Yes No Low Medium High
Pump set up

Placement
Overhead Boom set up
Cables
Boom operation

Starting to pump a new load of

concrete
Contact with
End-Placing
Grouting Up
Hose

Clearing lines with compressed

Contact with
air
pipes, hoses
and sponge
balls
Pump set up
Placement
Obstructions
Boom set up
Boom operation
Set up pumping equipment
Ground
Vehicle Access
Conditions
Pedestrian Access
Underground Set up pumping equipment
Services
Underground Set up pumping equipment
Voids / Vaults
Vehicle movement to/from site
Traffic
Vehicle

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 Manoeuvring on site
Site and Public Interaction with public highway
Handling of pumping equipment
including steel lines and
Manual
ancillary items.
Handling
Control of flexi-hose at point of
placement.
Setting up delivery lines and
Concrete equipment
delivery line
Pumping concrete
(interaction with
Access/Egress (walkways)
TW, Equipment
and operatives) Demobilise delivery lines and
equipment
Operator/ Pumping concrete
Gang fatigue Finishing concrete
due to over- Driving to – from site
run.
Set up pumping equipment
Operating boom
Tower/Mobile
Operating crane
Cranes
Demobilise pumping equipment
Demobilise crane
Vibration Compacting concrete
(include Pumping concrete
potential to
disturb ground)
Surplus Pumping concrete
Concrete/ Wash out
Spillage
Noise Concrete pumping
Using compressed air for deck
Equipment/
clearing.
Deck Cleaning
Cleaning out delivery lines.
Ground stabilisation
Enabling Works
Isolation of services
Set up pumping equipment
Communication
Pumping operation
(radio – visual)
Demobilise pumping equipment
Operation of Pump
Lighting
Placing/finishing concrete
 Operation of boom
Wind
Operation of Pump Engine
Fumes

Other
Hazard(s)
 APPENDIX C - PUMP LAYOUT PLAN

PUMP LAYOUT PLAN

This drawing shows the agreed position of Pump & delivery line travel paths where necessary. It
should be completed in plan and elevation, detailing secondary hazards.
Note: This hand-drawn document can be replaced by an electronic Site Layout Drawing if available.

APPENDIX D –
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 GENERAL GUIDANCE FOR CALCULATING OUTRIGGER PAD SIZE

For very large mobile concrete pumps, or special situations or where the ground conditions
are not straight forward (e.g. layered strata, paved areas etc) the foundation must be
specially designed by a geotechnical engineer.

The tables below have an in-built Factor of Safety 2 (FOS)

 APPENDIX E - Daily - Weekly Checks and Inspections Record
Name: Depot or Site Address: Fleet No.: Week Ending:

Weekly Servicing Checks

Daily Pre-use Checks M T W T F S S A. Battery and Water Level Daily Site Checks M T W T F S S
1. Engine oil level(s) B. Windscreen Washer Reservoir Ground Conditions
2. Fuel level/Leaks C. Grease Boom Overhead Power Cables
3. Coolant level D. Transmission Levels Washout Facility
4. Hydraulic Oil Level E. Brake and Clutch Levels Protection for Nearby Cars/Property
5. Hydraulic System Leaks F. Hydraulic Oil Level & Filters Customer Provided Method Statement
6. Tyre Pressures and Condition G. Hydraulic Hoses
7. Wipers, Washers H. Check A/C Belt
8. Lights and Indicators I. Grease Slew Ring
9. Horn and Cab instruments J. Hydraulic Fan
10. Wheel Nuts and Studs K. Pumping Piston Fixing
11. Operation of Hand or Foot Brake L. Tyre Condition Defect Report
12. Hopper Grill and Safety Interlock M. Operation of Boom (All defects must be reported. Those affecting safe operation must be reported and repaired immediately)
13. Delivery Hoses N. Prop Shaft Belts Description:
14. Outrigger Support Plates/Timbers O. Outriggers for Cracks
15. Grease Pump Unit P. Boom & Boom Pipes for Cracks
16. Accumulator Pressure Further model specific checks as specified by manufacturer
17. Boom Pins and Keyways Q.
18. Ground Lines Pipes,Flex's & Clips R.
Further model specific checks as specified by manufacturer S.
19. T.
20. U.
21. V.
22. W.
23. X.
24. Y.
25. Z.
26. AA.
27. BB.
28.
Reported to: Date:

Description:

Reported to: Date:

Engine Hrs Chassis Miles

Operator's observations, requirements for oil, grease etc: Repairs Completed or Comments:

Fitter's Signature: Date:

Operator's Signature: Date: Manager's Signature: Date:

APPENDIX F – Copy of Concrete Mix Design

To be held in this section.