HEALTH & SAFETY NEWSFLASH OPERATOR ERROR

The Incident:
After setting up the 42m concrete pump the CPCS trained pump operator standing at the end of the boom commenced pumping. After approximately 1smq of concrete had been discharged the pump started to tilt coming to rest in the above position. There were no injuries although extensive damage was caused to the pump and concrete delivery truck. After 8 hrs the pump was placed in an upright potion and taken back to the depot for examination.

The Route Cause

The route cause of this incident was that the CPCS trained operators failed to fully extend one of the pumps rear out-riggers. A contributing factor was that the pump is fitted with a One-Sided Support function This allows for the pump to be set up with one side of the pumps out-riggers not in extended. The operator did not believe he was operating in OSS mode as he had half deployed the rear outrigger.

Remedail Action
1. 2. All concrete pump works on site must be controlled by a Truck Mounted Concerted Pump risk assessment. Prior to setting up the concreter pump a specific Concrete Pump Operators Permit to Work sheet must be fully completed.

3.

Concrete Pour Supervisors, Hopper Banksman & Pump Operators must be competent to fulfil their roles.

PHOTOGRAHS

RISK ASSESSMENT RECORD

HAZARD/WORK ACTIVITY ASSESSED LOCATION

USE OF TRUCK MOUNTED CONCRETE PUMPS

H = HIGH RISK, M = MEDIUM RISK, L = LOW RISK, I = INSIGNIFICANT SIGNIFICANT RISKS H M L I 1. the overturning / collapse of the pump X 2. persons struck by the placing boom X 3. air entrapped in the delivery line X 4. crushing of persons by reversing vehicles X 5. blockages X 6. the bursting of pipe-lines under pressure X 7. cleaning & dismantling the pipe-line X 8. contact with overhead services X 9. COSHH / noise X 10. contact with moving machinery / parts X RISK 1

WHO MAY BE HARMED EMPLOYEES SUBCONTRACTOR OFFICIAL VISITORS GENERAL PUBLIC PUMP OPERATOR .. ..

CONTROL MEASURES the overturning / collapse of the pump Every machine has the maximum possible loading displayed on its stabilisers; it is the responsibility of the hirer to ensure that the ground underneath the stabilisers is capable of supporting the imposed load. All the stabilisers must be extended and lowered before the boom is raised. If any stabilisers are not fully extended the pump must be set the One Sided Support mode. Generally, the machines carry their own sole-plates; in special circumstances it may be necessary for the hirer to supply extra sole-plates. Every machine has been tested for strength and stability when new and following substantial alteration or repair. Every machine has been thoroughly examined within the preceding twelfth months. All hydraulic rams on the placing boom are fitted with lock valves which prevent the boom sections from failing if a hydraulic pipe or hose bursts. persons struck by the placing boom Each machine is fitted with a remote control unit which allows the operator to operate the machine from a better position. Every remote control unit is fitted with an emergency stop control which, when activated, cuts off power immediately to the pump and placing boom. The driver must inform the gang of its position. When the operator is unable to see the tip of the boom or the concrete placing gang, the hirer must appoint a person to ensure that the correct concrete level in the concrete pump hopper is maintained. (See Risk 3 below). No-one, other than the concrete pump operator is allowed on the machine. It is inevitable that, when the boom is moved, the flexible delivery hose may swing, it is imperative that all members of the placing gang should be aware of the operators intention to move the pump and stand clear. air entrapped in the delivery line The correct level of concrete in the hopper of the concrete pump must be maintained to prevent air from being sucked in by hydraulic rams and subsequently pushed into the delivery line (the air will be compressed by the hydraulic pressure and will eject concrete forcefully from the end of the pipe-line). When the operator is working remote from the machine the hirer must appoint a person to supervise the concrete level in the hopper and advise the operator when the level is low. Employees of the hirer must not uncouple pipes without the operators permission. crushing of persons by reversing vehicles A banksman or the concrete pump operator must direct the driver of the truck-mixer during the reversing operation. Any site employee nominated to direct reversing truck-mixer drivers must be instructed on the dangers. Truck mounted mobile concrete pumps must fitted with a warning bleeper which is activated when reverse gear is selected. blockages Periodically, - the pipe-line may become blocked because the mix design or consistency is wrong, - the concrete may have become stiff because it has been standing for too long, - a member of the placing gang may have kinked the flexible placing hose, and pressure will increase behind the blockage, It is essential that the correct concrete pump mix design is ordered; The pump operator, through his experience, will recognise concrete that cannot be pumped; he will reject such loads; The flexible delivery hose must never be kinked; Nobody other than the operator should open pipe-line clips without his agreement.

the bursting of pipe-lines under pressure Flexible delivery hoses, steel delivery pipes and clips of a type suitable for the pressures likely to be encountered in a concrete pump pipe-line are the only type used. Because of the wear caused by harsh nature of the concrete being pumped through the pipes, wear takes place, wear is monitored regularly by the operator and measured by fitters when the machine is serviced; any pipes which fall below a tolerance level are replaced. cleaning & dismantling the pipe-line In special circumstances, the operator may have to use compressed air to clean out concrete from a pipe-line; The operator has a set procedure for this operation as agreed by his employer, site personnel should only be involved under his strict direction. The weight of a steel pipe full of concrete may be too heavy for one man to lift alone; operatives should be taught correct manual handling techniques in accordance with the Manual Handling Regulations 1992. contact with overhead services It is the responsibility of the hirer to ensure that the concrete placing boom cannot encroach the safety margins set for overhead cables. The overhead cable may be clearly marked or a solid barrier may be constructed to prevent contact; The pump MUST be set up in a position where it is impossible for the boom to encroach on safety margins (it may be necessary to construct a pipe-line to convey the concrete). Extra consideration should be given where the machine may have to be folded up or unfolded during the hours of darkness. COSHH / noise Noise assessments have shown that there is not a significant risk to hearing from the noise generated by a concrete pump at a distance of ten metres. However, the added noise from site plant, especially vibrators and petrol drive units, may cause noise levels to rise to levels where the issue of ear protection to operatives is essential. contact with moving machinery/parts All moving machinery on the concrete pump is fully guarded either by a mechanical guard or by position. The rotating remix shaft and valve gear either in or at the rear of the hopper are guarded by an automatic hydraulic interlock system.

10

INFORMATION, INSTRUCTION AND TRAINING 1. 2. Driver to CPCS standard only and certificates must be inspected prior to commencement of the works. Pump operating / driving by uncertified operatives is not permitted, this also applies to subcontractors.

SAFETY HELMET SAFETY BOOTS GOGGLES / VISOR OVERALLS GLOVES EAR PLUGS EAR DEFENDERS

PERSONAL PROTECTIVE EQUIPMENT RESPIRATORY PROTECTION: .. .. .. .. REMEMBER PPE IS ALWAYS A LAST RESORT

The concrete placement gang / contractors must be advised as to the danger of exposure of their skin to wet concrete.

COMPLETED BY

SIGNATURE

DATE

CONCRETE PUMP OPERATORS PERMIT TO COMMENCE WORK

The following permit has been completed by the Concrete Pour Supervisor who has been appointed on this project to ensure that the required position for which the pump is to be set up is suitable, the concrete pump operator has set the pump up correctly and that the Hopper Bankman has been appointed and aware of his duties.

1. 2. 3. 4.

Who is the Hirers appointed Concrete Pour Supervisor ? Who is the Owner competent Concrete Pump Operator ? Who is the Hirers appointed Concrete Hopper Banksman ?

.. .. ..

Have all persons identified in items 1, 2 & 3 signed onto the Truck Mounted Concrete Pump risk assessment ? signed declaration by the 3 parties below -

I confirm that I have read and understood my duties outlined in the Truck Mounted Concrete Pump risk assessment. If in the event I feel that my duties become compromised I will stop the pour and inform the Senior Site Manager immediately.

Concrete Pour Supervisor

Concrete Pump Operator

Concrete Hopper Banksman

5.

Specific Concrete Pour Supervisor Duties :5.1 5.2 5.3 5.4 Does the Concrete Pump Operator hold a valid CPCS competence card ? Is the Hopper Banksman aware of his duty to ensure air does not enter the delivery line by keeping the level higher than the intake values ? Is the ground bearing pressure suitable to withstand the pumps loadings ? Are there any obstructions which will impact on the safe slewing of the boom i.e. adjacent structures, overhead cables, services or plant ? Yes / No Yes / No Yes / No Yes / No Yes / No

6.

Specific Pump Operator Duties :6.1 6.2 Has the Pump Operator set up the pump fully extending all outriggers ? If no then question 6.2 must be answered. If yes then go to 6.3 Has the Pump Operators confirmed that he has engaged the One-Sided Support system? If OSS is to be engaged the Pump Operator must describe the reason/s why and identify which sides out riggers will not be extended in the right box below -

Yes / No

6.3 6.5 6.6

Has the Pump Operator set all engaged out riggers on outrigger pads Has the Pump Operator agreed that the concrete design is pumpable ? Has the Pump Operator instructed all operatives to stand clear until the concrete is flowing smoothly from the hose end ? Has the Hopper Banksman identified the minimum level for which the concrete shall not be allowed to drop below ? -

Yes / No Yes / No Yes / No

7.

Specific Hopper Banksman Duties :7.1 Yes / No The Approved Risk Assessment Number is...

The Concrete Pour Supervisor has agreed that the concrete pump can be set up in the agreed location :-