CONCRETE & SCREED PUMPING METHOD STATEMENT
1.0. Description and sequence
Use of vehicle-mounted pump for placement of concrete
2.0. Method
2.1. Before leaving the depot
2.1.1. Walk round inspection of the vehicle, to ensure roadworthiness, including general visual check, hydraulic hoses (to check for any breaks), tyres, mirrors & lights, and hopper guard grid is secure and serviceable.
2.1.2. Defrost all windows (during winter conditions to provide good all-around driving visibility.
2.1.3. Allow engine to "warm up" and idle for 10 minutes prior to departure, to build up air reservoirs for brakes.
2.2. Arrival on site
2.2.1. Park safely outside and report to the site.
2.2.2. Wear appropriate PPE
2.2.3. Go through the induction process if required.
2.2.4. Walk to area designated for the pump setup area, and visibly assess the environment. Check for ground stability (responsibility for suitable preparation down to the site manager/hirer); overhead obstructions; visibility to the work area; access conditions and route for delivery Lorries.
2.2.5. Establish a code of signals between the pump operator and the concrete-laying gang/foreman before the commencement of pumping works.
2.3. Additional Safety Controls
2.3.1. Pre-Operational Equipment Check
Inspect the concrete pump, hoses, and all related equipment for wear, damage, and proper functioning before each use.
2.3.2. Secure Work Area
Set up barriers and signage to keep unauthorized personnel away from the pumping area and moving parts of the pump.
2.3.3. Proper PPE Usage
Ensure all workers wear appropriate personal protective equipment (PPE), including helmets, safety glasses, gloves, hearing protection, and sturdy footwear.
2.3.4. Stability of Pump and Boom
Position the pump on a level, stable surface and ensure the boom is fully supported to prevent tipping or collapse during pumping.
2.3.5. Communication Protocols
Establish clear communication between the pump operator, the person handling the hose, and other crew members. Use radios or hand signals if needed.
2.3.6. Regular Cleaning of Equipment
Periodically clean the pump, hoses, and other equipment during and after operations to prevent blockages and ensure optimal performance.
2.3.7. Pressure Monitoring
Continuously monitor the pump pressure to avoid overloading or blockages, which could lead to hose bursts or equipment failure.
2.3.8. Proper Hose Handling
Train workers to handle the hose safely, avoiding kinks and ensuring it remains secure during pumping to prevent it from whipping or moving uncontrollably.
2.3.9. Emergency Shutoff Readiness
Ensure the emergency stop button is accessible and workers are trained to use it in case of any malfunction or dangerous situation.
2.3.10. Post-Operation Maintenance
After pumping, ensure the equipment is safely shut down, cleaned, and maintained. Store hoses and tools in designated areas to avoid tripping hazards
2.4. Pump setup
2.4.1. Verify whether the customer has obtained a permit from the council for the temporary closure of the footpath. If the permit is not available, the customer must provide a ramp to ensure safe passage over the pipe.
2.4.2. If none of the above is available the area should be coned off and the customer informed he would be liable for any penalties incurred.
2.4.3. Remove rubber pipes (necessary to reach the pour starting point) from the reel, and carry to the lay-out position.
2.4.4. Layout necessary pipes in approximate assembly locations.
2.4.5. Join pipes together using couplings with rubber sealing rings and safety pins.
2.4.6. After connecting all hoses, perform a final inspection by walking through and checking each hose and coupling, beginning at the pour point and concluding at the pump hopper.
2.5. During works
2.5.1. Reverse the concrete delivery lorry to align with the hopper for discharge (if necessary).
2.5.2. Ensure that the hopper grid is in a lowered position, before the approach of the mixer lorry and at all times during discharge and pumping operations.
2.5.3. Let the delivery vehicle run the mixer drum for a few minutes before discharge to prevent initial separation of aggregates
2.5.4. Discharge concrete into the hopper to check the slump and suitability of concrete before starting to pump through hoses.
2.5.5. Establish a suitable position of work - to be able to see concrete/screed discharge into the hopper and point of delivery from the hose.
2.5.6. Start pumping concrete or screed at a rate that allows site operators to spread it effectively and ensures the lorry discharges at a pace that keeps the hopper sufficiently full.
2.5.7. Until concrete/screed is flowing smoothly out of the end of the delivery hose, or when a blockage occurs in the pipeline, all personnel should remain clear of the delivery hose.
2.5.8. The danger zone is the area surrounding the delivery hose where it may swing or move. This zone extends to a distance twice the length of the delivery hose.
2.5.9. If a blockage occurs during the pour, the pump operator must stop pumping immediately and instruct personnel to move to a safe position before attempting to remove the blockage.
2.5.10. If the pump operator needs to open the delivery pipeline to clear the blockage, he must first release the pressure inside the pipeline as much as possible, e.g. by reversing the pumping act. The pipeline must be treated as being pressurized at all times.
2.5.11. Proper eye protection must be worn at all times when opening the pipeline to ensure safety.
2.5.12. The operators are to ensure that site personnel DO NOT under any circumstance open or attempt to open the pipeline under pressure.
2.5.13. At the end of the discharge of each load remove any disconnected hoses and wash out immediately to avoid concrete/screed drying inside hoses and pipes.
2.5.14. If the concrete pump needs to be left unattended, ensure that the pump is properly isolated to prevent accidental operation.
2.6. On completion of works
2.6.1. Concrete/screed in the hopper should be discharged until only a small amount is left in the hopper {just covering the chambers)
2.6.2. The pressure in the pipeline should be released by retracting concrete/screed into the hopper.
2.6.3. The access point should be opened, a wetted sponge ball inserted into the line, and the access cover secured.
2.6.4. A cage, or protective backboard, should be erected at the end of the delivery hose (to receive and confine the cleaning ball).
2.6.5. Secure the end of the discharge hose to prevent any risk of whiplash.
2.6.6. Ensure all personnel involved in laying the concrete are relocated to a safe area away from the discharge hose.
2.6.7. The cleaning ball should then be advanced through the remaining pipes and hose, at reduced engine revs, until it emerges at the discharge point.
2.6.8. The ball should then be recovered thoroughly cleaned and washed off.
2.6.9. Ensure all hoses are thoroughly cleaned and stored on the lorry.
2.6.10. All couplings should be cleaned, washed and stored on the lorry bed.
2.6.11. Ensure all pipes, clips, and hoses are stowed in their respective areas on the lorry, and ready for road travel.
2.6.12. Complete client invoice/delivery note and present to clients representative.
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