# Job Hazard Analysis: Concrete pump truck operations URL: https://hardhatbinder.com/en/jha/concrete/pump-truck Last updated: 2026-10-23 Truck-mounted boom pump placing ready-mix concrete for slabs, footings, walls, and elevated decks. Covers site setup, outrigger placement, boom deployment, pumping and hose handling, cleanout, and stowing. Crew: pump operator, hose handler(s), signal person, and finishers. Ready-mix trucks back up to the hopper during the pour. > 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. Walk the site and plan the pump location before the truck arrives. - **Overhead power lines in the boom's reach** (High): 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 outriggers** (High): 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. Back the pump truck into position, set outriggers and cribbing, and level the truck. - **Struck by the backing pump truck or ready-mix trucks** (High): 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 setup** (High): 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 legs** (Medium): Keep hands and feet clear while outriggers move; the operator confirms everyone is clear first. ### 3. Unfold the boom, attach the end hose, and run the pre-pour check. - **Boom contact with power lines or structures** (High): 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 pressure** (High): 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. Prime the line and start pumping concrete. - **End hose whipping when air comes out at startup or after a blockage** (High): 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 valve** (High): 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 hydraulics** (Medium): Wear earplugs or earmuffs when working at the hopper or near the truck. ### 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 edge** (High): 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 eyes** (Medium): 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 concrete** (Medium): Cap exposed rebar ends and walk the path before the pour starts. ### 6. Clean out the line and hopper, and wash out at the designated area. - **Clean-out ball or concrete shooting out under pressure** (High): 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 eyes** (Medium): Wash out only in the lined washout area and wear gloves and goggles. ### 7. Stow the boom, raise outriggers, and leave the site. - **Boom or truck contact with lines and workers while leaving** (High): 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 site** (Low): Pick up cribbing, cones, and hose sections; clean spills from walkways. ## Required PPE - Hard hat — At all times around the truck and under the boom. - Safety goggles or ANSI Z87.1 safety glasses — Goggles at the hose, hopper, and washout; glasses at minimum elsewhere. - Waterproof gloves — Nitrile or butyl when handling concrete or washout water. - Rubber boots — Steel or composite toe, pants tucked outside the boots. - High-visibility vest — At all times near trucks and traffic. - Hearing protection — Earplugs or earmuffs at the hopper and near the running pump. - Long sleeves and long pants — To keep wet concrete off skin. - Full-body harness and lanyard — At unprotected edges 6 ft or higher without guardrails. ## Training - Pump operator trained and qualified by the employer on this make and model; ACPA certification recommended. - Power line hazard training for operator, spotter, and crew. - Hose handler training on whip zones, startup, and blockage procedures. - Hand signal or radio communication training for signal persons. - Hazard communication training on cement and concrete burns. - Fall protection training for anyone working at deck edges. ## Emergency If the boom touches a power line: stop, do not touch the truck or anyone touching it, and keep everyone 35 ft back. Operator stays on the truck unless there is fire; then jump clear with feet together and shuffle away. Call 911 and the utility, give the site address, and give first aid only once the line is confirmed dead. ## Official sources - [29 CFR 1926.701](https://www.ecfr.gov/current/title-29/section-1926.701) — Concrete and masonry — general requirements - [29 CFR 1926.600](https://www.ecfr.gov/current/title-29/section-1926.600) — Motor vehicles and mechanized equipment — equipment - [29 CFR 1926.601](https://www.ecfr.gov/current/title-29/section-1926.601) — Motor vehicles - [29 CFR 1926.416](https://www.ecfr.gov/current/title-29/section-1926.416) — Electrical — general requirements - [29 CFR 1926.21](https://www.ecfr.gov/current/title-29/section-1926.21) — Safety training and education - [29 CFR 1926.59](https://www.ecfr.gov/current/title-29/section-1926.59) — Hazard communication - [29 CFR 1926.501](https://www.ecfr.gov/current/title-29/section-1926.501) — Duty to have fall protection - [29 CFR 1926.28](https://www.ecfr.gov/current/title-29/section-1926.28) — Personal protective equipment --- Source: HardHat Binder, operated by Leadspire LLC. Templates to be reviewed by a competent person before use; not legal advice; not affiliated with OSHA.