High Risk Work Licence - Concrete Placing Boom (PB) cheat sheet

A concrete placing boom (PB) is high risk work; the operator must hold a current PB licence for the boom's configuration, and employers must verify it before allowing operation.

Primary duty holders: the person conducting a business or undertaking (PCBU) must ensure health and safety so far as reasonably practicable; officers exercise due diligence; workers take reasonable care and follow safe systems.

PCBUs must manage risks using the hierarchy of control: eliminate, substitute, engineer, administratively control, then PPE as the last line.

High risk work licensing requires written evidence of competency, and licences must be produced on request to an inspector or employer.

Designers, manufacturers, importers and suppliers must ensure plant is safe and without risks when used as intended, including adequate information and guarding.

Registration or notification requirements may apply to certain plant; the PB must be inspected and maintained per the manufacturer and applicable plant regulations.

Consultation with workers and their representatives is mandatory when identifying hazards and making decisions about risk controls.

Incident notification: serious injuries, dangerous incidents and fatalities must be reported to the regulator within the prescribed timeframe (commonly 24-48 hours depending on jurisdiction).

Records of licences, inspections, maintenance, training and risk assessments must be retained and made available to regulators.

Key PB hazards: contact with overhead power lines, boom collapse or structural failure, overturning, crushing during setup, concrete hose whip, falls from height, and manual handling.

Overhead power line control: maintain the legislated exclusion distance (e.g., 4 m for low voltage, greater for high voltage) and use spotters; de-energise or isolate where possible.

Risk assessment formula: risk = likelihood × consequence; controls must reduce risk to as low as reasonably practicable (ALARP).

Ground bearing pressure must be checked against the outrigger load and soil bearing capacity; use mats or pads if the ground is soft or unknown.

Exclusion zones under and around the boom must be barricaded; no personnel under the boom or concrete discharge area.

Wind speed limits: stop operations when wind exceeds the manufacturer's rated limit (commonly 20 m/s or 38 km/h for many booms); monitor with an anemometer.

Concrete hose whip and blockages can cause serious injury; use whip checks and never stand in line with a pressurised hose.

Fatigue, heat stress and noise are common environmental hazards; manage with rotation, hydration and hearing protection.

Types: truck-mounted boom (boom pump), separate placing boom on a mast or tower, and trailer-mounted or stationary booms.

Articulating sections are called the boom; the number of sections (e.g., 3, 4, 5) determines reach and flexibility.

Key components: pedestal or turret, slewing ring, boom sections, hydraulic rams, outriggers, counterweight, hopper, and delivery pipes.

The concrete pump (piston or rotor) delivers concrete through the pipeline to the boom's end hose.

Reach is measured as horizontal and vertical reach from the slew centre; the load chart is specific to the boom configuration.

The end hose is typically 3-5 m long and must be secured with a safety sling or whip check.

Slew, luff (raise/lower) and telescope are the primary boom motions; each has rated speed and limits.

Outriggers transfer load to the ground; the outrigger spread and pad size determine the effective bearing area.

The pipeline must be earthed or bonded where required, and the boom must be kept clear of electrical conductors.

Pre-start checks: hydraulic fluid levels, leaks, hose condition, structural cracks, pin and bolt security, outrigger pads, tyre condition and pressure, and safety devices.

Verify the load chart, radius indicator, anemometer, horn, lights and emergency stop function before operation.

Setup: position the boom on firm, level ground; extend outriggers fully on pads; check the spirit level is within tolerance.

Ground bearing: confirm the soil bearing capacity exceeds the calculated outrigger pressure; use timber or steel mats to spread load.

Check for overhead power lines, underground services, excavations and slopes within the boom's reach and outrigger footprint.

Barricade the exclusion zone; confirm the concrete supply, washout area and access routes are clear.

Complete a documented pre-operational checklist and record any defects; do not operate if a safety-critical defect is found.

Ensure the boom is not set up over excavations, trenches or recently filled ground without engineering verification.

Operate the boom smoothly; avoid sudden starts and stops that cause load swing and hose whip.

Keep the boom within the rated load chart for the current configuration; never exceed the maximum radius or capacity.

Position the boom so the end hose is over the pour area; avoid dragging the hose through concrete or over obstructions.

Maintain communication with the pour crew and spotter; stop immediately if the signal is unclear or personnel enter the exclusion zone.

Never allow personnel to ride on the boom or end hose; never use the boom as a crane or hoist.

Keep the boom clear of power lines, structures, scaffolding and other plant; maintain the legislated exclusion distances.

Monitor wind, ground conditions and outrigger stability continuously; stop if conditions change.

When finished, retract and stow the boom per the manufacturer's sequence and wash out the pipeline safely.

The load chart gives the maximum allowable load at a given radius and boom configuration; always use the chart for the specific boom model.

Moment (stability) = load × radius; overturning occurs when the load moment exceeds the counterweight and base moment.

Outrigger load = (total weight × distance to centre of gravity) / outrigger base dimension; check against ground bearing capacity.

Ground bearing pressure (kPa) = outrigger load (kN) / pad area (m²); increase pad area to reduce pressure.

Reach is the horizontal distance from the slew centre to the end hose; capacity decreases as radius increases.

The boom's own weight, pipeline and concrete in the pipe must be included in the load calculation.

Never add counterweight or modify the boom; stability depends on the manufacturer's design.

If the load chart is missing or illegible, do not operate until the correct chart is obtained.

Standard signals: hand signals, radio, or whistle; the operator must stop when a signal is unclear.

Only one designated signal person should direct the operator; all others must relay through that person.

Radio communication must be tested before the pour; use a dedicated channel and clear, standard phrases.

The spotter monitors the boom, exclusion zone, power lines and ground conditions, and has authority to stop the operation.

Emergency stop signal: any person may give a stop signal; the operator must comply immediately.

Communication must continue throughout the pour; loss of communication means stop until restored.

Brief the pour crew on the exclusion zone, hose handling and emergency procedures before starting.

Emergency stop: activate the E-stop, stop the pump, and lower the boom to a safe position if possible.

Power line contact: keep everyone clear, do not touch the machine, call the electricity authority, and evacuate to the safe distance.

Boom collapse or structural failure: evacuate the area, isolate the machine, and do not re-enter until made safe by a competent person.

Injury or fatality: provide first aid, call emergency services, secure the scene, and notify the regulator within the required timeframe.

Fire: use the appropriate extinguisher, shut down the pump and hydraulics, and evacuate if the fire cannot be controlled.

Hydraulic hose failure: stop the pump, lower the boom safely, and isolate the hydraulic system before repair.

Post-incident: preserve evidence, record statements, and do not return the machine to service until inspected and cleared.

Shutdown sequence: stop the pump, wash out the pipeline, retract and stow the boom, lower outriggers, and secure the machine.

Daily pre-start inspection is required before each use; record the results and any defects.

Periodic inspections (e.g., monthly, quarterly, annual) must follow the manufacturer's schedule and applicable regulations.

Structural welds, pins, bolts, hydraulic hoses, slew ring and outriggers are critical inspection points.

Safety devices (limit switches, radius indicators, anemometer, E-stop) must be tested and functional.

Defects must be reported to the supervisor and recorded; safety-critical defects require the machine to be tagged out and removed from service.

Maintenance must be performed by competent persons using manufacturer-approved parts and procedures.

Records of maintenance, repairs and inspections must be retained and available for review.

Do not operate a machine with an expired inspection or an unresolved safety-critical defect.

Ground conditions: check for soft spots, voids, excavations, underground services and recently filled ground before setup.

Weather: monitor wind speed, lightning, heavy rain and temperature; stop operations when conditions exceed limits.

Overhead and underground services: locate and mark all services; maintain exclusion distances and use spotters.

Site access: ensure adequate space for the boom, outriggers, concrete trucks and washout; plan traffic management.

Washout: contain concrete washout to prevent environmental contamination; never discharge to stormwater.

Noise and dust: manage with appropriate controls and monitor exposure for workers and neighbours.

Public safety: barricade the exclusion zone and keep the public clear of the boom and discharge area.

Environmental spills: contain and report fuel or hydraulic oil spills per site procedures.