Product Overview

Summary: This Concrete Pump Operation Safe Operating Procedure provides a clear, step-by-step framework for planning, setting up, operating and shutting down concrete pumps safely on Australian worksites. It helps businesses control high-risk activities such as boom movements, line blockages and concrete under pressure, while supporting compliance with WHS laws and industry standards.

Concrete pumping is a high-risk construction activity that combines heavy plant, moving booms, concrete under pressure and busy work zones. Without a robust, documented procedure, businesses are exposed to serious incidents such as boom collapse, line bursts, workers being struck by plant, and uncontrolled concrete spills. This Concrete Pump Operation Safe Operating Procedure sets out a practical, end‑to‑end method for managing these risks – from pre-start inspections and site set-up, through to safe pumping, wash-out and demobilisation.

Developed for Australian conditions and WHS expectations, the SOP helps you systemise how concrete pumping is planned, communicated and controlled on every pour. It clarifies who does what on site, how exclusion zones are established, how stability and ground conditions are assessed, how communication with pump operators and spotters is maintained, and what to do if something goes wrong. By embedding this procedure into your daily operations, you create a consistent standard of work that supports legal compliance, improves coordination with concrete suppliers and placing crews, and protects workers, subcontractors and the public from foreseeable harm.

This document is particularly valuable for companies operating mobile boom pumps and line pumps on civil, commercial and residential projects. It supports safe use of plant in congested environments, near live services and traffic, and provides a defensible framework you can use during inductions, toolbox talks, incident investigations and regulator inspections.

Key Benefits

• Ensure consistent, safe set-up and operation of concrete pumps across all sites and crews.
• Reduce the risk of serious incidents such as boom strikes, line bursts, concrete blow-outs and plant rollovers.
• Demonstrate compliance with Australian WHS legislation, concrete pumping guidance and plant safety requirements.
• Standardise communication between pump operators, spotters, concrete suppliers and placing teams to minimise delays and rework.
• Improve training, onboarding and competency assessment for new and existing concrete pump operators.

Who is this for?

• Concrete Pump Operators
• Line Pump and Boom Pump Operators
• Concrete Placing Workers
• Site Supervisors
• Construction Project Managers
• Principal Contractors
• WHS Managers and Safety Advisors
• Plant and Maintenance Coordinators
• Civil and Structural Engineers (Site-Based)

Hazards Addressed

• Boom contact with overhead powerlines and other services
• Struck-by incidents from moving booms, hoses and plant
• Concrete line blockages and sudden release of pressurised concrete
• Hose whipping and blow-back at the discharge point
• Plant instability, overturning or ground failure under outriggers or stabilisers
• Pinch points and crush injuries during set-up, folding and maintenance of booms and lines
• Exposure to wet concrete causing skin and eye irritation or burns
• Slips, trips and falls around wet concrete, hoses and wash-out areas
• Noise and vibration exposure from pumping equipment
• Traffic interface risks between concrete trucks, pumps, workers and the public
• Manual handling injuries from moving hoses, line sections and reducers

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Concrete Pumps (Boom and Line)
• 3.0 Roles and Responsibilities (PCBU, Supervisor, Pump Operator, Spotter, Workers)
• 4.0 Required Licences, Competency and Training
• 5.0 Required PPE and Safety Equipment
• 6.0 Pre-Start Planning and Risk Assessment (SWMS, permits, service locating)
• 7.0 Site Assessment and Set-Up Requirements
• 8.0 Ground Conditions, Outrigger Placement and Stability Controls
• 9.0 Exclusion Zones, Traffic Management and Public Protection
• 10.0 Pre-Operational Checks and Plant Inspection
• 11.0 Safe Concrete Pumping Procedure (Start-Up, Priming, Pumping and Shutdown)
• 12.0 Communication Protocols Between Operator, Spotter and Concrete Crew
• 13.0 Managing Line Blockages, Blow-Back and Hose Whip
• 14.0 Working Near Overhead and Underground Services
• 15.0 Wash-Out, Cleaning and Waste Management Procedures
• 16.0 Maintenance, Fault Reporting and Tag-Out
• 17.0 Emergency Procedures (Powerline Contact, Plant Instability, Injury, Spills)
• 18.0 Environmental Considerations (Slurry, Run-off and Noise)
• 19.0 Monitoring, Review and Continuous Improvement
• 20.0 Document Control and Recordkeeping

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory equivalents)
• Work Health and Safety Regulation 2011 (Cth and relevant state/territory equivalents) – Plant and High Risk Work provisions
• Safe Work Australia – Managing the Risks of Plant in the Workplace Code of Practice
• Safe Work Australia – Construction Work Code of Practice
• AS 2550.15: Cranes – Safe use – Concrete placing equipment
• AS 1418.15: Cranes, hoists and winches – Concrete placing equipment
• AS/NZS 4024 series: Safety of machinery (for guarding and control systems)
• Electrical Safety legislation and guidelines relating to work near overhead and underground electric lines (state/territory specific)