Job Hazard Analysis: Concrete pump truck operations

A general example for this task. Your JHA should reflect your crew, equipment and site — review it with a competent person before work starts.

Steps, hazards and controls

1. 1. Walk the site and plan the pump location before the truck arrives.

   • Overhead power lines in the boom's reachHigh
     • Pick a pump spot where the boom cannot reach within 20 ft of any power line in any direction.
     • If you cannot keep 20 ft, call the utility to de-energize or insulate the lines before the pour.
     • Assign a dedicated spotter whose only job is watching the boom near lines.
   • Soft ground, backfill, or buried utilities under outriggersHigh
     • Keep outriggers away from excavation edges, fresh backfill, manholes, and septic tanks.
     • Ask the GC for locates and mark buried lines before the truck sets up.

2. 2. Back the pump truck into position, set outriggers and cribbing, and level the truck.

   • Struck by the backing pump truck or ready-mix trucksHigh
     • Use a spotter in hi-vis for every backing move; the driver stops if he loses sight of the spotter.
     • Check that the backup alarm works before moving.
     • Cone off the truck and outrigger area to keep workers and traffic out.
   • Truck tip-over from undersized outrigger pads or unlevel setupHigh
     • Fully extend outriggers as the manufacturer chart requires and set them on rated pads or cribbing sized for the soil.
     • Level the truck within the manufacturer limit before raising the boom.
   • Pinched feet or hands under outrigger legsMedium
     • Keep hands and feet clear while outriggers move; the operator confirms everyone is clear first.

3. 3. Unfold the boom, attach the end hose, and run the pre-pour check.

   • Boom contact with power lines or structuresHigh
     • Raise the boom slowly with the spotter watching the lines and the operator watching the spotter.
     • Keep everyone off and away from the truck while the boom moves.
   • Worn pipe, clamps, or end hose bursting under pressureHigh
     • Inspect pipe wear, clamps, pins, and the end hose; replace anything worn before pumping.
     • Never attach anything except the end hose to the boom tip; no kinks or extra hoses beyond the manufacturer limit.

4. 4. Prime the line and start pumping concrete.

   • End hose whipping when air comes out at startup or after a blockageHigh
     • Clear everyone at least the length of the end hose plus 3 ft away from it at startup and restart.
     • Hose handler stays out of the whip zone until steady concrete flows.
     • Keep the hopper full so the pump does not suck air.
   • Hands in the hopper grate or moving valveHigh
     • Keep the hopper grate in place at all times; never reach through it.
     • Shut off and lock out the pump before clearing anything in the hopper.
   • Noise from the pump engine and hydraulicsMedium
     • Wear earplugs or earmuffs when working at the hopper or near the truck.

5. 5. Place concrete with the end hose at the pour and move the boom between spots.

   • Hose handler pulled off balance or over a deck edgeHigh
     • Protect deck edges 6 ft or higher with guardrails, or tie off to an approved anchor.
     • Never wrap the hose around your body or stand where the hose can push you over an edge.
     • Hose handler and operator use agreed hand signals or radio; stop pumping before moving the boom.
   • Wet concrete burns on skin and splashes in eyesMedium
     • Wear waterproof gloves, rubber boots with pants over the top, and safety goggles.
     • Wash concrete off skin right away with clean water; keep an eyewash bottle at the pour.
   • Slips and trips on rebar, forms, and wet concreteMedium
     • Cap exposed rebar ends and walk the path before the pour starts.

6. 6. Clean out the line and hopper, and wash out at the designated area.

   • Clean-out ball or concrete shooting out under pressureHigh
     • Use water to push the clean-out ball when possible; never use compressed air unless the pump maker's procedure allows it.
     • Put a catch basket on the discharge end and keep everyone clear of the outlet.
     • Release all line pressure before opening any clamp.
   • Caustic washout water on skin and eyesMedium
     • Wash out only in the lined washout area and wear gloves and goggles.

7. 7. Stow the boom, raise outriggers, and leave the site.

   • Boom or truck contact with lines and workers while leavingHigh
     • Fold the boom fully into its rest before lifting any outrigger.
     • Use a spotter to guide the truck out and keep the crew clear.
   • Debris and leftover concrete left on siteLow
     • Pick up cribbing, cones, and hose sections; clean spills from walkways.