Concrete Pumping

8/17/2019 Concrete Pumping

http://slidepdf.com/reader/full/concrete-pumping 1/75

Concrete PumpingHealth and Saf ety GuidelinesFEBRUARY !"#



Ministry of Business, Innovation and Employment (MBIE)

Hi)ina * +ha)atutu)i &ifting to ma)e successful

,B-E de.elops and deli.ers policy/ ser.ices/ ad.ice and regulation to support economic gro0th and the

prosperity and 0ell1eing of 2e0 3ealanders4

,B-E com1ines the former ,inistries of Economic $e.elopment/ Science 5 -nno.ation/ and the

$epartments of &a1our/ and Building and Housing4

,ore information

0004m1ie4go.t4n6

!7!! ! 8! !

-nformation/ e9amples and ans0ers to your

:uestions a1out the topics co.ered here can

1e found on our 0e1site 0004m1ie4go.t4n6 or 1y

calling us free on !7!! ! 8! !4

Disclaimer

;he ,inistry of Business/ -nno.ation and Employment and the

Concrete Pumping Association of 2e0 3ealand ha.e made e.ery

effort to ensure that the information contained in this pu1lication

is relia1le/ 1ut ma)e no guarantee of its accuracy or completeness

and do not accept any lia1ility for any errors4 ;he ,inistry and the

Concrete Pumping Association of 2e0 3ealand may change the

contents of this pu1lication at any time 0ithout notice4

-SB2 8'7<!<('7<#8"!"<= >online?

,arch !"#

©Crow n Copyr ight 20!

;he material contained in this report is su1@ect to Cro0n copyright protection

unless other0ise indicated4 ; he Cro0n copyright protected material may 1e

reproduced free of charge in any format or media 0ithout re:uiring specific

permission4 ;his is su1@ect to the material 1eing reproduced accurately and not1eing used in a derogatory manner or in a misleading conte9t4 +here the

material is 1eing pu1lished or issued to others/ the source and copyrightstatus should 1e ac)no0ledged4 ;he permission to reproduce Cro0n copyright

protected material does not e9tend to any material in this report that is

identified as 1eing the copyright of a third party4 Authorisation to reproduce

such material should 1e o1tained from the copyright holders4

http://www.mbie.govt.nz/






ACKNOWLEDGEMENTS

These guidelines are based on the Industry Standard for Concrete Pumping from WorkSafe

Victoria, Australia. The Ministry of Business, Innovation and m!loyment and the

"oncrete #um!ing Association of $e% &ealand thank WorkSafe Victoria and the Victorian

Work"over Authority for the use and ada!tation of their material.

The Ministry and the "oncrete #um!ing Association of $e% &ealand also thank'

• SiteSafe $e% &ealand for the use of their Task Analysis Tem!late

• $e% &ealand (eady Mi) "oncrete Inc for the use of their Concrete Truck Driver Hand

Signals !oster.

Cover photograph: "onstruction site %ith concrete mi)er and cement !um!. #hoto

by e%g*+iStock!hoto.

Disclaimer: The Ministry of Business, Innovation and m!loyment and the "oncrete#um!ing Association of $e% &ealand have made every effort to ensure that the

information contained in this !ublication is reliable, but make no guarantee of its accuracy

or com!leteness and do not acce!t any liability for any errors. The Ministry and the

"oncrete #um!ing Association of $e% &ealand may change the contents of this !ublication

at any time %ithout notice.

#ublished by the "oncrete #um!ing Association of $e% &ealand in association %ith the

Ministry of Business, Innovation and m!loyment

"oncrete #um!ing Association of $e% &ealand

#- Bo) /Beachlands

Auckland /012

% % % .c ! a n 3 . c o.n3

Ministry of Business, Innovation and m!loyment

#- Bo) *24

Wellington 5400

Website' %%%.mb ie.g ovt. n3

ISB$' 6278481278*60408

#ublished' March /40*

"o!yright 9 "oncrete #um!ing Association of $e% &ealand

http://www.cpanz.co.nz/



http://www.cpanz.co.nz/




TABLE OF CONTENTS

NT!OD"CTON #################################################################################################################### $

SECTON %: GENE!AL ############################################################################################################ &

0.0 #ur!ose ................................................................................................................... 7

0./ Sco!e...................................................................................................................... 7

0.* (elationshi! to $e% &ealand Standards ....................................................................... 7

0.1 (eference documents ................................................................................................ 7

0. +efinitions ............................................................................................................... 7

0.5 :egislation ............................................................................................................... 7

0.2 ;a3ard controls ........................................................................................................ 7

SECTON ': MANAGNG STE (A)A!DS############################################################################### %*

/.0 Manual handling ha3ards ......................................................................................... 04

/./ "ement ha3ards ..................................................................................................... 00

/.* $oise ha3ards......................................................................................................... 0/

/.1 "arbon mono)ide ha3ards ........................................................................................ 05

/. -verhead !o%er lines and other electrical e<ui!ment .................................................. 02

SECTON +: ,LANNNG AND ,!E,A!ATON ######################################################################## '*

*.0 =eneral ................................................................................................................. /4

*./ The construction site !rinci!al .................................................................................. /4

*.* "oncrete !um!ing contractor ................................................................................... /0

*.1 <ui!ment hirer...................................................................................................... //

SECTON -: SET.", ############################################################################################################# '+

1.0 =eneral ................................................................................................................. /*

1./ Arrival on site......................................................................................................... /*

1.* #um! set8u! .......................................................................................................... /*

1.1 Boom set8u! .......................................................................................................... /*

1. -utriggers ............................................................................................................. /1

1.5 #lacing the boom .................................................................................................... /1

1.2 (eceiving ho!!er .................................................................................................... /

1.7 -!erational safety 3one ........................................................................................... /5

1.6 +elivery !i!eline set8u! ........................................................................................... /7

SECTON /: O,E!ATON###################################################################################################### +'

.0 =eneral ................................................................................................................. */

./ "ommunications ..................................................................................................... */

.* #um! and boom o!erators ....................................................................................... */

.1 #um! o!erator,hose8hand ....................................................................................... */

. ;ose8hand ............................................................................................................. **

.5 Workers................................................................................................................. *1

.2 Trainee %orkers ...................................................................................................... *

.7 "oncrete delivery drivers ......................................................................................... *

.6 "leaning of e<ui!ment............................................................................................. *

.04 #re!aration for road travel ................................................................................... *7

SECTON 0: E1",MENT###################################################################################################### -*

5.0 =eneral re<uirements .............................................................................................. 14

5./ +ocumentation ....................................................................................................... 14



5.* Identification .......................................................................................................... 14

5.1 #i!eline com!onents ............................................................................................... 10

5. ;ydraulic systems ................................................................................................... 10

5.5 "ontrols................................................................................................................. 10

5.2 #i!eline and hose sections ....................................................................................... 10

5.7 Manuals and logbooks ............................................................................................. 105.6 Warning and safety signs ......................................................................................... 1/

5.04 +is!osal and ac<uisit ion of used e<ui!ment............................................................ 1/

5.00 Ac<uisit ion of unserviceable e<ui!ment .................................................................. 1*

SECTON $: MANTENANCE AND NS,ECTON##################################################################### --

2.0 =eneral ................................................................................................................. 11

2./ Annual ins!ections .................................................................................................. 11

2.* Ma>or ins!ection ..................................................................................................... 1

2.1 (e!airs and modifications ........................................................................................ 1

2. Testing !i!eline com!onents .................................................................................... 15

A,,END2 A: S"MMA!3 OF T(E (EALT( AND SAFET3 N EM,LO3MENT ACT %44' ############# /*

Introduction ...................................................................................................................... 4

=eneral res!onsibilities of em!loyers .................................................................................... 4

=eneral res!onsibilities of em!loyees.................................................................................... 4

;a3ard management .......................................................................................................... 0

Information for em!loyees .................................................................................................. 0

Training and su!ervision ..................................................................................................... 0

Accidents and serious harm recording and notification ............................................................ *

+uties of others ................................................................................................................. 1

A,,END2 B: !EFE!ENCE DOC"MENTS ############################################################################### /0

Acts.................................................................................................................................. 5

(egulations ....................................................................................................................... 5

A!!roved "odes of #ractice ................................................................................................. 5

Standards ......................................................................................................................... 5

-ther !ublications .............................................................................................................. 5

(esearch documents........................................................................................................... 2

A,,END2 C: DEFNTONS ################################################################################################ /4

A,,END2 D: (AND SGNALS FO! CONC!ETE ,"M,NG##################################################### 0-

A,,END2 E: CONC!ETE T!"CK D!5E! (AND SGNALS #################################################### 0$

A,,END2 F: SGNFCANT (A)A!D !EGSTE! 6E2AM,LE7################################################ 0&

Significant ha3ard register ................................................................................................... 20

A,,END2 G: TASK ANAL3SS WO!KS(EET ######################################################################## $'

A,,END2 (: ,,ELNE NS,ECTON LOG S(EET ############################################################### $-



LST OF TABLES AND FG"!ES

Ta8les

Table 0' Sym!toms of carbon mono)ide e)!osure at increasing levels .......................................... 05

Table /' (e<uired minimum a!!roach distances ?%here %ritten consent has been obtained@

0

.......... 02Table *' Minimum !i!e %all thickness ?mm@ .............................................................................. 12

Fig9res

igure 0' Truck8mounted !lacing boom ....................................................................................... 2

igure /' Wet cement caused the burns to this !ersons leg. ....................................................... 00

igure *' $oise levels of selected construction tools .................................................................. 0*

igure 1' Be%are of ha3ards %hen set u! in enclosed areas......................................................... 0

igure ' Minimum safe distances for the o!eration of mobile !lant near conductors ..................... 07

igure 5' #osition !um!ing e<ui!ment clear of e)cavations ......................................................... /*

igure 2' :ook u! and live 8 com!ly %ith area restrictions ........................................................... /

igure 7' Cee! clear %hen truck is reversing 8 dont stand bet%een the truck and ho!!er ............... /2

igure 6' Cee! clear %hen truck is reversing 8 remain in the drivers vie% ..................................... /2

igure 04' Securely fi) the !i!eline to avoid movement .............................................................. /6

igure 00' Duick8release clam! %ith locking !in ......................................................................... *4

igure 0/' Ese anchor brackets to restrict !i!e movement .......................................................... *4

igure 0*' nd8hose and reducer %ith safety slings .................................................................... *0

igure 01' +o not allo% hose to kink ........................................................................................ *1

igure 0' :et the boom do the %ork ........................................................................................ *1

igure 05' The end8hose should be secured or removed ............................................................. *5

igure 02' Cee! clear of discharge end of !i!e........................................................................... *5igure 07' $ever dismantle !i!eline %hile under !ressure ........................................................... *5

igure 06' +angerous cleaning !ractices ................................................................................... *2

igure /4' +angerous cleaning !ractices ................................................................................... *7

igure /0' "onfirm everything is secured before moving ............................................................. *6

igure //' Warning and safety signs must be legible .................................................................. 1/

igure /*' Worker %earing !ersonal !rotective clothing .............................................................. *



NT!OD"CTON

"oncrete !um!ing is an efficient method of moving and !lacing concrete. This!rocess is used in the manufacture of !re8cast and tilt8u! !anels, concreteform%ork, slab construction, concrete !aving and concrete s!raying.

The construction and concrete !um!ing industries must be a%are of theobligations to !revent harm to em!loyees, contractors and others under the;ealth and Safety in m!loyment Act 066/ ?the Act@ and its regulations.

These guidelines !rovide !ractical advice about the safe o!eration andmaintenance of concrete !um!ing e<ui!ment. The em!hasis is to ensure a safe%orking environment %henever this e<ui!ment is used. They are not intended tobe an all8encom!assing design, maintenance and o!eration manual. Thisinformation is available in manufacturersF o!erating manuals.

This document is based on the current kno%ledge of construction methods %ithinthe industry, and is not intended to e)clude other methods or !rocesses that canbe sho%n to meet the re<uirements of !roviding a safe %ork!lace under the Act.

The guidelines %ere !re!ared by a committee of re!resentatives from the"oncrete #um!ing Association of $e% &ealand ?"#A$&@ and under%ent a !ublicconsultation !rocess. This resulted in submissions from a range of affected!arties, including the self8em!loyed, em!loyers and em!loyees %ithin theindustry.

"onsultation %ith the Ministry of Business, Innovation and m!loyment ensuredoverall com!atibility %ith occu!ational health and safety legislation and technicalalignment %ith standards.

Fig9re %: Tr9c.mo9;te< placi;g 8oom



SECTON %: GENE!AL

%#% ,9rpose

This guideline !rovides !ractical guidance about the health and safety issues ofconcrete !um!ing to ensure as far as !racticable a safe %orking environment for!eo!le in the industry. It !rovides guidance for !rinci!als, em!loyers, contractorsand !um! o!erators ?em!loyees or contractors@ on ho% to meet their obligationsto !rovide a safe %orking environment %hen using concrete !um!ing e<ui!ment.

%#' Scope

The guideline a!!lies to the su!!ly, ac<uisition, dis!osal, ins!ection,maintenance, registration and safe o!eration of all ty!es of concrete !um!s andassociated !lacing e<ui!ment used in !um!ing or s!raying concrete in theconstruction industry throughout $e% &ealand.

%#+ !elatio;ship to Ne= )eala;< Sta;<ar<s

This guideline com!lements the key $e% &ealand and Australian standardsa!!lying to concrete !um!s ?listed in A!!endi) B@.

%#- !e>ere;ce <oc9me;ts

+ocuments referenced in this guideline are listed in A!!endi) B. This a!!endi)also !rovides a list of suggested documents for further reading.

%#/ De>i;itio;s

A list of definitions is !rovided in A!!endi) ".

%#0 Legislatio;

A summary of a!!licable health and safety legislation is !rovided in A!!endi) A.

%#$ (a?ar< co;trols

All !racticable ste!s must be taken to ensure that ha3ards are eliminated orisolated, or minimise the significance of the ha3ard by ?for e)am!le@ changing ormodifying the !ro!osed %ork method, construction method, or by usingalternative e<ui!ment.

A significant ha3ard is something that has the !otential to cause a !erson seriousharm. GSerious harmH is defined in A!!endi) ".

If the ha3ard cannot be eliminated or isolated, control measures must be !ut in!lace to minimise risk to em!loyees. In these circumstances, measures such asbarricading areas of danger, !roviding s!ecific safety training and %orkinstructions, using !rotective e<ui!ment and !osting of %arning signs ?ase)am!les@ should be im!lemented.

Such measures should be discussed %ith em!loyees and other %orkers, and

evaluated to ensure that they are effective and do not create additional ha3ards.



While it is not a legal re<uirement to record identified ha3ards and strategies forcontrols on a ha3ard register, this is recommended to ensure that everyone hasreceived the a!!ro!riate information on ho% to kee! safe %hen e)!osed to theha3ards.

An e)am!le of a ha3ard register is located at A!!endi) .

Task Analysis

A task analysis that lists the ha3ards and safe %ork !rocedures should be!re!ared for each concrete !um!ing o!eration. A generic task analysis may beacce!table in some cases, but it is likely to be modified to reflect s!ecific sitesituations.

The minimum re<uirements for a task analysis include'• identifying the ha3ards

• assessing the significance of the ha3ards and the control measures

re<uired to eliminate, isolate or minimise harm !osed by the ha3ards• identifying a !erson or !eo!le res!onsible for im!lementing and

monitoring the control measures.

An e)am!le of a task analysis %orksheet is located at A!!endi) =.



SECTON ': MANAGNG STE (A)A!DS

This section outlines some of the significant ha3ards that are likely to occur onconcrete !um!ing sites.

'#% Ma;9al ha;<li;g ha?ar<s

An em!loyer has a duty to identify and control ha3ards, including ha3ardousmanual handling tasks. These tasks must be assessed, and if the !otential forserious in>ury is determined, control measures should be !ut in !lace to reducethe likelihood that harm %ill occur.

These and other manual handling tasks should be addressed as likely causes of in>ury'

(a?ar< Co;trolsD9ri;g set.9p@ p9mp =orers ma;9all Where !racticable, establish %alk%ays around the

ha;<le items s9ch as tim8er pa<s@ re<9cers@ site and kee! it clear of obstacles and debris.

pipes a;< hoses# Whe; ha;<li;g these #rovide non8sli! ram!s %here %orkers are

items@ the terrai; or the access to the =or re<uired to %alk u! inclines.

area ma i;crease the ris o> i;9r#

The 9se o> hammers o; clamps a;< the nsure that im!act tools are ke!t in good

>lapper 8o lever@ i> carrie< o9t i; areas o> condition %ear a!!ro!riate !rotective

restricte< access@ are tass that ma create e<ui!ment, such as eye !rotection. Where

a; i;crease< ris o> i;9r <9e to =ori;g i; !racticable, conduct %ork in environments %here

crampe< positio;s# there is more s!ace to move.

The i;correct positio;i;g o> the p9mp@ #lan the %ork before the !our commences to

i;e>>ective 8oom placeme;t@ =i;< >orces or ensure that the hose8hand can %ork in the

oscillatio; <9e to p9mpi;g ma ca9se the o!timal area. Also refer to section .1 for further

hose.ha;< to >orci8l restrai; the hose i; information.

the re9ire< positio;@ risi;g strai; i;9ries#

The lai;g o9t o> pipes is a tas that Where !racticable, use mechanical e<ui!ment to

re9ires carri;g 89l o8ects# The ris o> lift and move bulky ob>ects. #osition bulk stores

i;9r prese;te< 8 this tas ca; 8e of e<ui!ment as close as !racticable to labouringi;crease< 8 =ali;g lo;g <ista;ces a;< the sites to minimise carrying.

;ee< to ma;oe9vre pipes aro9;< o8stacles#

Be;<i;g o;es 8ac to move 8e;eath Where !racticable, establish %alk%ays that are

o8ects@ a;< steppi;g over o8str9ctio;s ke!t clear of debris. Ese mechanical e<ui!ment

=hilst carri;g pipes i;creases the ris o> to lift !i!es over ob>ects or u! to higher floors.

i;9r#

The locatio; a;< <esig; o> the storage

poi;ts o; the tr9c >or thi;gs lie pipes@

hoses@ re<9cer a;< o9trigger pa<s have a

8eari;g o; the operators post9res a;< the

<ista;ce these items m9st 8e carrie<#

#osition the truck as close as !racticable to the

concrete !our site. +o not use hoses longer than

s!ecified by the concrete !um! manufacturer.



Cleari;g 8locages i; pipeli;es ca; 8e a

highl ha?ar<o9s tas@ as their removal ma

release 89ilt.9p air press9re# This ma also

8e the case <9ri;g clea;.9p or =he;

removi;g a;< i;verti;g the hose re<9cer to

empt o9t co;crete#

•

The end of the hose should not be enclosed by

metal. nsure that non8necessary !ersonnel

are ke!t clear of the !our area. The end8hose

should not be longer than %hat the concrete!um! manufacturer recommends.

• -!erators should be trained in ho% to

recognise the !otential signs of %hen air

blockages could occur in the hose, for e)am!le'

%hen first starting, re8starting after moving,

%hen the ho!!er is em!ty, if the concrete is too

stiff and %hen the !um! is reversed ?although

it should be recognised

that sometimes it may not be !ossible to

!redict %hen an air blockage has occurred

inside the hose@.

'#' Ceme;t ha?ar<s

-verseas research sho%s thatbet%een five and ten !ercent ofconstruction %orkers may besensitised, or allergic, to cement.)!osing the skin to cement cancause both irritant and allergicdermatitis.

Irritant dermatitis occurs becausethe abrasive and drying nature of cement on the skin causes it tobecome dry, itchy, red and scaly.

Allergic dermatitis is caused by a!erson becoming allergic to achemical com!onent in the cement,usually chromium salts. This usuallyoccurs u!on skin e)!osure to %et

cement. urther, re!eated e)!osureto cement can lead to allergiccontact dermatitis. The more oftenthe !erson is e)!osed, the %orsethe dermatitis becomes. Affected!eo!le may have to leave theindustry if the dermatitis becomesserious.

Fig9re ': Wet ceme;t ca9se< the 89r;s to

this perso;s leg#



The sym!toms of dermatitis usually sho% %ithin /1817 hours of cement e)!osure.+e!ending on the severity of e)!osure, sym!toms include'

• a red rash or bum!s on the e)!osed skin• itching, sometimes severe

• dry, cracked, red !atches resembling a burn• blisters that drain fluid or become crusted

• !ain, tenderness or heat on the e)!osed skin

• scaly, ra% or thickened lesions.

Some com!onents or additives in the cement are classified as ha3ardoussubstances. This means that the cement su!!lier has to !rovide the !erson incharge of the !lace of %ork %ith safety data sheets. Safety data sheets containuseful information on ho% to kee! safe %hen handling the concrete, %hat to do if an emergency occurs or if significant health reactions occur.

Wet cement can cause burns if tra!!ed against the skin ?see figure /@. #ersonal!rotective clothing or e<ui!ment such as gloves or boots must not allo% %etcement to be held against the skin.

;o%ever, if this occurs, it is im!ortant to immediately %ash the area %ith soa!and %ater to remove cement from the skin.

(a?ar< Co;trols

Wori;g i; =et ceme;t • Wear a!!ro!riate !rotective clothing and

e<ui!ment' gloves, safety goggles ?if s!lashes

to the face could occur@, long clothing,

%ater!roof foot%ear.

•

(emove foot%earclothing immediately and

%ash skin %ith a !;8neutral soa! and %ater if

direct contact %ith concrete occurs.

• If the sym!toms of dermatitis a!!ear, see a

doctor as soon as !ossible for treatment.

'#+ Noise ha?ar<s

Workers in the construction industry use a variety of tools and machinery in the

course of their %ork. A significant ha3ard of using this e<ui!ment, or %orkingnear !eo!le %ho use this e<ui!ment, is e)cessive noise.

#rolonged e)!osure to e)cessive noise causes !ermanent hearing loss. It is not ageneral loss of hearing the ability to hear some fre<uencies of sound is lost. It isa bit like listening to music %ith the treble control turned all the %ay do%n.Although a !erson %ith hearing loss may hear !eo!le talking, it becomes moredifficult for that !erson to understand %hat they are saying.

"ontinuous e)!osure to noise above 7dB?A@ ?an average noise level of 7decibels over an eight8hour %ork shift@ %ill cause !ermanent hearing damage. As

a rule, %orksite noise e)ceeds 7dB?A@ if conversation at a normal level bet%een!eo!le is difficult %hen standing one metre a!art.



$oise is measured on a logarithmic scale instead of a linear scale. This meansthat if machine A is 7dB and machine B is 77dB, machine B is, in fact, t % i ce a sl ou d as machine A.

-n many construction sites, noise levels can be difficult to control. ;o%ever, if anoise level assessment sho%s that %ork!lace noise e)!osure e)ceeds 7dB?A@over an eight8hour timeframe, the em!loyer must im!lement ha3ard controlssuch as'•

elimination ?for e)am!le, substituting noisy e<ui!ment for less noisye<ui!ment, or using less noisy %ork !rocesses@

• isolation ?for e)am!le, noise8reducing booths %here noisy !ortable %ork can beconducted@

• minimisation ?for e)am!le, reducing %orker e)!osure to the noise by

conducting noisy %ork at less busy times of the day or night, increasingem!loyeesF %orking distances from noise sources, and !roviding hearing!rotection and conducting health monitoring@.

The Ministry of Business, Innovation and m!loyment has carried out noise tests on

common construction tools to give an estimate of ho% loud they are. See figure *' $oise

levels of selected construction tools ?overleaf@.



BE&; SA2$ER

-GSA+

8"< 8= dB

HA2$ HE&$

P&A2ER A

,AS%2R Y $R-&&

(t i mber then concrete)

8A<"!! dB

Sound le.els

measured in

deci1els (dB)

E&EC;R-C C

CHA-2SA+78< 8# dB BE2CH

GR-2$ER

8< 8 dB

E&EC;R-C

%R-&&

R%U;ER HA,,ER

PAS&%$E

2A-& GU2

8' <"!( dB

BE&; SA2$ER

'8< 7# dB

>into 0ood?8! < 8( dB %2 2A-&

"into tim#er)

8#< 8' dB

Faintest

Audible

Sounds

Conversation

Jetcra ft

taking off

25m away

! /44 2 W $% &0 0 0 0 0

444

0

'ver age 'llowa#le

Exposure limit over

an 8 hour per iod

in ew ealand C-RCU&AR SA+

8(< 87 dB

CU; %FF SA+ A

E&EC;R- C GR-2$ER

(on aluminium)

87 < "! dB

P%+$ER AC;UA;E$ ;%%&

>into tim1er ? "!!<"!( dB

>into masonary? "!' < ""!

dB

*+ ,E-EC.E/ C*(,.0&C.I*( .**-, BE2CH R-P SA+

8=< 88 dB

Best Practice GuidelinesD Concrete Pumping Page - "(

44/

0

(1

*I,E -E2E-,



Fig9re -: Be=are o> ha?ar<s =he; set 9p i; e;close< areas

An increase to normal o!erating noise levels may occur due to sound beingreflected back from other structures. Suitable control measures may need to be!ut in !lace to ensure that %orkers in the area are !rotected. These %orkersinclude'

• the %orkers in the affected area• the concrete !um! o!erators

• the delivery truck drivers• the o!erators of other associated e<ui!ment.

When !ositioning the !um!, efforts should be made to minimise the effect of thesurroundings on the %orkersF overall noise e)!osure.

If %orkers in affected areas are !rovided %ith hearing !rotection to controle)!osure to noise, the hearing !rotection must be %orn all of the times %hennoise levels e)ceed 7dB?A@. Atmos!heric testing is re<uired %hen hearing!rotection is %orn, as the noise ha3ards fluctuate de!ending u!on the %orkactivities.

or further information on noise level monitoring, refer to the Approved Code of

Practice for the Management of Noise in the orkplace, available at%%% .o s h .d o l .g o v t .n 3 o rd e rc a t a l o g u e 0 .s h t m l .

Visit the $e% &ealand -ccu!ational ;ygiene Society at %%% .n 3 o h s .o rg .n 3 to finda noise level testing !rovider, or contact the Ministry of Business, Innovation andm!loyment on 4744 /4 64 /4.

http://www.osh.dol.govt.nz/order/catalogue/15.shtml




http://www.nzohs.org.nz/


http://www.nzohs.org.nz/



'#- Car8o; mo;oi<e ha?ar<s

If concrete !um!ing e<ui!ment is set u! in an enclosed or semi8enclosed area,s!ecial attention should be given to the ha3ards created by the build8u! ofha3ardous e)haust va!ours, !articularly carbon mono)ide.

"arbon mono)ide ?"-@ is a deadly !oison J it is colourless, odourless and non8irritating. -ver 04K of !eo!le %ho have survived high carbon mono)idee)!osures are left %ith a !ermanent brain in>ury. "arbon mono)ide is more likelyto build u! in enclosed or !oorly ventilated areas %here machines using !etrol,diesel or gas are o!erated. All !racticable ste!s must be taken to control thisha3ard.

This is %hat ha!!ens to the body %hen e)!osed to increasing levels of carbonmono)ide'

Co;ce;tratio; o>car8o; mo;oi<e i; air

Smptoms

+/ppm ;eadaches and di33iness %ithin si) to eight hours of continual e)!osure

%**ppm ;eadache %ithin t%o to three hours

'**ppm ;eadache %ithin t%o to three hours loss of >udgement

-**ppm ;eadache %ithin one to t%o hours

&**ppm ;eadache, di33iness, nausea and convulsions %ithin 1 minutes

unconscious %ithin t%o hours

%@0**ppm ;eadache, accelerated heart rate, di33iness and nausea %ithin /4

minutes, death in less than t%o hours

+@'**ppm ;eadache, di33iness and nausea %ithin five to ten minutes death %ithin

*4 minutes

0@-**ppm ;eadache and di33iness in one to t%o minutes convulsions, breathing

sto!s, and death in less than /4 minutes

%'@&**ppm Enconsciousness after t%o to three breaths death in less than three

minutes.

Ta8le %: Smptoms o> car8o; mo;oi<e epos9re at i;creasi;g levels

(a?ar< Co;trols

Epos9re to car8o; mo;oi<e >rom petrol@

gas or <iesel.po=ere< machi;er

nsure that engine e)haust gases from the !um!

and delivery trucks are directed to the o!en air,

and that a build8u! of va!ours such as carbon

mono)ide cannot occur in the %ork area.

"onfined areas may re<uire e)traction ventilation

andor air8su!!lied breathing a!!aratus.



'#/ Overhea< po=er li;es a;< other electrical e9ipme;t

If a concrete !lacing boom is set u! in the vicinity of aerial !o%er lines,the !rinci!al and concrete !um!ing contractors should take all !racticable ste!sto ensure that %orkers are not harmed by the significant ha3ards faced by%orking near high8voltage electricity, such as electrocution from direct contact%ith the lines, or arc flash, %here a flashover of electric current leaves itsintended !ath and travels through the air from to another conductor or theground.

In line %ith the hierarchy of controls, %here %ork is being !lanned in the vicinityof overhead !o%er lines, !rinci!als and concrete !um!ing contractors should takeall !racticable ste!s to eliminate the ha3ard by de8energising the !o%er linesthrough the line o%ner. #lease note that the line o%ner %ill re<uire a reasonable!eriod of notice for this to be arranged.

If it not !racticable to de8energise the !o%er line, !rinci!als and concrete!um!ing contractors must ensure, during all stages of the concrete !um!ingo!eration, that no !art of the concrete !lacing boom comes %ithin FO"!

MET!ES of live !o%er lines, unless the o!erator has received %ritten consentfrom the line o%ner allo%ing a reduced distance.

(easonable notice should be !rovided for %ritten a!!lications for consent to %ork%ithin reduced minimum a!!roach distances or to turn the !o%er off to the area.

If a!!roval to %ork closer to overhead !o%er lines has been obtained in %riting,the minimum a!!roach distance bet%een a !o%er line and any mobile !lant ?in

this case, the concrete !lacing vehicle@ shall not be less than s!ecified in Table /0.

Circ9it voltage Mi;im9m approach <ista;ce 6m7

$ot e)ceeding 0 kV J insulated conductor 4.0

$ot e)ceeding 0 kV J conductor not insulated 0.4

)ceeding 0 kV but not e)ceeding 55kV 0.4

)ceeding 55kV but not e)ceeding 004 kV a.c. or d.c. 0.

)ceeding 004 kV but not e)ceeding //4 kV a.c. or d.c. /./

)ceeding //4 kV d.c. but not e)ceeding /24 kV d.c. /.*

)ceeding /24 kV d.c. but not e)ceeding *4 kV d.c. /.7

)ceeding *4 kV d.c. or //4 kV a.c. 1

Ta8le ': !e9ire< mi;im9m approach <ista;ces ?%ritten consent has been obtained@0

0 Table 5 J (educed Minimum A!!roach +istances ?%here %ritten consent has been obtained@ from

$&"# *1'/440 Ne! "ealand #lectrical Code of Practice for #lectrical Safe Distances, nergy Safety

Service ?Ministry of conomic +evelo!ment@

Best #ractice =uidelines' "oncrete #um!ing #age L 02



#age L 07 Best #ractice =uidelines' "oncrete #um!ing

"onsent from the !o%er line o%ner shall also include'• the section of !o%er line to %hich the consent a!!lies

• any other reasonable conditions to be observed %hen %orking in !ro)imityto or above the !o%er line.

Competent employees

If the o!erator of any mobile !lant is a com!etent !erson %orking in, or in the!ro)imity of, an overhead !o%er line, the a!!roach distances may be reduced inaccordance %ith the safety !ractices determined by the overhead !o%er lineo%ner.

It is recommended in these cases that the mobile !lant o!erator is assisted by as!otter, %ho can determine the machineFs !ro)imity to the !o%er lines.

If concrete !lacing booms or other mobile !lant are likely to be used at any time

in the !ro)imity of overhead !o%er lines, the o%ner or o!erator of the !lantshould affi) an a!!roved %arning notice in a cons!icuous !lace as near as!racticable to the o!eratorFs !osition. The notice shall be maintained in a legiblecondition and shall state'

WA!NNG: KEE, CLEA! OF ,OWE! LNESH#

When considering minimum a!!roach distances, take into account the surgeaction of the concrete !um! boom %hen it is !um!ing. This action has resulted inserious harm and fatal accidents through contact %ith electrical conductors.

or further information on safe distances %hen %orking in the vicinity of overhead!o%er lines, refer to the Ne! "ealand #lectrical Code of Practice for #lectrical

Safe Distances $&"# *1'/440, available from the nergy Safety Service of theMinistry of Business, Innovation and m!loyment ?conomic [email protected]' %%% .me d.g o v t .n 3.

It is recommended that concrete !um!ing com!anies engage !roactively %ith the!o%er line com!anies in order to ensure a viable and efficient %orking!artnershi!.

Fig9re /: Mi;im9m sa>e <ista;ces >or the operatio; o> mo8ile pla;t ;ear

co;<9ctors' ?overleaf@

/ Source' $&"# *1'/440 Ne! "ealand #lectrical Code of Practice for #lectrical Safe Distances , nergy

Safety Service ?Ministry of conomic +evelo!ment@

http://www.med.govt.nz/

http://www.med.govt.nz/



SECTON +: ,LANNNG AND ,!E,A!ATON

+#% Ge;eral

#lanning and !re!aration is the first ste! in ensuring that concrete !um!ing isdone safely, and must involve consultation %ith all those engaged in the %ork.

#lanning should incor!orate the !ro>ectFs total !um!ing o!erational re<uirements.This !lan may need to be revie%ed each time a concrete !um!ing o!eration isscheduled, to take into account any unforeseen circumstances.

Information regarding principals’ legal duties

Section 07 of the ;ealth and Safety in m!loyment Act 066/ ?the Act@ !laces aduty on a !rinci!al to a contract to take all !racticable ste!s to ensure thatcontractors, subcontractors and their em!loyees, are not harmed %hile

undertaking any %ork under the contract.

A !rinci!al or contractor may also be an em!loyer, a self8em!loyed !erson, or a!erson %ho controls a !lace of %ork ?%ith duties under section 05 of the Act@.

A !rinci!als duty under the Act is limited to matters %hich they can reasonablybe e)!ected to control. There are situations %here control of a !lace of %ork maybe shared by the !rinci!al and by contractors. or e)am!le, an electricalsubcontractor %orking on scaffolding on a construction site may not be sub>ect tothe control of the main contractor ?a !rinci!al in this case@ regarding theelectrical %ork he or she is doing, but the use of the scaffolding may be under the

control of the !rinci!al.

Section 07 is intended to cover situations %here either'• the contractor does not have full control because of conditions in a

contract or because ha3ards are under the control of the !rinci!al, or• %ork is being carried out %here there is no em!loyerem!loyee

relationshi!, and the !rinci!al retains control of the !lace of %ork.

or further information about health and safety in contract management, read G APrincipal$s %uide to Contracting to Meet the Health and Safety in #mployment Act

&''(H ?refer to A!!endi) B@.+#' The co;str9ctio; site pri;cipal

The construction site !rinci!al, in consultation %ith other involved contractors andthe !um!ing contractor should'

• ensure that enough trained and com!etent %orkers are available to safely

use the !um!ing e<ui!ment• ensure that !um!ing e<ui!ment is %ell maintained and in a sound

mechanical condition• select the most suitable location for the !um! set8u!, including'

o an accessible, reasonably level area %ith a firm base, able tosu!!ort the fully loaded %orking !um! and concrete delivery trucks

o clearance from obstructions and e)cavations

Best #ractice =uidelines' "oncrete #um!ing #age L /4



o observing the restrictions of o!erating near overhead !o%er lineso the !um!Fs o!erational safety 3one

• if the !um! unit or delivery area is set u! in the street'

o observe all local by8la%so observe any re<uirements for traffic managemento ensure that the general !ublic is !rovided %ith safe and segregated

access a%ay from the !um!ing o!eration• have an a!!ro!riate method for the collection of residue or %aste

concrete, before it enters storm %ater drains, %hich may result from'o concrete truck deliverieso s!illageo the %ash8out and cleaning of the !um! or lines

• set a realistic time schedule for !um!ing concrete, allo%ing for'

o %eather conditionso ca!acity of the !um!o volume of concreteo slab and site limitationso traffic re<uirementso local by8la%so the concrete contractorFs %ork ca!acity.

+#+ Co;crete p9mpi;g co;tractor

The concrete !um!ing contractor, after consulting %ith the !rinci!al and otherinvolved contractors, should ensure that the most suitable location for the !um!set8u! is selected, including'

• an accessible, reasonably level area %ithin the o!erating ca!acity of the

e<ui!ment• a firm base able to su!!ort the fully loaded %orking !um! and delivery

trucks• clearance from obstructions and e)cavations

• observing electricity safety, including the restrictions of o!erating nearoverhead !o%er lines

• the !um!Fs o!erational safety 3one.

The !um!ing contractor must ensure that any su!!lied !um!ing e<ui!ment is in amechanically sound condition and has'

•

legible identification on each !iece of e<ui!ment• com!rehensive o!eratorFs instructions or the manufacturerFs o!eration

manual?s@• all of the correctly !ositioned, legible %arning and safety signsstickers• all re<uired safety e<ui!ment

• an ade<uate su!!ly of !acking for the stabiliser base !lates

• a com!leted assessment of the risks of in>ury from all associated tasks

• current e<ui!ment maintenance logbooks?s@

• any re<uired trans!ort authority !ermits and vehicle registration

• detailed maintenance and ins!ection records available u!on re<uest.

The !um!ing contractor must ensure that'• enough %orkers are available to safely !um! concrete



• safe systems of %ork are being follo%ed

• !ersonal !rotective e<ui!ment ?##@ is !rovided and used

• other re<uired safety e<ui!ment is su!!lied and used

• all %orkers are ade<uately trained andor su!ervised.

Other equipment

ach mobile concrete !um! should be e<ui!!ed %ith all necessary safetye<ui!ment, including a'

• stocked first aid kit• charged and current fire e)tinguisher

• a sufficient number of reflective traffic cones ?minimum 14mm high foridentifying %et roads or !avements@.

Additional safety e<ui!ment may need to be !rovided if the !um! is set u! on ornear a road%ay, and may include'

•

!edestrian %arning and diversion signs• vehicle traffic %arning signs

• traffic management e<ui!ment.

+#- E9ipme;t hirer

A su!!lier %ho hires or leases out concrete !um!ing e<ui!ment has duties underthe (egulation 52 of the ;ealth and Safety in m!loyment (egulations 066,including ensuring that the !um!ing e<ui!ment is'

• %ell8maintained and in a sound mechanical condition

• e<ui!!ed %ith all necessary safe use and o!erating information

•

!rovided %ith the re<uired maintenance and ins!ection records.

The vehicle com!onent of the concrete !um! shall have a suitable "ertificate of itness and be registered to o!erate on the road.



SECTON -: SET.",

-#% Ge;eral

"oncrete !um!ing e<ui!ment in o!eration should not create a ha3ard to theo!erators, other %orkers or the !ublic.

-#' Arrival o; site

When arriving on site ?%here !racticable@, the concrete !um! o!erator, or othere)!erienced re!resentative, should be sho%n the set8u! area, and the siteconditions revie%ed %ith the other contractors involved in the !um!ing o!eration.Where any of the conditions under %hich the !um!ing e<ui!ment is to o!erateare not satisfactory, or if confirmation of the e<ui!mentFs mechanical soundnessis not available, rectification should occur before !um!ing commences.

-#+ ,9mp set.9pThe concrete !um!ing area should be reasonably level, solid and free ofobstructions, %ith careful attention !aid to the !ositioning of the !um!inge<ui!ment and any stabilising devices. In !articular, the area should be'

• clear of e)cavations, trenches or holes in the ground• clear of inade<uately com!acted or soft ground• clear of cellars, basements, !its or back8filled ground, unless stability is

a!!roved in %riting by a <ualified engineer• clear of overhead !o%er lines and fi)ed electrical e<ui!ment

• of a si3e enough to allo% for safe o!eration

•

of a si3e enough to allo% for the safe discharge from the concrete deliverytrucks.

-#- Boom set.9p

The boom !lacement system should be set u! level or at no greater angle thanrecommended by the manufacturer, as s!ecified in the o!eratorFs instructionmanual.

Fig9re 0: ,ositio; p9mpi;g e9ipme;t clear o> ecavatio;s



-#/ O9triggers

Where outriggers are fitted, ensure that'• ade<uate !acking of sufficient strength and load bearing area is available

for the outrigger stabilising !ads. #acking may include engineered bogmats or suitable timbers. The use of loose soft%ood timbers is notrecommended

• before the boom is erected, that the outriggers are e)tended, lo%ered andlocked in !osition. Wherever !ossible, the outriggers should be fullye)tended.

o If outriggers are not fully e)tended, the reduced safe o!eratingradius must be kno%n and recorded in the task analysis.

• the !ads are clear of e)cavations soft or filled ground or other obstaclesare liable to interfere %ith the safe o!eration of the machine

• regular ins!ections of the outrigger !ads are conducted to check forsubsidence and loss of stability

• the boom is folded in the travel !osition before raising the outriggers %henmaking any !ositioning ad>ustments.

-#0 ,laci;g the 8oom

A concrete !lacing boom should not be'• raised or left e)tended %hen %inds e)ceed the ma)imum safe %ind s!eed

for o!eration ?s!ecified by the manufacturer@• raised or left e)tended during an electrical storm or thunderstorm

• used as a crane

• used to !um! concrete %ith the rams in tension, unless designed for this

!ur!ose• raised, lo%ered or moved %hen there is insufficient light to do so safely.

In addition, any truck8mounted !lacing boom should'• have the earth safety chain de!loyed before o!eration

• not be raised from the travel !osition if under a !o%er line, unless

com!lying %ith section /.5.



Fig9re $: Loo 9p a;< live . compl =ith area restrictio;s

Note: Tiger battens do not !rotect !eo!le from the risk of electrocution or electricshock 8 they only !rovide a visual %arning for !eo!le %orking in the area of !o%er lines.

-#$ !eceivi;g hopper

General

The concrete !um! should be !ositioned so the receiving ho!!er is at a heightthat allo%s a gravity flo% of concrete from the !re8mi) delivery trucks into theho!!er.

Hopper guard

The concrete !um! should not be o!erated unless the ho!!er o!ening is fitted%ith a grille8ty!e safety guard'

• u!on %hich no8one is allo%ed to stand• %hich !revents access to dangerous moving !arts

•

is constructed of !arallel or mesh bars com!lying %ith AS 0107.0' Cranes)Including Hoists and inches* + Concrete Placing #,uipment

• %hich re<uires a tool to be removed

• is connected to an interlocked cut8out s%itch designed to sto! all moving!arts if the guard is lifted.

A correctly fitted ho!!er guard reduces the risk of body entra!ment %ithin themoving !arts of the ho!!er, but due to its design, it cannot !rotect against all!ossible contact %ith the moving !arts. <ui!ment manufacturers use a range of additional measures to limit the likelihood of entra!ment, including'

• se!arating the o!eratorFs controls a%ay from the moving !arts• raising the height of the ho!!er lid from the ground.



When %orking in the vicinity of the ho!!er, the manufacturerFs o!erating andsafety instructions should be strictly observed.

-#& Operatio;al sa>et ?o;e

General

Access to areas around the concrete !um! and delivery !i!eline should berestricted 8 the most a!!ro!riate method of isolating the area should be used.

The use of one or more of the follo%ing controls is recommended'• covered %alk%ays

• barricades

• !osts and safety mesh• !osts and danger ta!e or flags.

Where the !um!ing or !i!eline set8u! is for a longer duration !ro>ect, theisolation methods should be made more !ermanent.

Other people

$o !erson, other than those %orkers directly involved in the concrete !um!ingo!eration, should be in the o!erational safety 3one during concrete !um!ing.

Concrete delivery area

The concrete truck delivery area, including the area around the !um! ho!!er,should be set u! to ensure that'

• %orkers are safe from other vehicles• ade<uate lighting is !rovided if !um!ing in non8daylight hours• a!!ro!riate signage is !osted• there is clear access for delivery trucks.

If multi!le concrete deliveries are e)!ected and on8site traffic management is not!rovided, only one delivery truck should a!!roach and discharge into the ho!!erat a time.

If a designated on8site traffic controller is !rovided, the follo%ing safety rulesshould be follo%ed'

•

all !ersonnel connected %ith discharging from concrete trucks are to %eara!!ro!riate high8visibility safety vests• all concrete delivery trucks must have o!erational reversing bee!ers

• the traffic controller and truck driver should be in !ositions %hich !reventthem from being caught bet%een the ho!!er and a reversing truck

• the traffic controller should %arn the driver at the !um! of the !resence of

another truck being reversed into !osition• the traffic controller should be in a !osition visible to the reversing driver

and %here the ho!!er area can be observed• delivery drivers should ensure that their vehicles remain clear of the

discharge area until signalled to reverse into !osition by the traffic

controller



• if the driver loses sight of the traffic controller %hen reversing into!osition, the driver should sto! immediately.

Fig9re &: Keep clear =he; tr9c is reversi;g i;to positio; . <o;t sta;<

8et=ee; the tr9c a;< hopper

Fig9re 4: Keep clear =he; tr9c is reversi;g i;to positio; . e;s9re that

o9 remai; i; the <rivers vie=

Hand signals

Information about hand signals for concrete truck reversing is located atA!!endi) .

Pulic areas

If the concrete !um!ing e<ui!ment or !i!eline is in an area accessible to thegeneral !ublic, the !rinci!al should !rovide ade<uate control measures to !rotectthe !ublic from any dangers associated %ith the !um!ing o!eration.



A- Pedestrian Controls

If the general !ublic can come close to any !art of the concrete !um!ingo!eration, the follo%ing o!tions are recommended'

• directing the !ublic to an alternative foot!ath, or !roviding an alternative!ath%ay

• installing !rotective screens to !revent concrete s!lashing on members of the !ublic

• erecting barricades and %arning signs that are com!liant %ith $e%

&ealand Trans!ort Agency ?$&TA@ re<uirements.

or longer concrete !um!ing o!erations, !edestrian controls should be of a more!ermanent nature.

.- Traffic Controls

The !rinci!al, in consultation %ith the !um!ing contractor, should !rovide

ade<uate traffic control measures to com!ly %ith $&TA or local governmentre<uirements.

or further information, refer to the Code of Practice for Temporary Traffic

Management , available from Transit $e% &ealand ?refer to A!!endi) B' (eference+ocuments@.

-#4 Deliver pipeli;e set.9p

When installing a !i!eline system, all individual com!onents must be com!atibleand com!ly %ith the !um! manufacturerFs s!ecifications for minimum !ressurerating and ma)imum diameter. A !i!eline should be installed in accordance %ithAS /4.0' Cranes + Safe use + Concrete placing e,uipment , ensuring that'

• unnecessary bends are avoided• each section of the !i!eline is ade<uately su!!orted and secured to the

building to avoid e)tra load on the !i!e clam!s• %hen changing the !i!eline from the hori3ontal to the vertical, the !i!eline

is fi)ed to sto! movement of the bend or the vertical and hori3ontal lines%hich may cause the 64N bend to sna! off at the clam!s

• cranes or hoist to%ers, scaffolding or form%ork are not to be used tosecure the !i!eline unless designed for this !ur!ose

• all metal !i!es and !i!eline com!onents are identified and ins!ected

before installation• the designed !ressure of the !i!eline is com!atible %ith the rated

ma)imum concrete !ressure of all !um!s to be used on the !i!eline duringnormal o!erations.



Fig9re %*: Sec9rel >i the pipeli;e to avoi< moveme;t

Note: If a !um! fails during o!eration, a re!lacement may be re<uired tocom!lete the !our and clean out the !i!eline. If a !um! of the same or lo%er ?if suitable@ !ressure rating is not available, a higher !ressure rated !um! may beused to com!lete the !our, !rovided'

• the concrete !ressure rating of the !i!eline is kno%n• there is a method of monitoring concrete !ressure

• an o!erator is continually monitoring the concrete !ressure

• the concrete !ressure does not e)ceed the !ressure rating of the !i!eline.

Note: if the manufacturer !rovides a conversion factor, the !um!Fs hydraulic!ressure gauge may be used as an indicator of concrete !ressure.

Pipe clamps

"lam!s connecting concrete !i!ing need to be of the correct si3e, a!!ro!riate forthe !ressure rating of the !um!, and maintained in good condition.

All !i!e clam!s used on any !i!eline system must be'•

able to sustain the ma)imum concrete !ressure a!!lied to the !i!eline bythe !um!• regularly ins!ected by a com!etent !erson for signs of %ear or fatigue

• immediately re!laced if deformed or damaged.

"lam!s should also be !ermanently marked %ith the manufacturerFs name ?ortrademark@, and the ma)imum !ermissible o!erating !ressure. The clam!sshould be rated at a %orking !ressure e<ual to or greater than the ma)imum%orking !ressure of the concrete !um!.



Fig9re %%: 19ic.release clamp =ith loci;g pi;

Duick8release !i!e clam!s may only be used if !rovided %ith locking !ins, andshould be visually checked !rior to each !um!ing o!eration.

:ocking !ins, (8ty!e or e<uivalent, are to be fitted and engaged %hen <uick8release !i!e clam!s are used on fi)ed or vertical !i!elines, or'

• %here com!ressed air is used for cleaning !i!elines

• the rated ma)imum concrete !ressure e)ceeds 14 Bar.

All !i!eline connections from the boom must be secured by safety chains or %irestro!s to !revent the !i!eline falling to the ground if a clam! fails.

Pipeline movement

Fig9re %': "se a;chor 8racets to

restrict pipe moveme;t

The !i!eline should be ade<uatelysecured to the building or structure,%ith attention given to the reactionforces generated %here high !um!!ressures are involved. The mountingsystem should be designed to ensurethe !i!eline remains in !lace.

Su!!ort brackets in a vertical !i!elineshould be s!aced no more than threemetres a!art. )!ansion anchors ofthe high8load sli! control ty!e or other

fi)ing methods of at least the samestructural strength should be used iffi)ed to masonry.

The surging action of the !um! should not cause e)cessive !i!e movement. If re<uired, additional anchor brackets or other suitable methods to restrict !i!emovement should be used.

!nd"hose

The rubber delivery end8hose should'• be ins!ected for e)cessive %ear or damage !rior to being fitted



• %here connected to a boom' be secured by a safety chain, sling or otherrestraining device

• not contain metallic !arts

• not be longer than s!ecified by the !um! manufacturer.

If concrete !um!ing has sto!!ed and the hose is manoeuvred over a %ork or!ublic area, the o!erator must !revent concrete falling from the hose outlet.

!nd"hose and reducer comination

If the delivery end8hose is re!laced by a hose and reducer combination, onlythose combinations assembled to the manufacturerFs instructions should be used,and'

• locking !ins are to be engaged on all <uick8release !i!e clam!s in theassembly

• each !iece must be ca!able of %ithstanding the rated ma)imum !ressure

of the !um!• each hanging !iece is tethered by a safety cable, sling or chain• the combined %eight of all !ieces MEST $-T O"+ the %eight of the

manufacturerFs recommended end8hose.

Fig9re %+: E;<.hose a;< re<9cer =ith sa>et sli;gs



SECTON /: O,E!ATON

/#% Ge;eral

To safely o!erate any ty!e of concrete !um!ing e<ui!ment, it is necessary tohave enough %orkers to control the !um!ing o!eration. These %orkers need notbe directly em!loyed by the concrete !um!ing contractor, but should be trainedand e)!erienced, and re<uire their em!loyerFs authorisation before commencingthe %ork.

/#' Comm9;icatio;s

The effective !assing of directions from the hose8hand to the !um! o!erator isessential for safe concrete !um!ing. The follo%ing e)am!les may be used'

• non8verbal' a set of standard hand signals %hich cover all of the !um!Fso!erational functions ?refer to A!!endices + and @

• verbal' standard o!erational !hrases that may be delivered by a dedicatedt%o8%ay radio system.

/#+ ,9mp a;< 8oom operators

The concrete !um!ing e<ui!ment o!erator should be trained in the o!eration of the ty!e of !lant being used, and'

• be familiar %ith the instruction manual?s@• be able to carry out daily maintenance ins!ections

• before !um!ing commences, carry out a visual ins!ection of the !i!eline

• not leave o!erating e<ui!ment unattended

• not ad>ust the hydraulic !ressure of the !um! and !i!eline to %hich the!um! is connected

• not !um! concrete unless the ho!!er guard is in the closed !osition• not stand or allo% any other !erson to stand on the ho!!er guard or

beneath the raised boom• be located at the !um! controls, or if using a remote control, have a clear

vie% of either the hose8hand or the ho!!er• follo% the directions of the hose8hand

• if using hand signals and out of vie% of the hose8hand, be assisted byanother %orker to relay directions

• if out of vie% of the ho!!er, have a %orker !ositioned at the ho!!er too!erate emergency systems and control the discharge !rocess

• re!ort defects to the !um!ing su!ervisor %ithout delays if they are

considered to be a significant ha3ard, sto! !um!ing o!erations until theyare re!aired

• record daily ins!ections, defects and re!airs in the logbook.

/#- ,9mp operatorIhose.ha;<

If a mobile concrete !um! is fitted %ith remote control facilities, the o!erator mayo!erate as a hose8hand and also control the concrete !um! under the follo%ingconditions'

• a site8s!ecific task analysis has been com!leted that addresses all issuesrelating to this dual function



• a %orker is !ositioned at the ho!!er to o!erate the emergency systemsand to control the discharge !rocess.

If a mobile concrete !lacing boom is to be controlled, these additional conditionsshould be follo%ed'

• the ha3ards of accessibility by the !ublic or other %orkers have beenaddressed

• the boom is visible to the o!erator and the !um! is in an audible range

• there are no obstructions %hich the moving boom may contact during the!um!ing o!eration.

/#/ (ose.ha;<

atal accidents have occurred %here hose8hands have been killed by the end8hose %hi!!ing around under high !ressure and hitting their head or body. This isa significantly ha3ardous o!eration, and all !racticable ste!s to ensure the safety

of the hose8hand and others in the vicinity of the hose must be taken.Hose"#hip

;ose8%hi! can occur either during the concrete !um!ing o!eration, or %hen thehose is being cleaned out. It is generally caused by air getting tra!!ed in thehose line, usually behind a concrete blockage. If this ha!!ens, the air !ressurebehind the blockage builds u!, and can e>ect the blockage %ith such force thatthe hose becomes unmanageable. -ften the hose P%hi!s aroundF and strikes theo!erator %ith force. atal accidents have occurred %hen the hose has strucko!erators in the head or face.

(a?ar< Co;trols

Fatal or serio9s acci<e;ts ca9se<

8 hose.=hip

•

+o not attach metal fittings to the free end of the rubber

delivery hose.

•

Ins!ect the delivery hose for %ear or deterioration before

use.

•

Ese concrete that is of a !um!able consistency s!ecified

by the concrete su!!lier. "oncrete that is too stiff is

likely to cause blockages.

•

+o not let the concrete solidify in the line, as this also

causes blockages.

•

The hose8hand should be able to communicate %ith the!um! o!erator at a distance.

• )!erienced o!erators should be used to o!erate the

hose. ?Trainee %orkers may o!erate the hose under the

direct su!ervision from a com!etent and e)!erienced

o!erator@.

• Start the concrete !um! slo%ly to minimise air getting

into the hose.

•

+o not stretch the hose if it cannot reach the !ouring

location.

• The hose length should not e)ceed the manufacturerFs

recommendations.

•

Wear the a ro riate ersonal rotective e ui ment



including a hard hat.

• Maintain good housekee!ing around the !our site to

minimise tri!!ing ha3ards.

• If !ossible, avoid %orking directly beneath the raised

boom by manoeuvring the hose from the side.

•

The delivery hose on a boom !um! should hang

vertically and only be guided ?instead of forced@ by the

hose8hand.

•

+o not allo% concrete to fall out of the hose %hen

!um!ing is sto!!ed ?this lets air into the hose@.

•

The hose8hand should stand on a flat surface, and not on

%alls or unguarded structure edges.

• nsure that someone is in !osition to vie% the ho!!er

and shut the !um! do%n if air gets into the system, for

e)am!le, if concrete runs out.

•

-ther !ersonnel ?not related to concrete !um!ing@

should be ke!t clear of the !our area.

Fig9re %-: Do ;ot allo= hose to i; Fig9re %/: Let the 8oom <o the =or:

/#0 Worers

All %orkers engaged in concrete !um!ing should be instructed in the concrete!um!ing task analysis. Where it is a!!licable to the tasks undertaken, additionalinstruction may need to include'

• manual handling !rocedures relating to concrete !um!ing• communication methods for relaying directions

• traffic management if directing multi!le reversing !re8mi) concretedelivery trucks.

-nly those %orkers %ho are a!!ro!riately trained in traffic management and roadsafety !rocedures should act as road traffic controllers.



Note: =enerally, drivers of !re8mi) concrete delivery trucks should not beconsidered %orkers for concrete !um!ing o!erations, unless trained to carry outthis function and authorised to act in this ca!acity by their em!loyer or theconcrete !um!ing contractor.

/#$ Trai;ee =orersTrainee %orkers must be under the direct su!ervision of a suitably trained ore)!erienced %orker %ho has been a!!ointed as a su!ervisor by the em!loyer orcontractor, and can immediately take action to rectify a dangerous situation.

/#& Co;crete <eliver <rivers

When delivering to the site, it is essential that all concrete delivery drivers follo%the directions of the %orker?s@ res!onsible for controlling traffic and the concretedischarge !rocess. This is critical %hen multi!le trucks are discharging ormanoeuvring at the !um! site.

A number of concrete mi)er drivers have been in>ured by bursting !um! lines andcou!lings. The follo%ing actions should be undertaken by drivers %orking nearconcrete !um!ing o!erations'

• stay %ell clear of !um! lines and cou!lings %here !racticable• %ear all re<uired !ersonal !rotective e<ui!ment ?##@ and

• immediately re!ort any safety !roblems to the !um! o!erator or foremanfor action.

/#4 Clea;i;g o> e9ipme;t

"leaning out residual concrete from !um!ing e<ui!ment should only be carriedout by trained %orkers in accordance %ith the manufacturerFs !rocedures or thedetailed %ritten instructions develo!ed by a com!etent !erson. When concrete!um!ing e<ui!ment is being cleaned out, ensure that another !erson is in theimmediate vicinity to !rovide hel! in an emergency.

Pipeline

When cleaning out !i!elines, the follo%ing safety !recautions should be observed'• the end8hose should be secured or removed before cleaning to !revent the

hose %hi!!ing around• the discharge end of the !i!eline should be fitted %ith a cage to safely

catch the cleaning device, but at the same time allo% the concrete to flo%• all %orkers are to be ke!t clear of the discharge end %hile the concrete is

under !ressure• never attem!t to dismantle the !i!eline %hile it is still under !ressure.



Fig9re %0: The e;<.hose sho9l< 8e sec9re<

or remove<

Fig9re %&: Never <isma;tle pipeli;e =hile

9;<er press9re

Fig9re %$: Keep clear o> <ischarge e;< o> pipe

If com!ressed air is used to clean the !i!eline, the follo%ing safety !recautionsa!!ly'

•

the air entry !oint to the !i!eline is to be fitted %ith'o a large diameter discharge air ball valve, to allo% de8!ressurisation

?venting@ of the line before removalo a smaller air entry ball valveo a !ressure gauge, to sho% the air !ressure in the !i!eline.

$emi"permanent pipeline

If a semi8!ermanent !i!eline is installed, ?for e)am!le, a large construction!ro>ect@, the clean8out !rocedure?s@ should be s!ecifically designed for thatinstallation, taking into account the general re<uirements in section 5.6 ands!ecific site conditions.



Pump and hopper

When cleaning out the !um! andor ho!!er, the o!erator should ensure that themanufacturerFs cleaning instructions are follo%ed. To !revent the risk ofentanglement, the follo%ing should be taken into account'

• mechanically locking the moving !arts in !osition• shutting do%n the e<ui!ment

• disengaging the hydraulic !um!s

• e)hausting accumulated hydraulic or air !ressure and allo%ing time for the

!ressure to be fully released from all systems• ensuring the !um! is not under !ressure before it is dismantled• not allo%ing any !art of the %orkerFs body to be !laced into the !um! or

ho!!er %hile cleaning.

Fig9re %4: Da;gero9s clea;i;g practices



Fig9re '*: Da;gero9s clea;i;g practices

Note: Where fitted, the interlocked cut8out s%itch on the ho!!er guard shouldnot be solely relied on to !revent movement of !arts during cleaning.

/#%* ,reparatio; >or roa< travel

The manufacturerFs instruction manual should al%ays be follo%ed and mayinclude'

• the boom being is folded and !laced in the travel !osition before theoutriggers are retracted, and securely sto%ed in the travel !osition %ithlocking devices engaged

• any loose com!onents ?such as !i!es, cou!lings, or tools@ are to becorrectly sto%ed or restrained on the vehicle as !er the $e% &ealand (oad

(ules• all !o%er take8off ?#T-@ drives to hydraulic !um!s for the concrete !um!,

boom and outriggers are disengaged and the controls !ut in the -!osition

• before moving, visually ins!ect the vehicle to confirm everything issecured.



Fig9re '%: Co;>irm everthi;g is sec9re< 8e>ore movi;g



SECTON 0: E1",MENT

0#% Ge;eral re9ireme;ts

All concrete !um!ing e<ui!ment should fully com!ly %ith the 0107 series of

Australian Standards, including AS &/&0-&1 + Concrete Placing #,uipment , ore<uivalent standards.

0#' Doc9me;tatio;

Any e<ui!ment J ne%, used, im!orted or locally manufactured 8 should beaccom!anied by all the a!!ro!riate documentation, including evidence ofcom!liance to the a!!ro!riate standards, and should be retained for the life of thee<ui!ment. All documentation, including o!eration and safe use instructions,should be in nglish.

0#+ <e;ti>icatio;

%ata plates and vehicle permits

"oncrete !um!s and associated e<ui!ment !rior to o!eration must have'• all re<uired vehicle !ermits and road registration

• if it is a truck8mounted !lacing boom, a "ertificate of itness and

registration• legible and !ermanently marked data !late?s@ in !rominent !osition?s@,

containing'o the manufacturerFs, distributorFs or certifying com!etent !ersonFs

nameo the date of manufacture, or if unkno%n, the date the data !late

%as issuedo the make and model numbers if kno%no the serial number.

The Manufacturers-!erators Manual should include the follo%ing information'• rated length and height of the boom

• ma)imum allo%able concrete !ressure

• ma)imum length and nominal si3e of the end hose

• ma)imum nominal si3e of delivery !i!e

•

ma)imum loading, if fitted, of each outrigger leg• ma)imum hydraulic !ressure

• ma)imum concrete !ressure

• !um! ca!acity.

?The manufacturerFs or o!eratorFs manual should al%ays be carried in the cab of the vehicle@.

A vehicle chassis on %hich any concrete !um!ing e<ui!ment is mounted must'• be registered for travelling on !ublic roads

• be in a road%orthy condition

• have an engineerFs re!ort for any structural alterations

• if re<uired by trans!ort regulations, have a vehicle logbook.



0#- ,ipeli;e compo;e;ts

The manufacturer or su!!lier must certify that all materials, !i!es, hoses andaccessories are safe to use in concrete !um!ing systems and are %ithin the

calculated design !ressures. When com!onents from different manufacturers areassembled, all com!onents should be com!atible, and the !i!eline must have thedesign !ressure of the lo%est8rated com!onent.

0#/ (<ra9lic sstems

The main hydraulic control !anel should be fitted %ith an easy8to8read andaccurate gauge that indicates the hydraulic fluid !ressure su!!lied to the concrete!um!ing e<ui!ment. The entire concrete !um!ing system shall be !rotectedagainst over8!ressurisation.

Where variable !ressure is available, the ma)imum must not e)ceed themanufacturerFs recommended ma)imum safe o!erating !ressure.

0#0 Co;trols

All concrete !um!ing e<ui!ment controls should com!ly %ith the relevantre<uirements of AS 0107.0, including'

• emergency sto! button?s@ that immediately sto!s all movement and!um!s

• controls clearly marked %ith symbols or %ords in nglish to sho% theirfunction

• %here !racticable, movement of controls should corres!ond %ith the

direction of the motion being controlled• all controls, %hen released, should return to the neutral !osition

• %here multi!le control !ositions are fitted, be o!erable from only one!osition at a time.

0#$ ,ipeli;e a;< hose sectio;s

#rior to being !laced in service, each !i!eline and hose com!onent should beclearly and !ermanently identified %ith a uni<ue mark or number to distinguish itfrom other com!onents of the !i!eline.

The follo%ing information should also be !ermanently recorded on the !i!e or inthe !i!eline ins!ection logbook'

• the grade of !i!e

• designated !i!e diameter

• ma)imum concrete !ressures and minimum %all thickness

• if a fle)ible hose, the manufacturerFs recommended ma)imum o!erating!ressure.

0#& Ma;9als a;< log8oos

The !um!ing contractor or hirer must ensure that the !um!ing e<ui!ment has'•

a co!y of the manufacturerFs or o!eratorFs manual, or sufficiently detailed%ritten instructions develo!ed by a com!etent !erson, covering'



o trans!ortationo set8u! and safe o!erationo emergency !rocedureso minor maintenance and re!airso ;ote: !um!ing e<ui!ment should only be o!erated under those

conditions s!ecifically covered in these manuals• a maintenance logbook that contains the information listed on the data

!lates and has been maintained u!8to8date, listing'o any defects foundo all re!airs carried outo details of all e<ui!ment ins!ectionso details of monthly !i!e ins!ectionso ;ote: logbooks are available to !urchase from concrete boom

manufacturers and su!!liers• maintenance records that are u!8to8date %ith any additional information

from the manufacturer.

The !um!ing contractor or the !rinci!al contractor must ensure that the !um!o!erator is trained and com!etent in'

• understanding the o!eratorFs manual or instructions

• carrying out the daily o!erational ins!ections

• maintaining the logbook.

0#4 War;i;g a;< sa>et sig;s

The !um!ing contractor or hirer must ensure that all a!!ro!riate %arning andsafety signsstickers are available, in good condition and correctly !ositioned on

the e<ui!ment.

Fig9re '': War;i;g a;< sa>et sig;s m9st 8e legi8le

0#%* Disposal a;< ac9isitio; o> 9se< e9ipme;t

When selling or dis!osing of used concrete !um!ing e<ui!ment, the su!!liershould identify any com!onents of the !lant that are unserviceable. Theunserviceable com!onents may constitute a ha3ard in the o!eration of the !lant.Where !lant is identified as not fully serviceable, the su!!lier shall inform the!urchaser in %riting that the !lant should not be used until the !lant is fullyserviceable.



The su!!lier should !rovide any information in their !ossession relating to thesafe use of e<ui!ment and any ins!ection, maintenance and re!air records.

It is recommended that !rior to !urchasing any concrete !um!ing e<ui!ment, ane)!erienced engineer, or the manufacturerFs agent or re!resentative or similar

com!etent !erson, should ins!ect the e<ui!ment and determine if its condition issuch that is can be e)!ected to be safe for use of the re!airs necessary to make itserviceable.

Section 07A of the Act also a!!lies, !lacing duties on !eo!le %ho sell or su!!ly!lant for use in a !lace of %ork. The intention of section 07A is to ensure thatany !lant used or for use in a !lace of %ork is designed and made, and has beenmaintained, so that it is safe for its intended use.

0#%% Ac9isitio; o> 9;servicea8le e9ipme;t

A !erson %ho ac<uires concrete !um!ing e<ui!ment in need of re!air mustensure this e<ui!ment com!lies %ith the necessary standards before it can bereturned to service. An e)!erienced engineer, or the manufacturerFs agent orre!resentative or similar com!etent !erson, should certify in %riting that the unitcom!lies %ith the a!!ro!riate standard?s@, and its condition is such that it can bee)!ected to be safe for use until its ne)t scheduled ins!ection.

If a record of the maintenance and ins!ection is not su!!lied %ith the e<ui!ment,it should be sub>ected to a ma>or ins!ection and assessment in accordance %ithsection 2.* and AS /4.0, to determine its suitability for use.



SECTON $: MANTENANCE AND NS,ECTON

$#% Ge;eral

A !reventative maintenance and ins!ection regime is essential for the safe andefficient o!eration of concrete !um!ing e<ui!ment.

Programme types

This maintenance and ins!ection !rogrammes should follo% either'A. a !rogramme designed by a com!etent !erson to com!ly %ith the

re<uirements of AS /4.0 orB. a !rogramme based on the manufacturerFs recommendations in

consultation %ith a com!etent !erson. This ty!e of !rogramme canonly be established %here there are verifiable records stating that'

?i@ the concrete !um!ing e<ui!ment has been continually

maintained in accordance %ith those recommendationssince the !um! %as first !ut into service or

?ii@ the manufacturer, at the time of !urchase, hadins!ected the used concrete !um!ing e<ui!ment andissued a certificate deeming it satisfactory forcontinued service, and has been maintained inaccordance %ith the manufacturerFs recommendationssince being !ut back into service.

Programme structure

The maintenance and ins!ection !rogramme should include !rovisions for'• !re8o!erational tests and checks

• routine ins!ection and maintenance at s!ecified time intervals

• recording in the logbook and maintenance records all'

o ins!ections and maintenanceo defects found and re!airs undertakeno structural alterations.

$#' A;;9al i;spectio;s

General

All concrete !um!ing e<ui!ment should be ins!ected annually by a com!etent!erson such as a chartered !rofessional engineer ?"#ng@ at intervals note)ceeding *5 days.

Where there are no verifiable records of !revious maintenance, ins!ection, re!airsor modifications, a ma>or ins!ection should be carried out by the com!etent!erson to determine the e<ui!mentFs suitability for use.

Criteria

The annual ins!ection should be in accordance %ith the maintenance andins!ection !rogramme defined in AS /4.0 or in the manufacturersFrecommendations, and must include a re!ort on s!ecific critical %ear and stressissues.



The ins!ection %ill also include an audit of the e<ui!mentFs logbook to'• determine that the re<uired ins!ections and maintenance have occurred

• revie% the record of defects

• ensure the necessary re!airs have been carried out.

$#+ Maor i;spectio;

The !ur!ose of this ins!ection is to ensure that older e<ui!ment is suitable tocontinue in service.

Assessment for continued service

All concrete !um!ing e<ui!ment over 04 years old that does not meet there<uirements of section 2.0 should be sub>ect to an initial ma>or ins!ection inaccordance %ith AS /4.0.

This ins!ection re!ort, !re!ared by a com!etent !erson ?such as a "#ng@,should include'

• a confirmation of visual and selected stri!8do%n of critical com!onents asre<uired or %here necessary

• any defects discovered and all remedial actions undertaken to bring the

e<ui!ment u! to standard• an assessment of the mechanical condition of the e<ui!ment• a revie% of the e)isting ins!ection and maintenance regime to assess its

continued suitability and modify as re<uired• a confirmation of the im!lementation of the ins!ection and maintenance

regime• a s!ecified time !eriod ?not greater than five years@ until the ne)t

assessment for continued service.

$#- !epairs a;< mo<i>icatio;s

Any re!airs made to concrete !um!ing e<ui!ment should follo% the detailedinstructions of the manufacturer or the com!etent !erson as outlined in themaintenance and re!air manuals.

All re!airs and any re!lacement of com!onents should be'• carried out by trained and com!etent !ersons

• com!atible %ith the e<ui!ment and !arts su!!lied from the manufacturer• recorded in the logbook

• detailed in the maintenance records.

itting of any concrete !um!ing e<ui!ment %hich involves modifications to acarrier vehicle should com!ly %ith AS /4.0.

&elding

Welding of any ty!e of concrete !um!ing e<ui!ment or !i!eline com!onentshould be'

•

carried out by a suitably <ualified %elder• recorded in the logbook

• detailed in the maintenance records.



-utriggers and concrete !lacing booms or any other stressed load bearingcom!onents should be %elded in accordance %ith AS$&S 01 by a <ualified%elder, com!etent in %elding high8stressed com!onents.

$#/ Testi;g pipeli;e compo;e;tsAll metal !i!es and !i!eline com!onents should be checked for %all thickness atfre<uent intervals and the results recorded. Any used com!onents in storageshould be tested before being returned to service. #i!ing that has a %allthickness less than the recommended thickness for the !um!Fs designedma)imum concrete !ressure should not be used.

An e)am!le !i!eline ins!ection log sheet is located at A!!endi) .

Criteria

Wall thickness testing should be conducted by ultrasonic test instruments or othersuitable method. All testing must be carried out by com!etent !ersons. The teste<ui!ment should be calibrated regularly and maintained according to themanufacturerFs re<uirements.

#i!es must not be used if the %all thickness is less than that recommended by the!i!e manufacturer for the ma)imum concrete !ressure of the !um!. Thesu!!liers of !i!es for concrete !um!s should !rovide data on the minimum %allthickness for differing !um! !ressures. The minimum %all thickness of single%all !i!e is de!endent on the grade of !i!e, the ma)imum %orking concrete!ressure of the !um! and diameter of the !i!e.

If the su!!lierFs information is not available, minimum %all thickness can becalculated using the formula in AS 1410' Pressure Piping ?refer to section*.01.*?a@?0@ of AS 1410 for greater detail@.

The follo%ing table, calculated using the formula in AS 1410, !rovides defaultminimum !i!e %all thicknesses for 047mm and 0**mm outside diameterseamless steel !i!es at different concrete !ressures. These minimum thicknessvalues cannot be used for !i!e %ith diameters greater than those s!ecified, norcan the table be e)tra!olated for other grades of !i!e.



Maim9m

press9re

O9tsi<e <iameter o> pipe

:,a Bar Gra<e '** Gra<e '/* Gra<e +/*IST./'

%*&mm %++mm %*&mm %++mm %*&mm %++mm

1,44 1 /./ /.2 0.2 /.0 0.* 0.5

5,444 54 /.6 *. /.* /.7 0.2 /.0

7,444 74 *.7 $A *.4 *.2 /.* /.7

04,444 044 $A $A *.7 $A /.6 *.

0/,444 0/4 $A $A $A $A *.1 $A

Ta8le +: Mi;im9m pipe =all thic;ess 6mm7

• =rade /44 !i!e thickness values are to be used if the grade of !i!e isunkno%n.

• 0/4 Bar thickness values are to be used if the ma)imum concrete !ressure

of the !um! is unkno%n.• These re<uirements are for normal o!erating conditions fi)ed !i!eline

systems for high8rise develo!ments could use greater !ressures and mayneed thicker !i!es.

• +ouble %all !i!e should use the manufacturerFs nominal outer %allthickness as a minimum %all thickness.

Testing personnel

A !erson %ho carries out testing or ins!ection of any !i!eline com!onent shouldbe com!etent and have received instruction in the method used, %hich mayinclude the'

• use of su!!lied test instruments• inter!retation of test results against the testing criteria

• methods to be follo%ed to achieve consistency of test results• recognition of double thickness or faulty readings

• visual ins!ection of test and ins!ection results.

'ltrasonic testing

When using ultrasonic testers it is essential to have the test instrument calibratedfor the material to be tested before carrying out any tests. This can be achievedby using a !iece of !i!e material of a kno%n thickness to calibrate the instrument

and by follo%ing the manufacturerFs instructions. The test e<ui!ment should bemaintained according to the manufacturerFs re<uirements, %hich may includeregular factory calibration and re!lacement of %orn transducers.

Test surface

The areas to be tested on any !i!e com!onent should be'• smooth %ith no im!erfections

• free of %eld s!atter

• !rotected from rust• free from thick !aint

• free of concrete residue and dirt.



$ingle #all pipe

Single %all !i!eline com!onents in regular use should be tested at least monthly.Tests should measure the %all thicknesses at all kno%n high %ear areas oncom!onents. =enerally these are close to the ends of straight sections of !i!eand on the outer radius of the bends. #um! o!erators may also be a%are ofother areas of high %ear, caused by the com!onentFs location %ithin the !i!eline.

#i!e sections should be tested at these kno%n high %ear areas and at locations%ithin 44mm of each flange. ach location should contain four test !ointsevenly s!aced around the circumference of the !i!e. or fi)ed hori3ontal !i!es,one of these test !oints must be on the bottom of the !i!e. Bends or elbo%sshould be tested at three evenly s!aced test !oints along the outside radius.

The lo%est thickness measurement of each com!onent should be recorded in the!i!eline logbook against the com!onentFs uni<ue identification number.

%oule #all pipe

The manufacturerFs recommendations for the testing of double %all !i!ecom!onents should be follo%ed. If the manufacturer recommends no testing!rior to a com!onent having !um!ed a !ortion of its design life, no monthlythickness testing is re<uired, !rovided'

• the manufacturerFs design life, in !um!ed cubic metres for the com!onent,is kno%n

• the manufacturerFs recommendation for starting !i!e testing ?in !um!edcubic metres@ is kno%n

• the com!onent has not !um!ed either the manufacturerFs recommended

!re8testing volume, or 54K of the !i!eFs design life, %hichever is thelesser

• an accurate log is ke!t of !um!ed cubic metres of the com!onent

• a visual ins!ection of the internal lining, or thickness test of the outer %allis undertaken every 04,444 !um!ed cubic metres.

-nce the volume of !um!ed concrete e)ceeds the manufacturerFsrecommendation, or 54K of the !i!e com!onentFs design life, %hichever is thelesser, a monthly visual ins!ection of the internal lining or a thickness test of theouter %all in accordance %ith the manufacturerFs recommendations should

commence.

Any double %all !i!e com!onent should be re!laced if'• %all thickness testing indicates %ear to the outer layer

• the inner lining is breached

• a visual ins!ection detects e)cessive or abnormal %ear to the inner lining.

A record of testing and ins!ection should be detailed in the !i!eline logbookagainst the com!onentFs uni<ue identification number.

Pipeline test recording

To assist o!erators to detect thickness error measurements, cross referencing to!revious %all thickness measurements during the testing !rocess is essential. A



suggested method of recording this information is to maintain a test sheet overthe life of each com!onent.

This record of !i!e com!onent testing may include'• Single %all'

o com!onent identification number or marko minimum allo%able %all thicknesso dates of testso monthly measurement for each of the test !oints.

• +ouble %all'o com!onent identification number or marko minimum allo%able %all thicknesso estimated life of com!onent in cubic metreso total volume of !um!ed concrete in cubic metreso visual ins!ections at 04,444 cubic metre intervalso volume in cubic metres %hen monthly testing is to commenceo monthly test or ins!ection results.

Hoses

Any hose that is used to !um! concrete should be visually ins!ected before everyconcrete !um!ing o!eration.



A,,END2 A: S"MMA!3 OF T(E (EALT( AND SAFET3 N

EM,LO3MENT ACT %44'

Note: This a!!endi) !rovides are summary of duties under the ;ealth and Safety

in m!loyment Act 066/. A com!lete co!y of the Act can be accessed at the $e%&ealand =overnmentFs :egislation %ebsite' %%%.l egisl ati on .govt .n3.

;tro<9ctio;

The ;ealth and Safety in m!loyment Act 066/ ?the Act@ re<uires the !rovision of a safe %orking environment and the !rotection of !ersons at %ork from healthand safety ha3ards. To achieve this, it im!oses duties on em!loyers, em!loyeesand others to ensure that %ork!laces and %ork !ractices are safe. The Act alsore<uires em!loyers and em!loyees to %ork together in good faith for the benefitof health and safety in the %ork!lace. +uties are also im!osed on the su!!liers

of !lant to a %ork!lace.

Ge;eral respo;si8ilities o> emploers

m!loyers have a duty to ensure the health and safety of em!loyees %hile at%ork. In !articular, they must take all !racticable ste!s to'

• !rovide and maintain a safe %orking environment• !rovide and maintain facilities for the safety and health of em!loyees

• ensure that the ha3ards associated %ith the set8u! and use of concrete!um!ing e<ui!ment are controlled so as to be safe for em!loyees

• im!lement a!!ro!riate ins!ection and maintenance regimes for concrete

!um!ing e<ui!ment• !rovide !rocedures to deal %ith emergencies that may arise %hile

em!loyees are at %ork.

m!loyers'• must inform em!loyees of the results of any health and environmental

monitoring• are res!onsible for the health and safety of !eo!le %ho are not em!loyees

but are in or near the %ork!lace• must take all !racticable ste!s to ensure that em!loyees do not harm any

other !erson %hile at %ork, including members of the !ublic or visitors to

the %ork!lace.

Ge;eral respo;si8ilities o> emploees

m!loyees are re<uired to take all !racticable ste!s to ensure their o%n safetyand of others in the %ork!lace. This includes considering both the things they doand the things they omit to do ?such as not using safety gear@.

m!loyers should make clear to em!loyees their res!onsibilities to use the!rovided safety e<ui!ment and to %ear !rotective clothing. The e)!ected level of an individual em!loyeeFs res!onsibility %ill often increase %ith kno%ledge andseniority, but the em!loyerFs overall res!onsibility to ensure a safe %ork!laceremains.

http://www.legislation.govt.nz/




The !racticable ste!s an em!loyee should take also includes re!orting to theem!loyer any ha3ards or accidents, so that their em!loyer can investigate and!ut safeguards in !lace to !revent any accidents.

An em!loyee has a right to refuse to undertake %ork that they consider likely to

cause them serious harm. ;o%ever, em!loyees have an obligation to %ork ingood faith %ith the em!loyer to try to resolve the matter !rior to consideringrefusal.

(a?ar< ma;ageme;t

The Act re<uires em!loyers to identify ha3ards, assess their significance in the%ork!lace, and to im!lement, monitor and revie% ha3ard control measures. Theha3ard control measures are usually defined as the Ghierarchy of controlH J toeliminate, isolate ?if elimination is im!racticable@, and minimise ?if elimination andisolation is im!racticable@ significant ha3ards in the %ork!lace.

Ha(ard identification

m!loyers must have effective methods in !lace to identify ha3ards and todetermine if there are significant ha3ards that re<uire further action.

G;a3ardH is defined in A!!endi) ".

;>ormatio; >or emploees

Before em!loyees begin %ork, they must be informed by their em!loyer about'• ha3ards they may be e)!osed to %hile at %ork

• ha3ards they may create %hich could harm other !eo!le

• ho% to minimise the likelihood of these ha3ards becoming a source ofharm to themselves and others

• the location and correct use of safety e<ui!ment ?including !ersonal

!rotective e<ui!ment or clothing@• emergency !rocedures.

m!loyers are also re<uired to inform em!loyees of the results of any health andsafety monitoring undertaken. In doing so, the !rivacy of individual em!loyeesmust be !rotected.

Trai;i;g a;< s9pervisio;

An em!loyer must ensure that every em!loyee %ho'• does %ork of any kind, or

• uses !lant ?machinery or e<ui!ment@ of any kind, or• deals %ith a substance of any kind

in a !lace of %ork has the kno%ledge and e)!erience Q or is su!ervised bysomeone %ho has Q so that they are not likely to suffer harm, or lead to theharm of others.

very em!loyee must be ade<uately trained in the safe use of all !lant, ob>ects,substances, !rotective clothing and e<ui!ment that they are, or may be, re<uiredto use or handle.



To %ork safely, em!loyees must be trained and instructed in safe %ork !ractices.m!loyers must ensure that an a!!ro!riately e)!erienced !erson maintains ahigh level of su!ervision of em!loyees %ho are not yet deemed com!etent tocarry out their %ork safely.

Such training should be in addition to, and not re!lace'• general construction industry occu!ational health and safety induction

training• site8s!ecific induction

• induction on these guidelines

• induction on the site concrete !um!ing task analysis

• tool bo) talks

• su!ervised !ractical e)!erience !rogrammes, s!ecific to the tasks being!erformed by the em!loyee.

Where !ossible, any education or training !rogramme should be com!lementaryto, or !art of a !rogramme leading to nationally recognised <ualifications.

It is recommended that s!ecific training in concrete !um!ing o!erational andmaintenance safety should reflect the detail in sections 1 to 2 of this =uide.

$pecific training

m!loyers are re<uired to !rovide the information, instruction, training andsu!ervision to em!loyees necessary to enable them to !erform their %ork in asafe manner.

Information, training and instruction should include'• safe %ork methods to be used in the set8u! and o!eration of concrete

!um!ing e<ui!ment• emergency !rocedures• identifying ha3ards associated %ith the use of !lant and e<ui!ment

• !rocedures for ins!ection and maintenance of concrete !um!inge<ui!ment

• the use of the manufacturerFs o!erating and service manuals

• the correct use, care and storage of'o !ersonal !rotective e<ui!ment

o other safety e<ui!mento e<ui!ment logbook and e<ui!ment documentationo !i!eline and hose sectionso tools and e<ui!ment

• electricity safety involving the dangers of'o overhead !o%er lineso ground8mounted electrical e<ui!ment

• the !rocedures to be ado!ted in the event of an accident or in>ury.

$upervision

Su!ervision must include sufficient monitoring of the %ork and %orkers to ensure'• that it is only carried out by com!etent, e)!erienced %orkers



• that a truck8mounted concrete !lacing boom is driven by a !erson %ith avehicle licence a!!ro!riate for the ty!e and %eight of the truck

• that all safe %ork !ractices are being follo%ed

• the use, by %orkers, of all !rotection systems and !ersonal !rotectivee<ui!ment.

Trainee #orkers

The em!loyer should ensure that a %orker undergoing training is directlysu!ervised by an authorised !erson %ho'

• understands %hat is re<uired in !roviding su!ervision

• is com!etent and e)!erienced in the use of the e<ui!ment

• can immediately take action to rectify a dangerous situation.

Personal protective equipment)clothing

"oncrete !um!ing em!loyers should ensure that their em!loyees use a!!ro!riate

!ersonal !rotective e<ui!mentclothing, %hich may include'• eye and hearing !rotection

• leather and rubber %ork gloves

• safety boots or safety gumboots

• safety helmets or hard hats• sunglasses ?safety ty!e@

• %ide brim hats

• sunscreen• a!!ro!riate high visibility or

reflective safety vests• a!!ro!riate clothing for the

%eather conditions.

#ersonal !rotective clothingre<uirements should be determinedfrom an assessment of the ha3ards the%orkers are likely to be e)!osed to. Fig9re '+: Worer =eari;g perso;al

protective clothi;g

Acci<e;ts a;< serio9s harm recor<i;g a;< ;oti>icatio;

The Act re<uires em!loyers, the self8em!loyed and !rinci!als to contractors tokee! a register of %ork8related accidents and serious harm.

or em!loyers, this includes every accident that harmed ?or might have harmed@'• any em!loyee at %ork, or

• any !erson in a !lace of %ork controlled by the em!loyer.

m!loyers are also re<uired to investigate all accidents, harm and Gnear missesH to determine %hether they %ere caused by a significant ha3ard.

Any accidents %here a serious harm in>ury has occurred must be notified to the:abour =rou! of the Ministry of Business, Innovation and m!loyment as soon as



!ossible after the occurrence becomes kno%n to the em!loyer.

+etails of the accident must also be re!orted to the Ministry on the !rescribedform %ithin seven days. orms are available from'%%%.osh .dol .govt .n3services n oti f icati on acc ident .sht ml .

If a !erson suffers serious harm, the scene of the accident must not be interfered%ith unless to'

• save the life of, !revent harm to or !revent suffering to, any !erson• maintain !ublic access for essential services, e.g. electricity, gas

• !revent serious damage or loss of !ro!erty.

D9ties o> others

Persons in control of a place of #ork

The Act !laces duties on !ersons %ho control a !lace of %ork in relation to !eo!lein the vicinity of the %ork!lace, and to visitors.

A !erson %ho controls a !lace of %ork is res!onsible for taking all !racticableste!s to ensure !eo!le in the vicinity are not e)!osed to harm 8 regardless of the!ur!ose for %hich they are in the vicinity.

Where !eo!le are visiting for %ork8related reasons, !ay to be there, or are!resent for the benefit of the controller, the !erson %ho controls the !lace of %ork is res!onsible for taking all !racticable ste!s to ensure they are not e)!osedto harm. This includes !eo!le in the !lace of %ork'

•

%orking as em!loyees, contractors, subcontractors ?or their em!loyees@for the !erson %ho controls the !lace or• %ith e)!ress or im!lied consent, and %ho have !aid to be there, or %ho

are customers or !otential customers.

There is a duty to authorised visitors not included in the above categories 8 to%arn all !eo!le %ho are to be in the !lace of %ork of kno%n significant, out8of8the8ordinary ha3ards arising from the %ork that has been, or is being, carried onthere. or this duty to a!!ly, the visitors must have'

• the e)!ress authorisation of the occu!ier to be in the !lace of %ork, or

• have given the controller of the !lace oral advice that they %ill be %orking

there under statutory authority.

#eo!le visiting a !lace of %ork under any other circumstances are o%ed no dutyunder section 05 by the controller. This includes !eo!le visiting for the !ur!ose ofrecreation or leisure.

#eo!le %ho are %orking in the !lace of %ork 8 but not as em!loyees orcontractors of the occu!ier 8 are o%ed only the %arning duty, and then only if they have e)!ress or statutory authority to be there.

#eo!le %ho control a !lace of %ork have no duty to tres!assers.

http://www.osh.dol.govt.nz/services/notification/accident.shtml





A G!erson %ho controls a !lace of %orkH includes a !erson %ho o%ns, leases,subleases or occu!ies a !lace of %ork, or %ho o%ns, leases or subleases !lant ore<ui!ment used in a !lace of %ork.

%uties of the self"employed

very self8em!loyed !erson must take all !racticable ste!s to ensure that noaction or inaction of theirs %hile at %ork harms the self8em!loyed !erson or anyother !erson.

%uties of principals

#rinci!als to contractors are re<uired to take all !racticable ste!s to ensure that'• no em!loyee of a contractor or subcontractor, or

• if an individual, no contractor or subcontractoris harmed %hile doing any %ork ?other than residential %ork@ that the contractor%as engaged to do.

Hirers* sellers and suppliers of plant

The Act !laces duties on !eo!le to ensure that any !lant or e<ui!ment that isused in a !lace of %ork is designed, manufactured and maintained so that it issafe for its intended use. The duties a!!ly to !eo!le %ho'

• hire, lease or lend !lant to another !erson that could be used in a !lace of %ork

• sell or su!!ly !lant ?other than for hire, lease or loan@

• install or arrange !lant in addition to either of the above.

or further information on legal re<uirements under the Act, go to%%% .o s h .d o l .g o v t .n 3 o rd e rc a t a l o g u e h se a c t 8 t e ) t in d e ) .s h tm l .

http://www.osh.dol.govt.nz/order/catalogue/hseact-text/index.shtml







A,,END2 B: !EFE!ENCE DOC"MENTS

Note: the Ministry of Business, Innovation and m!loyment and the "oncrete#um!ing Association of $e% &ealand ?"#A$&@ have made every effort to ensure

that the %ebsites referenced in this A!!endi) are correct at the time of!ublishing. ;o%ever, due to circumstances beyond our control, e)ternal %ebsiteaddresses may change %ithout notice.

Acts

• ;ealth and Safety in m!loyment Act 066/

!eg9latio;s

• ;ealth and Safety in m!loyment (egulations 066

ull co!ies of the Act and (egulations can be do%nloaded from the $e% &ealand:egislation %ebsite at %%%.legisl ati on .govt .n3.

Approve< Co<es o> ,ractice

• +e!artment of :abour, Wellington ?/440@. Approve< Co<e o> ,ractice

>or the Ma;ageme;t o> Noise i; the Worplace 6';<

E<itio;7.%%% .o s h .g o v t .n 3 o r d erc a t a l o g u e 0 .s h tml

• +e!artment of :abour, Wellington ?/404@. Approve< Co<e o> ,ractice

>or Cra;es 6+r<

E<itio;7 %%% .o s h .g o v t .n 3 o r d erc a t a l o g u e 0 4 .s h t m l

Sta;<ar<s

• AS /4.0 Cranes2 Hoists and inches + Safe 3se + Part &4 %eneral

5e,uirements

• AS /4.0 Cranes + Safe 3se + Part &14 Concrete Pumps

• AS 0107.0 Cranes )Including Hoists and inches* + Concrete Placing

#,uipment

• AS 1410 Pressure Piping

• AS /1/.* Non6Destructive Testing + Determination of Thickness + 3se of

3ltrasonic Testing

• AS *6/4.0 Assurance and Product 7uality + Pressure #,uipment

Manufacture

• AS 1*1* Pressure #,uipment + Ha8ard 9evels

• AS$&S 01 Structural Steel elding

AS$&S ?>oint Australian and $e% &ealand@ Standards are available to !urchasefrom %%% .s t a n da r d s .c o .n 3.

AS ?Australian@ Standards are available to !urchase from %%%.st an dards .com.au .

Other p98licatio;s

• +e!artment of :abour, Wellington ?/440@. Co<e o> ,ractice >or Ma;9al

(a;<li;g# %%% .o s h .g o v t .n 3 o rd e r ca ta l o g u e !d f m a nu a l c o d e .!d f


http://www.osh.govt.nz/order/catalogue/15.shtml






http://www.standards.co.nz/

http://www.standards.com.au/

http://www.osh.govt.nz/order/catalogue/pdf/manualcode.pdf








http://www.standards.co.nz/

http://www.standards.com.au/




• +e!artment of :abour Wellington ?/40/@. Best ,ractice G9i<eli;es >or

Wori;g at (eight i; Ne= )eala;<#

%%%.osh .govt .n 3!u bl icati on sbookl et s%orkin g8h eight in de).as!

• WorkSafe Victoria ?/441@' Co;crete ,9mpi;g ;<9str Sta;<ar<.%%% .%o r k safe .v i c .g o v .a u % ! s % c m c o n n e c t % s i nt e r n e t %o r k safe h o me f or m s R a n d R ! u b l i ca ti o n s ! u b l i ca ti o n s i m ! o r t c o n c re t e R ! u m ! i n g

• Transit $e% &ealand ?/441@' Co<e o> ,ractice >or Temporar Tra>>ic

Ma;ageme;t# %%% .n 3 t a.g o v t .n 3 re s o u r c e s c o d e 8 t e m!8t r a f fi c 8 m a n ag e m e nt i n d e) .h tml

• $e% &ealand (eady Mi)ed "oncrete Association Inc ?/445@' O;site

Ma;ageme;t o> Co;crete Wash=ater#

%%% .n 3r m ca .o rg .n 3 fil e s s it e m a n ag em e n t o f c o n c r e t e % a s h % a t e r 8gen eral edi ti on .!df

• $e% &ealand (eady Mi)ed "oncrete Association Inc ?/400@' Co;crete

Tr9c Driver (a;< Sig;als# %%%.n 3rmca.org.n 3n3rmca.ht m

• Scaffolding and (igging $e% &ealand ?SA($&@, /446' Best ,ractice

G9i<eli;es >or Sca>>ol<i;g i; Ne= )eala;<# Available for !urchasefrom SA($&'

#- Bo) *0 452:o%er ;utt 414

mail' i n f o b s c .o rg .n 3Website' %%%.sarn 3.org.n 3

• nergy Safety Service, /440. $&"# *1'/440 Ne= )eala;< Electrical

Co<e o> ,ractice >or Electrical Sa>e Dista;ces#

%%% .e n er g ys a fe t y .g o v t .n 3 u ! l o ad * * 1 1 * n 3ec ! * 1 / 4 4 0 .!d f.

• Work!lace ;ealth and Safety Dueensland ?/400@' Sa>et Alert: (ose

Whip o; Co;crete ,9mps#

%%% .d e i r .< l d.g o v .a u %o r k ! l a ce ! u b l i c a ti o n s a l e r t s h o se % hi ! ! u m ! s i n d e ). h tm

• +e!artment of :abour, Wellington ?/404@. A ,ri;cipals G9i<e to

Co;tracti;g to meet the (ealth a;< Sa>et i; Emplome;t Act

%44'# %%%.osh .govt .n 3ordercat al ogu econt ract ing 8gu ide.shtml

!esearch <oc9me;ts

• Work!lace ;ealth and Safety, Dueensland ?/446@' Co;crete ,9mpi;g

Complia;ce Campaig;#

%%% .d e i r .< l d.g o v .a u %o r k ! l a ce s u b >e c t s c o n c r e t e ! u m ! c o m ! l i a n cec a m!a i g n i n d e) .h tm

http://www.osh.govt.nz/publications/booklets/working-height/index.asp


http://www.worksafe.vic.gov.au/wps/wcm/connect/wsinternet/worksafe/home/fo







http://www.nzta.govt.nz/resources/code-temp-traffic-management/index.html






http://www.nzrmca.org.nz/files/sitemanagementofconcretewashwater-generaledition.pdf



http://www.nzrmca.org.nz/nzrmca.htm

mailto:[email protected]


http://www.sarnz.org.nz/

http://www.energysafety.govt.nz/upload/33443/nzecp34_2001.pdf





http://www.deir.qld.gov.au/workplace/publications/alerts/hosewhippumps/index.htm












http://www.osh.govt.nz/order/catalogue/contracting-guide.shtml

http://www.deir.qld.gov.au/workplace/subjects/concretepump/compliance/campaign/index.htm


















http://www.nzrmca.org.nz/nzrmca.htm


http://www.sarnz.org.nz/




http://www.osh.govt.nz/order/catalogue/contracting-guide.shtml






• Work!lace ;ealth and Safety, Dueensland ?/44@' Co;crete ,9mpi;g

Co<e o> ,ractice#

%%% .d e i r .< l d.g o v .a u %o r k ! l a cer e s o u r c es !d fs c o n c r e t e ! u m ! c o d e / 4 4 .!df

• "ement, "oncrete U Aggregates Australia' Co;crete ,9mp Sa>et#%%%.con cr ete.n et .au !u bl icati on s!df "oncr et e#u m!S af et yrev.!df

• WorkSafe Victoria "onstruction U Etilities (e!ort 45'441 ?/445@' E;<.

(ose o> Co;crete ,9mp B9rsts#

%%% .%o r k safe .v i c .g o v .a u % ! s % c m c o n n e c t % s i nt e r n e t %o r k safe h o me for m s R a n d R ! u b l i ca ti o n s e d u ca ti o n a l R m a t e r i a l e n d 8h oseRof Rconcr et eR!um!Rbu rst s

• Sydney ;os!ital ;and Enit ?/44/@' Safety, ;ealth and nvironmental

#rocedure'Fl9i< ;ectio; ,rotocol#

%%%.d!i .n s%.gov.au dat aassets!df fil e44 41 71 4 I #rot ocol .!df

• American "oncrete #um!ing Association ?/404@' Sa>et B9lleti;: (ose

Whippi;g. %%%.con cr ete!um!ers.com!dfs; ose%hi !B ul leti n I $A :.!df

• British "oncrete #um!ing =rou! ?/441@' Co<e o> ,ractice >or the Sa>e

"se o> Co;crete ,9mps. %%% .c! a. u k .n e t ! " o n c r e t e 8 # u m ! in g 8 I n t e r es t8= r o u !

• $ational (eady Mi)ed "oncrete Association, American Society of "oncrete

"ontractors, and the American "oncrete #um!ing Association' Checlist

>or ,9mpi;g !ea< Mie< Co;crete# %%% .c o n c r e t e ! u m ! e r s .c o m cg i 8bin st art .cgi h ome.ht ml

• ;ealth and Safety )ecutive' ;>ormatio; Sheet: Ceme;t. "onstruction

Information Sheet /5, /nd edition. %%% .h se .g o v .u k ! u b n s c i s / 5 .!d f

http://www.deir.qld.gov.au/workplace/resources/pdfs/concretepump_code2005.pdf






http://www.concrete.net.au/publications/pdf/ConcretePumpSafetyrev.pdf



http://www.worksafe.vic.gov.au/wps/wcm/connect/wsinternet/worksafe/home/forms%2Band%2Bpublications/educational%2Bmaterial/end-hose%2Bof%2Bconcrete%2Bpump%2Bbursts



















http://www.dpi.nsw.gov.au/__data/assets/pdf_file/0004/84505/FIProtocol.pdf




http://www.concretepumpers.com/pdfs/Hosewhip_Bulletin_FINAL.pdf

http://www.cpa.uk.net/p/Concrete-Pumping-Interest-Group/





http://www.concretepumpers.com/cgi-bin/start.cgi/home.html






http://www.hse.gov.uk/pubns/cis26.pdf











http://www.concretepumpers.com/pdfs/Hosewhip_Bulletin_FINAL.pdf








A,,END2 C: DEFNTONS

a#c# or AC

A;chor 8rac:ets

Alternating current.

Metal com!onents designed to su!!ort the %eight and movement

of !um! !i!elines %hen fi)ed to a structure.

All practica8le

steps

?;ealth and Safety in m!loyment Act 066/@' Gall !racticable

ste!sH, in relation to achieving any result in any circumstances,

means all ste!s to achieve the result that it is reasonable

!racticable to take in the circumstances, having regard to J

?a@ the nature and severity of the harm that may be suffered if

the result is not achieved and

?b@ the current state of kno%ledge about the likelihood that harm

of that nature and severity %ill be suffered if the result is not

achieved and?c@ the current state of kno%ledge about harm of that nature

and

?d@ the current state of kno%ledge about the means available to

achieve the result, and about the likely efficacy of each of

those means and

?e@ the availability and cost of each of those means.

To avoid doubt, a !erson re<uired by this Act to take all !racticable

ste!s is re<uired to take those ste!s only in res!ect of

circumstances that the !erson kno%s or ought reasonably to kno%

about.

Base plate -utrigger foot J a s%ivelling metal !late at the base of an

e)tendable outrigger stabilising leg that acts as a foot.

Boom p9mp A truck8mounted combination concrete !um! and boom system.

Boom A delivery system that uses a hydraulically o!erated, folding multi8

section boom and attached !i!eline to deliver concrete.

Chartere<

,ro>essio;al

E;gi;eer 6C,E;g7

A !erson %ho is registered and holds a current registrationcertificate under the "hartered #rofessional ngineers of $e%

&ealand Act /44/.

A list of "#ngs can be do%nloaded from I#$& ?Institute of

#rofessional ngineers $e% &ealand@ at

% % %. i! e n3 .o r g . n3 i! e n 3 fi n d in g c ! e n g S e a r c h s ea r c h .c fm

Compete;t perso; The !erson, %ho by their training or e)!erience has the skills and

kno%ledge to carry out the task they are to undertake.

Co;crete p9mp The e<ui!ment that a!!lies !ressure to the concrete and forces it

through the delivery !i!eline.

http://www.ipenz.org.nz/ipenz/finding/cpeng/Search/search.cfm










Co;crete p9mpi;g Any ty!e of e<ui!ment used for !um!ing concrete.

Co;crete resi<9e Matter left over from %et concrete o!erations, e.g. slurry or

cement run8off.

E<ge protectio; ).est Practice %uidelines for orking at Height in Ne! "ealand*4

Means a barrier or system to !revent !ersons andor ob>ects or

materials from falling to a lo%er level from %orking or access

surfaces. dge !rotection may involve a !ro!rietary system,

materials to form a guardrail andor barrier isolation, erected

scaffolding su!!orting a tem!orary edge !rotection system, or a

combination of solutions.

Emploee

Emploer

?;ealth and Safety in m!loyment Act 066/@' Sub>ect to sections

*" to * of the Act, means any !erson of any age em!loyed by an

em!loyer to do any %ork ?other than residential %ork@ for hire or

re%ard under a contract of service and, in relation to any

em!loyer, means an em!loyee of the em!loyer.

?;ealth and Safety in m!loyment Act 066/@'

?a@ means a !erson %ho or that em!loys any other !erson to

do any %ork for hire or re%ard and, in relation to any

em!loyee, means an em!loyer of the em!loyee and

?b@ includes, in relation to any !erson em!loyed by the chief

e)ecutive or other em!loyee of a "ro%n organisation to do

%ork for the "ro%n organisation for hire or re%ard, that"ro%n organisation.

E;close<Ico;>i;e<

area

Any s!ace of an enclosed nature %here there is a s!ecified risk of

serious in>ury from ha3ardous substances or conditions %ithin or

near the s!ace.

To)ic fumes and va!ours can also be !roduced by %ork inside the

enclosedconfined area, for e)am!le, e)haust fume from mobile

!lant, es!ecially on construction sites.

E;<.hose The rubber fle)ible !i!e fitted to the discharge end of the !i!eline

system

(a?ar< ?;ealth and Safety in m!loyment Act 066/@'

?a@ means an activity, arrangement, circumstance, event,

occurrence, !henomenon, !rocess, situation, or substance

?%hether arising or caused %ithin or outside a !lace of

%ork@ that is an actual or !otential cause or source of

harm and

?b@ includes J

?i@ a situation %here a !ersonFs behaviour may be anactual or !otential cause or source of harm to the



!erson or another !erson and

?ii@ %ithout limitation, a situation described in

sub!aragra!h ?i@ resulting from !hysical or mental

fatigue, drugs, alcohol, traumatic shock, or another

tem!orary condition that affects a !ersonFs

behaviour.

(SE Act The ;ealth and Safety in m!loyment Act 066/.

(opper The loading reservoir of a concrete !um!.

(ose.ha;< The %orker %ho controls the end8hose.

:5

Li;e p9mp

Cilovolts ?0,444 volts@.

A concrete !um! connected to a !i!eline system.

Log8oo A record setting out com!lete details of all ins!ections, tests,

re!airs, and modifications carried out on !um! e<ui!ment.

Ma;9al ha;<li;g

Mo8ile p9mp

Any activity re<uiring a !erson to interact %ith their environment

and use any !art of their muscles or skeletal system to lift, lo%er,

!ush, !ull, carry, thro%, move, restrain or hold any animate, or

inanimate, ob>ect.

A concrete !um! mounted on a truck chassis or trailer.

O9triggers or

o9triggi;g pa<s

The e)tendible structural members on a concrete !um! used to

increase the unitFs stability.

,ipe clamp A device used to firmlysecurely hold !i!eline >oints together.

,ipeli;e sstem A delivery system %hich uses rigid or fle)ible !i!e sections cou!led

together to deliver concrete.

,o9r area The locationsection %here concrete !ouring or concrete %ork

activities are being undertaken.

,ri;cipal ?;ealth and Safety in m!loyment Act 066/@' A !erson %ho or that

engages any other !erson ?other%ise than as em!loyee@ to do

%ork for gain or re%ard.

,9mpi;g

co;tractor

The !erson engaged to !rovide the concrete !um!ing e<ui!ment

%ith o!erator?s@ and to !um! concrete on8site.

,9mp operator The !erson %ho o!erates the controls of the !um!ing e<ui!ment.

19ali>ie< e;gi;eer A !erson, having a!!ro!riate <ualifications, e.g. "hartered#rofessional ngineer, %ith e)!erience in concrete !um!ing



follo%ing' an em!loyee, a self8em!loyed !erson, a contractor, or a

subcontractor.



O,EN O! E2TEND BOOM

Both forearms raised in front of

body, thumbs !ointing out in

o!!osite directions

CLOSE O! !ET!ACT BOOM

Both forearms raised,

thumbs !ointing to%ards the

centre.

STO, BOOM;and raised in front of body at

face level, hand closed into

fist.

STA!T ,"M, S,EED ",

orearm raised, inde) finger

!ointing u!.

Best #ractice =uidelines' "oncrete #um!ing #age L 5




SLOW ,"M, DOWN lbo%

raised, hand in front of body,

inde) finger !ointing do%n

and moving in a circle.

STO, ,"M,

Inde) finger !ointed, move

finger from one side to the

other at neck level.

LTTLE BT

lbo% raised, hand at face

level, thumb and inde) finger

>oined together to form a

!inch.

ALL DONE CLEAN ", Both

thumbs raised, !ointing u!.



A,,END2 E: CONC!ETE T!"CK D!5E! (AND SGNALS



A,,END2 F: SGNFCANT (A)A!D !EGSTE! 6E2AM,LE J NOT FO! "SE7

Locatio; Date o> Assessme;t

(a?ar<s ,ote;tial (arm Elimi;ate@ solate

or Mi;imise

Co;trols

Insufficient lighting • Walking into ob>ects

• Sli!s, tri!s, falls and

other in>uries

liminate • !rovide sufficient lighting so that tasks can be safely conducted regardless

of %eather conditions, time of day or building enclosure

• clearly define and light access%ays

#oor access to %orksite

#oor access around

%ork site

•

Sli!s, tri!s, falls andother in>uries

• Manual handling

in>uries

Minimise•

housekee!ing regimes to hel! kee! site clear• ensure sufficient s!ace around %ork areas

• ensure there is good access for concrete !ersonnel and e<ui!ment

• kee! other !eo!le not directly involved %ith concrete !ouring clear from

area

Working at height alls from height Isolate nsure scaffolding com!lies %ith SA($& .est Practice %uide for Scaffolding and

MBI .est Practice %uidelines for orking at Height in Ne! "ealand

#enetrations not

covered

alling onto shar! ob>ects Isolate nsure that !enetrations are secured, identified and covered

Inade<uate form%ork alls due to form%ork

failure

liminate • orm%ork to be structurally installed as !er engineerFs re<uirements

• (egularly ins!ect form%ork for defects and re!air immediately

)!osure to ultra8

violet light, glare

• Skin cancer

• ye damage

• sunburn

Minimise nsure that a!!ro!riate clothing and e<ui!ment is used%orn e.g. sunscreen,

shirts, sunglasses

Skineye contact %ith

concrete

• Skin rash or

allergydermatitis

• "oncrete s!lashed in

eye

• "oncrete burns

Minimise • ensure %ater is available to flush eyes

• ensure that eye !rotection is %orn in situations %here concrete s!lashes

may occur

• ensure that gloves and other !rotective clothing are %orn



(a?ar<s ,ote;tial (arm Elimi;ate@ solate Co;trols

or Mi;imise

"ontact %ith ha3ardous Short or long term health Minimise • Identify ha3ardous substances and !rovide Safety +ata Sheets

substances effects' liminate • Ese less or non8ha3ardous alternatives %here !ossible

• overcome by va!ours Minimise • nsure that users are ade<uately trained in the substanceFs safe use

• rashallergy and that a!!ro!riate !rotective clothinge<ui!ment is used

+isease

;ot %eather • +ehydration

• +i33iness

Minimise • nsure ade<uate drinking %ater is available

• Suitable clothing to be %orn e.g. light8coloured clothing

• nsure that there are shaded areas %here a!!ro!riate

• #rovide tem!orary cover for %ork areas

Violent e>ection of concrete Struck by concrete causing Minimise • =ive %arning !rior to starting or re8commencing the !our

from hose at first moment of body in>uries or falls • "heck hoses for air sources, such as'

delivery o blockage

o change in su!!ly

o !oor mi) or delays in the !our

• nsure delivery hose is not damaged !rior to !our

• Be a%are of !otential for blo% back in the line

• nsure a!!ro!riate edge !rotection

+elivery !i!e>oint failure Struck by concrete causing

in>uries or falls

Minimise • nsure connecting !i!es are ade<uately secured

• nsure brackets are !ositioned close together to minimise e)cessive

movement

• nsure that !i!eFs o!erating !ressure is a!!ro!riate for diameter of

!i!e

•

"heck !i!e to ensure it is of correct thickness for o!erating !ressure• +o not use damaged !i!es

• #rovide su!!ort %here a change in direction or reducer occurs

Walking on the concrete

foundation during the !our

Sli!!ing on %et !ly or

reinforcement

Minimise • +o not %alk back%ards during delivery

• Avoid getting feet caught in reinforcement



(a?ar<s ,ote;tial (arm Elimi;ate@ solate Co;trols

or Mi;imise

Shar! edges "uts from reinforcement Isolate • #ut ca!s on ends of e)!osed reinforcement bars

bar ends or tie %ire • Turn tie %ires into reinforcement cages

$oise from o!erating

machinery

;earing loss Minimise • Ese <uieter or muffled e<ui!ment %here !racticable

• #rovide ade<uate hearing !rotection suitable for the level of noise

e)!osure

umes from fuel • )!losion andor fire, Minimise • Ese correct fuel storage containers and funnels

uel used in vibrator burns, rashes or • +o not smoke %hen refuelling

allergies from skin • +o not refuel %hen machine is in o!eration

contact

• Illness, breathing Minimise • nsure there is ade<uate ventilation %hen refuelling and using the

difficulties from carbon vibrator

mono)ide

lectric !o%ered vibrator lectric shock Minimise • nsure e<ui!ment is not faulty or damaged !rior to use

• nsure e<ui!ment is earthed

• nsure e)tension leads are testedtagged by an electrician and that

faulty leads are not usedre!aired %ith ta!e

• nsure e)tension leads are not lying in %ater

Manual handling S!rains and strains Minimise • #rovide rest times

• Avoid long !eriods of t%isting, re!etitive movements

•

#rovide >ob rotation %here there are enough trained em!loyees• nsure the concrete is not too dry %hen screeding and shovelling



Sig;i>ica;t ha?ar< register

Locatio; Date o> Assessme;t

(a?ar<s ,ote;tial (arm Elimi;ate@ solate

or Mi;imise

Co;trols



A,,END2 G: TASK ANAL3SS WO!KS(EET

OB DESC!,TON LOCATONISTE O,E!ATO!S DATE

SE1"ENCE OF BASC STE,S ,OTENTAL SGNFCANT

(A)A!DS

(A)A!D CONT!OL MET(OD

:ist the four8eight ste!s re<uired to com!lete

the >ob. ?ollo% the flo% of the #roduct or the

#rocess.@

:ist the !otential SI=$II"A$T ha3ards

beside each ste!. ocus on %hat can cause

harm and %hat can go %rong. Ese Seven

#oint Analysis.

:ist the control methods re<uired to :IMI$AT, IS-:AT or MI$IMIS

each SI=$II"A$T ha3ard.

#erson

res!onsible to

im!lement

control?s@'

STE,NO

STE,NO

EIIM

,even 3oint 'nalysis Strain or sprain my 1ac) or other muscle Be caught in anything Slip/ trip or fall on the same or different le.el Cause a fire/ property damage or pollution

Be struc) 1y or against anything Come in contact 0ith a ha6ardous su1stance Come in contact 0ith an energy source



33E E4&IE/

.5' C*M3-E.E/ B6

/'.E

3-'. E4&IE/

,I7'7E E4&IE/

Best #ractice =uidelines' "oncrete #um!ing #age L 2*



A,,END2 (: ,,ELNE NS,ECTON LOG S(EET

Date Date Date Date Date Date Date Date Date Comme;ts

: : : : : : : : : : : : : : : : : :

,ipe No# Thic;ess Thic;ess Thic;ess Thic;ess Thic;ess Thic;ess Thic;ess Thic;ess Thic;ess


Concrete Pumping

Documents

Transcript of Concrete Pumping