Concrete Pump Operators

Concrete pumps move wet concrete through long booms and pipes to places a truck can’t reach. They are large machines with hydraulic booms, pressurized lines and heavy hoses. Pump accidents have killed operators and hose handlers when booms hit power lines, pumps tipped over, pipe burst or a hose whipped.

• Construction
• Concrete
• Equipment

Types of pumps

• Boom (truck-mounted) pumps have a folding boom that places concrete at the end of a hose. They set up on outriggers.
• Line (trailer) pumps push concrete through steel pipe and flexible hose from a ground position.
• Placing booms and stationary pumps are used on high-rise jobs.

Follow the manufacturer’s manual and your employer’s training. Many contractors train operators using programs from the American Concrete Pumping Association (ACPA). See also Concrete Work and Concrete Pump Trucks.

Site setup

• Walk the site first. Look for overhead lines, soft ground, slopes, excavations, buried utilities, tanks and vaults, trees and overhead obstacles.
• Set up on firm, level ground away from trench and excavation edges. Pump trucks are heavy, and the ground must hold the weight of the pump, the boom and the loaded concrete truck. See Excavations Near Structures and Slopes & Unstable Ground.
• Use outrigger pads sized for the ground, and extend all outriggers fully as the manufacturer requires. Never operate with an outrigger partly extended or not on solid support.
• Check the buried utilities and that the ground isn’t over a vault, septic tank or void. Call 811. See Call 811.
• Mark the pump area and keep unauthorized people out. Set up traffic control for the mixer trucks. See Work Zones.

Power lines

• Contact between a pump boom and a power line is a leading cause of pumping fatalities. The whole machine, the concrete and the hose can become energized.
• Keep the boom, the hose and every part of the pump at least the minimum clearance from lines, and assign a spotter. OSHA starts at 10 feet for lines up to 50 kV, and more for higher voltages. See Overhead Power Lines and When Equipment Contacts a Power Line.
• Know that wind, boom movement and sag change the distance. Plan the pour so the boom never comes close to a line.
• If contact happens, the operator stays in the cab or at the controls and everyone else stays at least 35 feet away until the utility de-energizes the line.

Operating the boom

• Only trained, authorized operators run the controls. Use remote controls from a position with a clear view of the boom and the placing crew.
• Unfold and fold the boom in the sequence the manual shows. Don’t exceed the outrigger and wind limits, and stop work in high wind, lightning or other conditions that the manual or the site plan lists. See Heat Illness for hot-weather care.
• Never use the boom as a crane or to lift loads or people, and don’t hang anything from the boom or the end hose beyond what the maker approves.
• Watch for overhead obstacles, forms, scaffolds and workers. Keep people from standing under the boom.
• Use clear signals and radios, and agree on stop signals. See Radio Signals.

Pipe, hose and blockages

• Concrete in the line is under pressure, and the pipe, couplings and hose can burst, kick or whip if there’s a blockage. Inspect pipe, clamps and gaskets for wear, and replace worn parts.
• The end hose handler should stand clear of the discharge and never wrap the hose around a body part. Keep a firm hold, but release it if it whips. Don’t kink the hose.
• Never open a coupling or clamp on a pipe that may be pressurized. Release pressure by reversing the pump, following the manufacturer’s steps, before opening a line.
• If a blockage forms, stop pumping and work out the cause. Don’t try to pump through it by running the pump at full pressure.
• Don’t stand in line with an open pipe end during cleaning.

Cleanout

• Clean out lines using the method in the manual, such as sponge balls pushed with water or air. Compressed air cleanout is especially dangerous because stored energy can launch the ball and concrete. Follow the manufacturer’s procedure, use a catcher, clear the area and don’t stand at the end of the hose.
• Wash out the pump and truck in a designated area, and don’t send washout water into storm drains. See Stormwater & SWPPP.
• Lock out the pump, release hydraulic pressure and block the boom before service. See Lockout/Tagout and Hydraulic Hazards.

Wet concrete and PPE

• Wet concrete is alkaline and can cause serious skin burns. Wear waterproof gloves and rubber boots, long sleeves, and eye protection. Wash right away. See Skin Disease & Dermatitis.
• Wear hard hat, safety glasses, hearing protection and high-visibility clothing. See Noise.
• Keep guards on the hopper, the agitator and moving parts. Never reach into a hopper while the pump is on.

Before the first pour

• Site walked; overhead lines and buried utilities identified; spotter assigned
• Pump on firm, level ground with outriggers fully extended on pads
• Pipe, clamps, gaskets and hose inspected
• Hose handlers briefed; signals and radios agreed
• Cleanout plan and washout area ready; compressed air method approved if used
• PPE on; people kept clear of the boom and discharge

Last updated: October 4, 2026