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Construction Testing Concrete Pumps Code of Practice
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1. uer ol ner Fiir te Gla eao mal ducta aper ine Pt Ty E Bue airu Bee Toc mc rura z End E irr mad hrrg high wind len a Aran Porr B La im aro oret o Fr boom in hidri pian Sopp 3 1 Henacud Frei eed and beet com rpm nr HII Cap in DIETE Frid He nam prag URE epee arma CF rica gpl pop freh deir ord ac em mea Tar ta Oe ering czn n tread Crimen og gx orm th fumi Lui OF bukri Tan HH 1 md mau epee a Hl rebua around irr eer 1n sim mod dae agis pra PAE ream ris UR a Th pH i FI arton on ade PaF BE BEPHE Sb ding bizarre napi fik vean sation amd Ve ad s Beam pe Een b Huoh mui ang Ai 6 ERR 6 mpat 2 2 cru WorkCover on Disk Codes of Practice CAUTION THE CONCRETE PLACING MUST NEVER BE USED AS ACRANE CPA 8 Two stickers each to be fixed high on the boom pedestal or slewing column head visible from each side of the machine to a person standing beside the machine CPA 8 2
2. CPA 11 One sticker on each side of the concrete pump placed adjacent to the outrigger control levers The sticker should be clearly visible to a person using the outrigger controls to set up the boom pump CPA 11 2 No 220 x 150 mm Red Black on White WorkCover on Disk Codes of Practice BEWARE OVERHEAD ELECTRICAL HAZARD STATUTORY AUTHORITY REGULATIONS FRECHIRE Minimum cr epp in roe bo liy A m bor uninga unita TELLE elesciricali b m dor vola peor 152 COD arid Lp l 530 KD b drspoctian ol tha wors alte tor BAHCE B m kr voltages nica 352 000 ngzarda baha eomm aeneis i ree me appliance ConE anit and n obses rescued wA warkirg ar crave ling the applanos vica af liye leer eed pein L heck alexis sho compl a Ih sow Ey Apis insere poplar EXTREME CARE TO BE TAKEN NOT TO INTERPOSE BODY BETWEEN OUTRIGGERS OR BOOM AND PUMP ASSEMBLY WHEN SETTING UP OPERATING OR FOLDING BOOM OR OUTRIGGERS WARNING OUTRIGGERS MUST BE FULLY EXTENDED AND ON A FIRM BASE BEFORE RAISING BOOM CPA 12 One sticker to be visible to a person at the operating position One sticker to be fixed inside the truck cabin ideally on the dashboard where it is visible to both the driver and passenger s The remaining two stickers should be placed on either side fo the concrete pump at the rear That is on the hopper sides catwalk sides or visible to persons st
3. No 250 x 175 mm Black on Yellow WorkCover on Disk Codes of Practice CAUTION IN DANGER AREA CPA 9 One sticker to be fixed each side of the last boom arm as near as practical to the end of the boom It should be fixed so that it is WorkCover on Disk Codes of Practice easily read when the boom is in the normal working position With roll fold booms this may mean that it will appear upside down when the boom is folded for transport CPA 9 2 No 220 x 120 mm Black on Yellow CPA 10 Two stickers to be fixed on each side of each hydraulic outrigger CPA 10 2 No 220 x 150 mm Black on Yellow WorkCover on Disk Codes of Practice BEWARE OVERHEAD ELECTRICAL HAZARD SIATUTORY AUTHORITY REGULATIONS REGUIAE F an epp in kr ligas A m kor snis ugs b 15 pire Irc m dcr 190 HO arid cp la 20 5E KI B m der vohages piro OSA B of the wors alie tor ellatrirel hazards tom imenelg 11 ime me appliance ConE anit and n obses rescued wA warkirg ar crave ling the applanos vica af liye leer eed pein L heck alexis sho compl a Ih sow Ey Apis insere poplar EXTREME CARE TO BE TAKEN NOT TO INTERPOSE BODY BETWEEN OUTRIGGERS OR BOOM AND PUMP ASSEMBLY WHEN SETTING UP OPERATING OR FOLDING BOOM OR OUTRIGGERS WARNING OUTRIGGERS MUST BE FULLY EXTENDED AND ON A FIRM BASE BEFORE RAISING BOOM
4. START PUMP SPEED UP 6 Start Pump Speed Up WorkCover on Disk Codes of Practice 9 SLOW PUMP DOWN 9 Slow Down Pump WorkCover on Disk Codes of Practice 10 Stop Pump WorkCover on Disk Codes of Practice LITTLE BIT 11 Little Bit WorkCover on Disk Codes of Practice 12 ADD WATER 12 Add Water WorkCover on Disk Codes of Practice ALL DONE CLEAN UP 13 All Done Clean Up
5. so that it can receive concrete flow readily from the discharge chute of the truck mixer A hinged grill should be provided to prevent access to dangerous moving parts such as feed or agitator mechanisms and valve gear The grill should be constructed of parallel bars spaced so that it is not possible for a person s hand to become trapped Spacing should not exceed 70mm and the distance from grating to moving parts should be a least 150mm 2 4 Access steps and working platforms Access steps and working platforms should be designed for the operator s safety 3 Placing booms and boom pipelines 3 1 Placing booms Placing booms and associated slewing mechanisms and mounting should be designed and constructed to withstand the static and dynamic loads to which they may be subjected in use The effects of fatigue wind loadings and service factors should also be taken into account Design should allow for the use of suitable placement hoses Lengths of hoses should be in accordance with manufacturers s recommendations Where booms are mounted on separate bases or tower structures these should also be suitably designed and adequately mounted Provision should be made to secure the boom in the stowed position for travelling Many aspects of the design of placement booms is similar to cranes The appropriate sections of AS1418 SAA crane code or DIN24117 Machines for the building and building materials industry should therefore be applied to the d
6. GED CONDUCTOR DEATH 06 SERIDUS INJURY WILL RESULT FROM SUCH CONTACT INADEQUATE CLEARANCE CPA 5 WorkCover on Disk Codes of Practice To be visible to a person at the operating position ie the position where a person would start the pump engine and control the pump CPA 5 1 No 120 x 170 mm Red Black on White CAUTION 1 INSPECT VEHICLE AND BOOM INCLUDING OPERATION PRIOR TO USE 2 FOR OPERATION VEHICLE MUST BE SECURELY PARKED AND STABILISED BEFORE 00 IS OPERATED 3 BEFORE OPERATING THE AERIAL BEIGE EQUIPPED WITH DUTRIGGERS EXTER THEM TO SOLID FOOTING CPA 6 To be visible to a person standing beside the concrete pump generally toward the rear of the machines Post only if the concrete pump can be stop started by remote control CPA 6 2 No 220 x 150 mm Black on Yellow WorkCover on Disk Codes of Practice CPA 7 1 gt 15 H SAFETY OPERATING INSTRUCTIONS we EHA cpu rin ee ar Bo rH ih THe paa rri am Fal nie roe an rg TE fen uu ee ere oo mA as a afe CAR LEER PROCLI m La d aed huma ricum ecu nop apanninn amd mcincm and Marien conto enl imapa dm condho MFVEZ 27 e ee LF Wm auly mpl bee auae rar pal ra zm vimi ara duree 2paralian zr 15 mahan Fun FUHR 1 CPT 82 bhi rmp
7. WorkCover on Disk Codes of Practice CODE OF PRACTICE Construction Testing Concrete Pumps gazetted 26 November 1993 commenced 1 March 1994 1 Introduction 1 1 Citation This Code of Practice may be cited as Code of Practice Construction and testing of concrete pumps 1993 1 2 Purpose This Code of Practice sets out guidelines for the construction and testing of concrete pump units and placing booms pipes hoses and couplings 1 3 Scope This Code applies to pump units placing booms and ancillary equipment used for the conveyance of concrete where the pump unit is skid mounted trailer mounted or vehicle prime mover mounted 1 4 Commencement This Code of Practice commences on 1 March 1994 1 5 Authority This Code of Practice is approved as an Industry Code of Practice pursuant to section 44A of the Occupational Health and Safety Act 1983 by the Minister of Industrial Relations and Employment on the recommendation of the WorkCover Authority of NSW 2 Pump unit Dangerous parts should be safeguarded as far as practicable in accordance with the Occupational Health and Safety Act 1983 and Regulations 2 1 Mounting a Skid mounted lifting eyes or fittings for attaching lifting gear should be provided to ensure the safe handling of the pump unit by crane A clearly visible permanent notice indicating the overall weight should be fixed to the unit b Trailer mounted Trailers should be constructed in accordance
8. Y CHARGED CONDUCTOR DEATH GR SERIOUS INJURY WILL RESULT FROM SUCH CONTACT OR INADEQUATE CLEARANCE CPA 15 One sticker to be visible to a person at the operating position and adjacent to CPA 12 One sticker to be fixed immediately beside the boom remote control cable output terminal box visible to a person unpacking or stowing the remote control cable were fitted CPA 15 2 No 120 x 165 mm Red Black on White WorkCover on Disk Codes of Practice CAUTION INSPECT VEHICLE AND BOOM INCLUDING OPERATION PRIOR TO USE FOR OPERATION VEHICLE MUST BE SECURELY PARKED AND STABILISED BEFORE BOOM 15 OPERATED BEFORE OPERATING THE AERIAL DEVICE EQUIPMENT WITH OUTRIGGERS EXTEND THEM TO SOLID FOOTING CFAT16 CPA 16 To be fixed to the truck dashboard clearly visible to the truck driver and passenger s CPA 16 2 No 70 x 85 mm Black on Yellow CPA 17 To be fixed nearby to the operating position next to CPA 7 WorkCover on Disk Codes of Practice 1 Boom Up WorkCover on Disk Codes of Practice 2 Boom Down WorkCover on Disk Codes of Practice 3 Boom Left WorkCover on Disk Codes of Practice 4 Boom Right WorkCover on Disk Codes of Practice 5 xm OPEN OR EXTEND BOOM 5 Open or Extend Boom WorkCover on Disk Codes of Practice amp S CLOSE OR RETRACT BOOM WorkCover on Disk Codes of Practice 7 Stop Boom WorkCover on Disk Codes of Practice
9. anding near to the rear sides of the concrete pump unit CPA 12 2 No 120 x 75 mm Red Black on White UNLAWFUL TO OPERATE THIS EQUIPMENT WITHIN 3 METRES OF POWER LINES WorkCover on Disk Codes of Practice Two stickers should be placed adjacent to stickers CPA 8 and two stickers should be placed adjacent to stickers CPA 9 CPA 13 2 No 120 x 150 mm Red Black on White DANGER ELECTROCUTION HAZARD KEEP CLEAR DEATH OR SERIOUS INJURY CAN RESULT FROM CONTACT WITH ANY PART OF THIS MACHINE OR VEHICLE IF THEY BECOME ELECTRICALLY CHARGED EPA CPA 14 a One sticker should be fixed to each of the rear sides of the concrete pump near to the operating position and in a location that is visible to persons generally standing nearby such as truck mixer drivers or persons likely to be talking to the pump operator b One sticker to be placed on the inside face of each front outrigger leg so that the sticker is clearly visible from the upper end of the pump when the outrigger leg is extended or folded out CPA 14 4 No 120 x 150 mm Red Black on White WorkCover on Disk Codes of Practice DANGER ELECTROCUTION HAZARD THIS MACHINE IS NOT INSULATED SAFE ELERRANEES ELECTRICAL POWER LINES AND APPARATUS YOU MUST ALLOY FOR BOOM AND PLATFORM SWAY ROCK OR SAG AND ELECTRICAL LINE AND LOADLIME SWAYING THIS MACHINE DOES NOT PROVIDE PROTECTION FROM CONTACT WITH OR PROXIMITY AN ELECTRICALL
10. ated on or above the splash board at the back of the hopper CPA 1 1 No 220 x 135 mm Black on Yellow WorkCover on Disk Codes of Practice DO NOT OPERATE THIS EQUIPMENT WITHOUT ALL SAFETY GUARDS IN POSITION CPA 2 One sticker on each side of the concrete pump visible to the operator in the operating position CPA 2 2 No 220mm x 100 mm Black on Yellow WorkCover on Disk Codes of Practice CPA 3 One sticker on each side of the concrete hopper CPA 3 2 No 220 x 150 mm Black on Yellow WorkCover on Disk Codes of Practice WARNING NEVEA ALLOW HANDS NEAR THE CONCRETE VALVE DANGER OF BRUISES AND CUTTING STOP THE DRIVING ENGINE MOTOR AND RELEASE ACCUMULATOR PRESSURE WHERE FITTED BEFORE CLEANING SERVICING CONCRETE VALVE ASSY Pal d CPA 4 a Squeez Crete type pumps One sticker on either side of the rotary pump housing b Piston pumps One sticker on the rear of the hopper adjacent to the concrete valve outlet s One sticker visible to the operator in the operating position CPA 4 2 No 220 x 150 mm Black on Yellow WorkCover on Disk Codes of Practice ELECTROCUTION HAZARD THIS MACHINE I NOT INSULATED MAINTAIN SAFE CLEARANCE FROM ELECTRICAL POWER LIMES AHO APPARATUS YOU MUST ALLOW FOR BOOM AND PLATFORM Sway ROCK Oft SAG AMD ELECTRICAL LIME LOADLINE SWAYING THIS MACHINE DOES HOT PAOYIDE PROTECTION FROM CONTRACT WITH OR PROXIMITY TD AH ELECTRICALLY CHAR
11. control systems should be approved by Telecom with a closely monitored transmitting frequency unique to the one machine It is essential that interference is not possible from another machine or from other sources that could accidentally operate the machine by remote control Controls should be water tight to prevent water leaking into electrical switch contacts causing an unselected movement of the control due to circuit bridging 6 5 Controls mounted on pump unit The controls should be positioned so that the operator has a clear view of the receiving hopper and of the placing boom if fitted The control station should be located so that the operator cannot be struck by the boom when using the controls Steps and handholds should be provided to give safe access to platforms or seats 6 6 Hydraulic controls For hydraulic powered engines the main control panel should include a gauge to indicate the pressure of the fluid supplied to the concrete pumping mechanism Where a hydraulic accumulator is installed or if the valve is controlled by a separate hydraulic circuit the panel should also include a gauge to indicate pressures of fluid supplied to the valve mechanism Each gauge should be clearly labelled 7 Pump unit stability testing 7 1 Testing standard All tests should be carried out in accordance with DIN 24117 or the stability test procedure laid down by the manufacturers 7 2 Test weights Test weights should be suspended at points a
12. dge of the relevant regulations and knowledge of concrete pumps and placing booms WorkCover on Disk Codes of Practice NATA The National Association of Testing Authorities Outriggers Extendible structural members on the pump unit to increase the dimensions of the stability base Owner The owner of any plant or substance or the controller manager lessee mortgagee hirer or borrower Placing boom A device to support and position the delivery pipeline It can incorporate folding luffing extending and slewing motions Principal contractor A person or company contracted by the owner to carry out the work Pump unit The concrete pump and the mounting Reducer A pipe that changes the internal diameter of the pipeline The Roads and Traffic Authority of NSW Appendix Safety stickers Safety stickers should be maintained so that they can be easily read by the operator or persons near to the concrete pump and or boom They should be replaced if they cannot be easily read Safety stickers should be located in positions indicated below If no space is available safety stickers should be fixed to sheet metal mountings attached to the concrete pump and or boom provided by the machine s owner DO NOT STAND ON GRATES mea CPA I To be visible to a person standing behind the concrete pump who is looking into the concrete hopper The sticker should not be lower than the lowest rim of the hopper and is ideally loc
13. esign of placing booms for concrete pump units 3 2 Boom pipelines Each section of rigid pipeline or flexible hose should be anchored to the booms so that in the event of a coupling failure no section of pipe or hose can fall from the boom Metal pipe swivels should be fitted in place of flexible hoses to accommodate the folding of boom sections Delivery pipes and flexible hoses supported by the boom and their adaptors and couplings should be as specified in sections 10 and 11 3 3 Pipeline security and reactions Concrete pumping lines are secured to the building or structure to withstand the often powerful reaction forces from high pump pressures It is essential that the reaction blocks or mountings at changes of direction of pipelines are designed to withstand these forces 3 4 Safety fittings Use chains wire ropes or webbing slings as a safety measure to secure sections of pipe such as reducers rubber hoses and bends which are liable to fail at the joint when attached to the final outlet of boom drop hose Safety chains wire ropes or webbing slings should have a minimum safe working load of 1 200kg Reducers should have compensation plates to which the anchorages are welded 4 General design requirements WorkCover on Disk Codes of Practice Concrete pumps and concrete placing booms should comply with the applicable engineering standards Modifications are allowed only if the required safety standards are met Wherever possib
14. evice that may be fitted on mobile pump units to prevent relative movement between a sprung pivoted road axle and the chassis frame in order to increase stability in service Bar A unit pressure 1 bar 100 kPa or 14 5 psi Catch basket A device fitted to the delivery end of the pipeline when the clean out adaptor is used to catch the sponge rubber balls or wads used in the cleaning operation Clean out adaptor A short length of pipe with one end blanked off and connections for a water or air hose coupled to the pipeline for cleaning purposes It should have a separate air relief valve vented to atmosphere and a pressure gauge when used with compressed air Competent person Means a person who an employer ensures has acquired through either training qualification or experience or a combination of those the knowledge and skill to correctly perform the task required Conditions of tipping A pump unit should be considered to be in the condition of tipping when the stability moment equals the overturning moment Coupling system The means of joining sections of delivery pipeline Delivery hose A flexible hose used in or at the end of the pipeline Delivery pipeline Portable rigid or flexible piping supplied in sections with the provision for joining together with a coupling system DIN Deutsche German Industrial Standard Engineer A person eligible for membership of the Australian Institute of Engineers who has a knowle
15. gid type secured by bolts or a quick release type that can maintain positive closure of the clamp such as a safety pin b Have the safe working pressure they can withstand specified by the manufacturer Substantiated by NATA test certificate i Incorporate a minimum safety factor of 2 1 i Have safety pins provided for lever toggle type couplings used on all booms and fixed pipeline installations 12 3 Pipe end fittings The type of end fittings on concrete pipelines and the clamping devices should suit the pressures attainable by the equipment being used a Do not use pipes with grooved ends where a groove is machined or rolled directly into the outside of the pipe wall for conveying concrete b light shrink or welded rings of under 4mm thickness should only be used on systems with a maximum attainable pressure of 50 bar 750 psi and NEVER on reducers or any pipeline with an internal diameter greater than 100mm 13 Reducers A reducing pipe that is a component of the pump unit should have couplings capable of withstanding the maximum concrete pumping pressure Reducers should be joined by a quick release type coupling with a facility for maintaining positive closure of the clamp when they have to be dismantled quickly due to a blockage Definitions For the purpose of this code the following definitions apply Australian Standard AS A standard rule code or specification of Standards Australia Axle lock A d
16. ickness of the delivery pipes to be used with their equipment 10 2 Materials for pipes The pipe should safely withstand the maximum working pressure in service have an adequate service life and not have any detrimental effects on the concrete 11 Flexible hoses 11 1 General Flexible hoses used as placing hoses and connected to lengths of rigid pipe in a delivery pipeline should be specified by concrete pump and placement boom manufacturers to avoid being subjected to pressures higher than those recommended Flexible hoses should be clearly marked with the a Manufacturer or supplier s name b Recommended operating pressure Fabric hose safety factor 4 to 1 Steel braided hose safety factor 1 75 to 1 11 2 Construction of hose Hose construction and materials should safely withstand the pressure in service have an adequate service life and not have any detrimental effects on the concrete 11 3 The suggested minimum operating pressures are 50mm 2 54 bar 800 psi 75mm 3 47 bar 700 psi 89mm 3 34 bar 500 psi 100mm 4 34 bar 500 psi 125mm 5 34 bar 500 psi 12 Coupling system 12 1 General Couplings should be designed and constructed for use and maintenance under site conditions The coupling and gasket should provide a leak proof joint and allow for a small angular movement between the two pipes they join WorkCover on Disk Codes of Practice 12 2 Couplings should a Be either the ri
17. le before modifications are made seek the advice of the manufacturer 4 1 Guarding All exposed moving parts should be guarded to prevent any body part making contact with any moving part Truck engines that drive concrete pumps should not be able to be started from the control panel of the concrete pump An exception is for engines that can only be started with all gears in neutral 4 2 Marking The following information should be displayed a Concrete pumps i Manufacturer or supplier ii Year of manufacture iii Serial number iv Model or type v Maximum permissible operating pressure of the pump hydraulic system in bar vi Maximum concrete pipeline pressure in bar b Concrete placing booms i Manufacturer or supplier ii Year of manufacture iii Serial number iv Model or type v Maximum permissible operating pressure of the boom hydraulic system in bar vi Maximum permissible pipeline internal diameter in millimetres and maximum hose length in meters vii Any restrictions on specified areas of operation 4 3 Safety stickers Safety stickers for pumps boom pumps and tower booms should be affixed to equipment in accordance with schedule contained in Appendix Safety stickers 5 Hydraulic operation of the pump and boom 5 1 General The specification and construction of hydraulic systems should be designed for the safety of personnel and long life of equipment 5 2 Horizontal stabilisers
18. long the boom as specified by the manufacturer 7 3 Test conditions When conducting a stability test the amount of fuel oil and the volume of washing water in the tanks should be the most unfavourable to the stability of the machine 7 4 Stability tests Stability tests should be carried out by the boom manufacturer or their qualified representative before putting a newly manufactured concrete placing boom into service Stability tests should also be carried out whenever modifications are made to a concrete placing boom or boom type concrete pump that may affect stability The results of all stability tests should be recorded in the machine s log book 8 Noise 8 1 Noise levels WorkCover on Disk Codes of Practice Concrete pumps should be constructed to ensure the minimum possible noise levels during operation 9 Instruction and service manuals Instruction manuals should be supplied with the pump unit and boom giving comprehensive instructions for operation testing maintenance and repair and include a parts catalogue A service manual should be supplied with the pump unit and boom detailing the frequency and type or service to be carried out Manufacturers and suppliers of pump units and booms should notify the pump owners of any alterations or additions to these manuals 10 Delivery pipelines 10 1 General Manufacturers of concrete pumps and placement booms are responsible for specifying the internal diameter and wall th
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20. outriggers Outriggers should have positive locking when fully extended or retracted 5 3 Hydraulic cylinders Hydraulic cylinders on concrete placing booms and hydraulic outriggers should be fitted with controllable non return valves so that the pressure in the hydraulic cylinder is maintained if a hose or pipe bursts A connecting pipeline between any cylinder and respective controllable non return valve is prohibited 6 Controls 6 1 Markings WorkCover on Disk Codes of Practice Controls should be clearly marked with symbols or words in English to show their function Where practicable the direction of movement of a control should correspond with the direction of motion being controlled See Appendix Safety stickers for recommended symbols 6 2 Control selections The control system should be arranged so that control selections cannot cause a motion not intended by the operator unless essential for the operation of a safety device or interlock 6 3 Dead man controls Where there is more than one set of controls the pump unit should be operable from only one position at any time Controls for slewing luffing and folding the boom should automatically return to the OFF position when the lever or knob is released by the operator All controls including remote controls should be full dead man so that in the event of operator release they return to neutral and lock in position 6 4 Radio controls full radio remote
21. with RTA regulations if the unit is designed for towing on public roads c Vehicle mounted the vehicle and equipment should comply with RTA regulations and be fitted with an audible reverse warning device permanent notice should be fixed in the driver s cab to indicate the maximum height of the unit in travelling order d Concrete pump and boom manufacturers or firms responsible for mounting these components on vehicles should ensure that the vehicle selected is suitable for the equipment to be mounted In particular the vehicle should be assessed for i Axle loadings and gross vehicle weight including any additional weight of ancillary equipment such as a full water tank for routine tasks pipes hoses and couplings ii Power weight ratio iii Performance on the highway iv Performance under site conditions v Stability both on the highway and under site conditions vi Torsion of chassis frame WorkCover on Disk Codes of Practice vii Engine cooling viii Auxiliary power takeoff s 2 2 Outriggers Mobile or trailer mounted pumps should have outriggers jacks or axle locks to provide stability during pumping operations A permanent notice should be fixed at a point near each outrigger on mobile boom pumps indicating the maximum force in kN that can occur at the foot of a fully extended outrigger See Appendix Safety stickers 2 3 Receiving hopper The receiving hopper should be positioned on the mounting
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