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CPMA27-2000 Version:

Concrete Pumps, Placing Booms,

and Delivery System

for

4.0.6

Safety Standard CPMA 27-2000

Version: 4.0.6

i CPMAv4.0.6

CPMA 27-2000 Safety Standard

Version 4.0.6

Date of issuance: September 16, 2002.

Becomes effective September 16, 2003.

Replaces version 3.0.1 before it became effective (would have been on September 16, 2003).

Version 2.0 was issued on October 9th, 1999, and became effective January 1st, 2000.

Version 1.0 was issued on April 28, 1999, and was replaced before it came into effect.

CPMA is a registered trademark of the Concrete Pump Manufacturers Association.

No part of this document may be reproduced in any form,in an electronic retrieval system or otherwise,

without the prior written permission of the publisher.

The Concrete Pump Manufacturers Association2310 S. Green Bay Rd.

Suite CPMB #174

Racine, WI 53406

copyright © 2002, 2003 by the

Concrete Pump Manufacturers AssociationAll Rights Reserved

Printed in U.S.A.

titlepageCPMA401 ii


Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Chapter 27-0 Scope, Definitions, and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Section 27-0.1 - Scope of CPMA27 - 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Section 27-0.2 - Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Section 27-0.3 - Reference to Other Codes and Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Examples of types of concrete pumps and placing booms . . . . . . . . . . . . 7

Chapter 27-1 Construction and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Section 27-1.1 - Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 927-1.1.1 Concrete Pump Rating and Identification Markings . . . . . . . . . . . . . . . . . . . . . . 927-1.1.2 Air Compressor Rating Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 927-1.1.3 Placing Boom Rating and Identification Markings . . . . . . . . . . . . . . . . . . . . . . . 927-1.1.4 Straight Delivery Pipes and Concrete Delivery Hose Rating and Identification

Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1027-1.1.5 Delivery System Elbow Rating and Identification Marking . . . . . . . . . . . . . . . 1027-1.1.6 Delivery System Accessory Identification Marking . . . . . . . . . . . . . . . . . . . . . 1027-1.1.7 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Section 27-1.2 - Concrete Pump Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1027-1.2.1 Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1027-1.2.2 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1027-1.2.3 Lifting Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Section 27-1.3 - Work Places, Access Walkways and Gangways . . . . . . . . . . . . . . . . . . . . . . . . 10Section 27-1.4 - Electrical Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Section 27-1.5 - Noise Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Section 27-1.6 - Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Section 27-1.7 - Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Section 27-1.8 - Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

27-1.8.1 Emergency Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1127-1.8.2 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1127-1.8.3 General Control Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1127-1.8.4 Standardized Joystick Movements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Section 27-1.9 - Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Section 27-1.10 - Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Section 27-1.11 - Pump Pressure Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

27-1.11.1 Reversible Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1427-1.11.2 Non-reversible Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Section 27-1.12 - Mobile and Stationary Placing Booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1427-1.12.1 Outriggers and Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1427-1.12.2 Placing Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

iii CPMAv4.0.6


Section 27-1.13 - Boom Tip Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Section 27-1.14 - Delivery Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

27-1.14.1 Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1427-1.14.2 Delivery System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Section 27-1.15 - Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Section 27-1.16 - Remote Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Section 27-1.17 - Standardized Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Section 27-1.18 - Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

27-1.18.1 Minimum Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1527-1.18.2 User Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Section 27-1.19 - Fuel and Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Chapter 27-2 Inspection, Testing, and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Section 27-2.1 - Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1927-2.1.1 Inspection Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1927-2.1.2 Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1927-2.1.3 Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2027-2.1.4 Inspection Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Section 27-2.2 - Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2027-2.2.1 Theoretical Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2027-2.2.2 Material Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Section 27-2.3 - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2027-2.3.1 Factory Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2027-2.3.2 Stability Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2127-2.3.3 Post Maintenance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Section 27-2.4 - Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2127-2.4.1 Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2127-2.4.2 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chapter 27-3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Section 27-3.1 - Qualifications For and Conduct of Operators and Operating Practices. . . . . . . 2327-3.1.1 Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2327-3.1.2 Qualifications for Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2327-3.1.3 Physical Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2327-3.1.4 Conduct of Operators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2427-3.1.5 Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2427-3.1.6 Operating Near Electric Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2427-3.1.7 Knowledge of Manual Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Section 27-3.2 - Concrete Pump Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Section 27-3.3 - Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

27-3.3.1 Standard Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2627-3.3.2 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2627-3.3.3 Special Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2627-3.3.4 Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

CPMA401bookTOC.fm iv


List of Figures

FIG. 1 Mechanical pea gravel concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FIG. 2 Hydraulic pea gravel and/or concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FIG. 3 Trailer mounted concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FIG. 4 Truck mounted concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FIG. 5 Truck mounted concrete pump with integral placing boom . . . . . . . . . . . . . . . . . . . . . . . . . 8

FIG. 6 Separate placing boom with electric power pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FIG. 7 Standardized joystick movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FIG. 8 Specifications for minimum and maximum hopper grate spacing . . . . . . . . . . . . . . . . . . . 13

FIG. 9 Standardized safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

FIG. 10 Area of extended outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

FIG. 11 Concrete Pumping Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

v CPMAv4.0.6


CPMA401bookLOP.fm vi


SAFETY STANDARD FOR CONCRETE PUMPS, PLACING BOOMS, AND DELIVERY SYSTEM

Introduction

General

This document is being drafted for the purposeof setting safety standards for the concretepumping industry. One purpose of the Standardis to serve as a guide to governmental authoritieshaving jurisdiction over subjects within thescope of the Standard. It is expected however,that the Standard will find a major application inindustry, serving as a guide to manufacturers,purchasers, and users of the equipment.

If adopted for governmental use, the referencesto other national codes and standards in the spe-cific volumes may be changed to refer to the cor-responding regulations of the governmentalauthorities.

The use of concrete pumps, placing booms, con-crete delivery systems, and the related accesso-ries is subject to certain hazards that cannot bemet by mechanical means but only by the exer-cise of intelligence, care, and common sense. Itis therefore essential to have personnel involvedin the use and operation of equipment who arecompetent, careful, physically and mentallyqualified, and trained in the safe operation of theequipment. Serious hazards include overloadingof the boom, blockages in the delivery system,and using equipment for a purpose for which itwas not intended or designed.

The Standards Committee fully realizes the im-portance of proper design factors, minimum ormaximum sizes, and other limiting dimensionscovered by the Standard, all of which are closelyconnected with safety. Sizes, strengths, and sim-ilar criteria are dependent on many different fac-tors, often varying with the installation and uses.These factors depend on the condition of theequipment or material; on the loads; on the ac-celeration or speed of the material being con-

veyed; on the type of attachments; on thenumber, size, and arrangement of boom sectionsor other parts; on environmental conditionscausing corrosion or wear; on the material beingtransported, and on many variables that must beconsidered in each individual case. The rulesgiven in the Standard must be interpreted ac-cordingly, and judgment used in determiningtheir application.

The Standards Committee will be glad to receivecriticisms of this Standard’s requirements andsuggestions for its improvement, especiallythose based on actual experience in applicationof the rules.

Suggestions for changes to the Standard shouldbe submitted to the Secretary of The ConcretePump Manufacturers Association, 2310 S. GreenBay Rd., Suite C, PMB #174, Racine, WI 53406and should be in accordance with the followingformat:

(a) cite the specific paragraph designation ofthe pertinent volume;

(b) indicate the suggested change (addition, de-letion, revision, etc.);

(c) briefly state the reason and/or evidence forthe suggested change;

(d) submit suggested changes to more than oneparagraph in the order that the paragraphsappear in the volume.

The Manufacturers Association will considereach suggested change in a timely manner in ac-cordance with its procedures.

1 CPMAv4.0.6


Section I - Scope

This Standard applies to the construction, instal-lation, operation, inspection, and maintenance ofreversible and non-reversible pumps for concretedistribution, wet mix shotcreting machines, con-crete placing booms, and concrete pumping ac-cessories including pipeline, hoses, clamps,gaskets, concrete diversion valves, concreteshut-off valves, pipeline blow-out heads and at-tachments.

This Standard does not apply to mortar convey-ing or spraying machines, dry mix shotcretingmachines, or any crane used for lifting, or equip-ment coming within the scope of the followingCommittees: A10, A17, A90, A120, B20, B30,B56, and B77.

Section II - Purpose

This standard is designed to:

(a) guard against and minimize injury to work-ers, and otherwise provide for the protectionof life, limb, and property by prescribingsafety requirements;

(b) provide direction to owners, employers, su-pervisors, and others concerned with, or re-sponsible for, its application; and

(c) guide governments and other regulatorybodies in the development, promulgation,and enforcement of appropriate safety direc-tives.

Section III - Interpretations

Upon request, the standards Committee will ren-der an interpretation of any requirement of theStandard. Interpretations can only be rendered inresponse to a written request sent to:

Secretary,

The Concrete Pump Manufacturers Association2310 S. Green Bay Rd.Suite CPMB #174Racine, WI 53406

The request for interpretation should be clearand unambiguous. It is further recommendedthat the inquirer submit his request utilizing thefollowing format.

Subject: Cite the applicable paragraph number(s)and provide a concise description.

Edition: Cite the applicable edition (version) ofthe pertinent volume for which the inter-pretation is being requested.

Question: Phrase the question as a request for aninterpretation of a specific requirementsuitable for general understanding anduse, not as a request for approval of aproprietary design or situation. The in-quirer may also include any plans ordrawings which are necessary to explainthe question; however, they should notcontain any proprietary names or infor-mation.

Requests that are not in this format will be re-written in this format by the Committee prior tobeing answered, which could change the intentof the original request.

CPMA procedures provide for reconsiderationof any interpretation when or if additional infor-mation which might affect an interpretation isavailable. Further, persons aggrieved by an inter-pretation may appeal to the cognizant CPMACommittee or Subcommittee. CPMA does not“approve,” “certify,” “rate,” or “endorse” anyitem, construction, proprietary device, or activ-ity.

Section IV - New and Existing Installations

(a) Effective Date. The effective date of thisvolume for the purpose of defining new andexisting installations is 1 year after its dateof issuance.

(b) New Installations. Construction, installa-tion, inspection, testing, maintenance, andoperation of equipment manufactured andfacilities constructed after the effective dateof this volume shall conform with the man-datory requirements of this volume.

IntroCPMA401 2


(c) Existing Installations. Inspection, testing,maintenance, and operation of equipmentmanufactured and facilities constructedprior to the effective date of this volumeshall be done, as applicable, in accordancewith the requirements of this volume.

It is not the intent of this volume to require retro-fitting of existing equipment. However, when anitem is being modified, the need to meet the con-struction and installation requirements of thecurrent standard shall be evaluated by a qualifiedperson selected by the owner (user). If there is asubstantial difference between the performanceof the item and the construction and installationrequirement(s) stated in this standard, which cancause a hazardous condition, changes recom-mended by the qualified person shall be made bythe owner (user) within one year.

Section V - Mandatory and Advisory Rules

Mandatory rules of this volume are character-ized by use of the word shall. If a provision is ofan advisory nature, it is indicated by use of theword should and is a recommendation to be con-sidered, the advisability of which depends on thefacts in each situation.

Section VI - Metric Conversions

The values stated in U.S. Customary units are tobe regarded as the standard.

3 CPMAv4.0.6


IntroCPMA401 4


CONCRETE PUMPS AND PLACING BOOMS

Chapter 27-0

Scope, Definitions, and References

Section 27-0.1 -Scope of CPMA27 - 2000

Standard CPMA27 - 2000 includes provisionswhich apply to the construction, installation,operation, inspection, and maintenance ofmechanical pea gravel, hydraulic pea gravel,trailer mounted, truck mounted (with or withoutintegral placing boom) concrete pumps; and sep-arate placing booms (see Figure 1 through Figure6).The requirements for mortar conveying andspraying machines are not included in this stan-dard.

Section 27-0.2 -Definitions

additives — material which is added to concreteor mortar to change the properties of the mix.

concrete and grout — homogenous mix of ce-ment, graded aggregate and water, to which non-toxic additives may be added.

concrete delivery hose — a flexible concrete de-livery hose which has two end couplings.

control panel — the control panel is consideredto be the place where the control actuating de-vices for the operation of the machine are lo-cated. A distinction shall be made between thecontrol panel on the machine and the remotecontrol, and between the control panel and themanual valve overrides.

delivery systems — delivery lines, hoses, andtheir components, as well as transfer valves arelines through which the material to be trans-ported is pumped.

designated — selected or assigned by the em-ployer or the employer’s representative as beingcompetent to perform specific duties.

designated person — a person selected or as-signed by the employer or the employers repre-sentative as being competent to perform specificduties.

end hose — a flexible concrete delivery hosewhich has only one end coupling.

grooved connection — a type of pipe connectionwhere a groove is machined or rolled directlyinto the outside of the pipe wall, creating aflange height of less than 0.15 inches.

hopper — a receptacle for the material to betransported, which can include an agitator, amixer, or both.

manual valve overrides — are mechanical valveactuators that can be used to operate a valve inemergency or breakdown situations. Manualvalve overrides are not to be considered controlpanels unless the manual valve override handleis the primary means of valve actuation.

metric connection — a type of pipe connectionwhere the raised flange diameter, shape, andthickness are manufactured to metric specifica-tions.

mobile and stationary concrete and wet mixshotcrete pumps — These are construction ma-chines that pump and spray concrete, with orwithout agitator, whereby the material to betransported is conveyed to the placing positionthrough delivery systems.

The conveyance is carried out mechanically.These mobile and stationary concrete and wetmix shotcrete pumps may be mounted on trucks,trailers, or special vehicles.

normal operating conditions — conditions dur-ing which a concrete pump is performing func-tions within the scope of the original design.

5 CPMAv4.0.6


placing booms — placing units and placingbooms are manual or power driven, slewableworking devices, consisting of one or more ex-tendable or foldable parts which support theconcrete delivery system, and which direct thedischarge into the desired location.

Placing booms may be mounted on trucks, trail-ers, or special vehicles.

qualified person — a person who, by possessionof a recognized degree or certificate of profes-sional standing, or who by extensive knowledge,training, and experience, has successfully dem-onstrated the ability to solve or resolve problemsrelating to the subject matter and work.

raised-end connection — a type of pipe connec-tion where the raised flange is tapered and selfaligning.

remote control — a control device for the ma-chine that is portable and may be connected tothe machine by a wire cable or linked by radio orother wireless means. A distinction shall bemade between the control panel and the remotecontrol.

Section 27-0.3 -Reference to Other Codes and Standards

Within the text reference is made to the follow-ing publications, copies of which may beobtained from one of the European Standardclearinghouses, such as Global Engineering, orfrom the publishers, as indicated. For dated refer-ences, subsequent amendments to or revisions ofany of these publications apply to this Standardonly when incorporated in it by amendment orprovisions. For undated references, the latest edi-tion of the publication referred to applies.

ANSI Z-244.1-1982Lockout/Tagout of Energy Sources—Minimum Safety Requirements

ANSI Z-535.1 -.4Product Safety Signs and Labels

EN 292-2: 1991 Safety of machinery; Basic concepts,general principles for design —part 2: Technical principles and speci-fications.

EN 418 Safety of machinery; Emergency stopequipment, functional aspects; Princi-ples for design

SAE J185 Platforms

SAE J833 Ergonomics

UNITED STATESFEDERAL CODE OF REGULATIONS

PART 1910.95. Chapter XVII of Title 29 (39 F.R. 7006)

Noise Exposure

scpdfrfCPMA401 6


Examples of types of concrete pumps and placing booms

FIG. 1 Mechanical pea gravel concrete pump

peagrvpmp.eps

Controlpanel

Remotecontrol

hydpgrvl.eps

FIG. 2 Hydraulic pea gravel and/or concrete pump

trlriso.eps

FIG. 3 Trailer mounted concrete pump

7 CPMAv4.0.6


FIG. 4 Truck mounted concrete pump

trkmntcp.eps

tkmtcpPB.eps

FIG. 5 Truck mounted concrete pump with integral placing boom

SPB.eps

FIG. 6 Separate placing boom with electric power pack

scpdfrfCPMA401 8


Chapter 27-1

Construction and Installation

Section 27-1.1 -Markings

27-1.1.1 Concrete Pump Rating and Identifi-cation Markings

The following information shall be legiblymarked on a durable identification plate on theconcrete pump:

(a) manufacturer, supplier, or importer;

(b) year of construction;

(c) fabrication (serial) number;

(d) type or model;

(e) maximum working pressure in the hydraulicsystem;

(f) maximum material pressure;

(g) power rating for high voltage electricalequipment (voltage, frequency, power, am-perage draw).

27-1.1.2 Air Compressor Rating Markings

If the machine is equipped with an air compres-sor, the following information shall be legiblymarked on a durable identification plate:

(a) At the compressor:(1) volume stream;(2) maximum working pressure;(3) highest working speed per minute;(4) installed engine performance in Kw or

HP;(5) power rating for high voltage electrical

equipment (voltage, frequency, power,amperage draw).

(b) At the air chamber:(1) permissible working pressure of the pres-

sure vessel;

(2) volume of the pressure vessel (e.g. in gal-lons);

(3) the construction identification for pres-sure vessels.

Note. This requirement does not apply to any partof the air system installed by the chassis manufac-turer.

27-1.1.3 Placing Boom Rating and Identifica-tion Markings

If the unit is equipped with a placing boom, thefollowing information shall be legibly marked ona durable identification plate on the placingboom:

(a) On the boom identification plate:(1) manufacturer, supplier or importer;(2) year of fabrication;(3) fabrication (serial) number;(4) type or model;(5) maximum working pressure in the hy-

draulic system;(6) maximum weight per foot of delivery sys-

tem, including concrete at 150 lbs/foot3;(7) maximum weight of the hanging system

components;(8) power rating for high voltage electrical

equipment (voltage, frequency, power,amperage draw).

(b) On a plate mounted to the tip of the boom,on the side with the last delivery elbow.

(1) Maximum weight of the hanging systemcomponents;

(2) Three examples of allowable size andlength combinations.

9 CPMAv4.0.6


27-1.1.4 Straight Delivery Pipes and Concrete Delivery Hose Rating and Identification Marking

The following information shall be legibly anddurably marked on straight delivery pipes longerthan 12 inches and concrete delivery hoses:

(a) manufacturer or supplier (name or code);

(b) nominal diameter;

(c) maximum working pressure, when new;

(d) weight of pipe (without ends) per foot, filled

with concrete at 150 lbs/ft3.

27-1.1.5 Delivery System Elbow Rating and Identification Marking

The following information shall be legibly anddurably marked on delivery system elbows:


(b) maximum working pressure, when new;

(c) weight of elbow, filled with concrete at 150

lbs/ft3.

27-1.1.6 Delivery System Accessory Identifica-tion Marking

The following information will be legibly anddurably marked on the following delivery systemcomponents: End hoses, shut-off valves, clamps, and reducers.


(b) maximum working pressure, when new;

(c) weight of the component, with concrete at 150

lbs/ft3.

27-1.1.7 Safety Labels

Safety labels shall be designed according to ANSIZ-535.

Section 27-1.2 -Concrete Pump Construction

27-1.2.1 Structural

(a) A design review shall be performed by themanufacturer to verify that the stability andstress calculations, the construction drawings,

and the materials used in the construction con-firm that the machine is constructed for its in-tended purpose.

(b) The manufacturers of the chassis and the con-crete pump should comply with the construc-tion and use regulations applicable to thecountry of use, taking into consideration thestress caused by on and off road use and theability of the chassis to handle the strains im-posed.

27-1.2.2 Stability

(a) The stability of the truck mounted concretepump with integral placing boom shall be de-termined by calculation of the static load im-posed by the boom and it’s systems andmountings, plus the maximum allowable loadimposed on the boom by the material in thedelivery system, including end hose, and theboom rotated to the least stable position. Thecalculation of the material load shall be based

on material with a bulk density of 150 lbs/ft3.

(b) A representative unit of each model and chas-sis in each intended operating configurationshall be tested to verify the calculated stabil-ity. See paragraph 27-2.3.2 on page 21 fortesting requirements.

(c) Stability may be influenced by such additionalfactors as wind, ground conditions, boomlengths, and proper operating speeds.

27-1.2.3 Lifting Attachments

(a) Machines or their parts which are intended tobe moved at building sites by cranes or otherlifting devices shall be equipped with suitableattachment points.

(b) Any component weighing more than 500pounds and having lifting attachments shallhave the component weight legibly and dura-bly marked on the component.

Section 27-1.3 -Work Places, Access Walk-ways and Gangways

(a) Work places, access walkways and gangwaysshall be designed to minimize slip, trip andfall hazards during operation.

con&charCPMA401 10


(b) Access for maintenance, assembly, disman-tling, and testing should be considered.

(c) The machine designer should considerweather conditions in the design phase.

(d) Access on and off of the concrete pump decksshall be designed per SAE J185.

Section 27-1.4 -Electrical Installations

Electrical installations above 100 volts shall be incompliance with the appropriate National ElectricCode. The equipment shall be connected via aground fault circuit interrupter or system that pro-vides an equivalent level of protection.

Section 27-1.5 -Noise Exposure

The machine designer shall consider Part 1910.95of the United States Federal Code of Regulations,Chapter XVII of Title 29 (39 F.R. 7006) inmachine design, construction, operation, and main-tenance.

Section 27-1.6 -Ergonomics

Control panels, manual override levers, accessdoors and covers shall be located to provide accessto accommodate human physical dimensions asoutlined in SAE J833.

Section 27-1.7 -Outriggers

(a) The machine shall be constructed so the oper-ator can see the area of movement.

(b) The machine shall be constructed so the out-riggers are securable when in the transport po-sition.

Section 27-1.8 -Controls

27-1.8.1 Emergency Stops

(a) Each machine shall be equipped with an emer-gency stop system.

(b) The emergency stop system shall be visible,accessible and easy to operate.

(c) The machine may be fitted with several emer-gency stop controls.

(d) Emergency stops shall:(1) cause the machinery to stop instanta-

neously, taking into account stored energy;(2) prevent the automatic restart of the ma-

chine. The machine will have to be startedintentionally;

(3) be constructed according to EN 418.

(e) The machine shall be equipped with emer-gency stop devices at the control panels and atthe remote control device.

27-1.8.2 Outriggers

(a) Control devices for slewable, telescopic, andadjustable outriggers shall be self resetting.

(b) Control devices for outriggers shall be situ-ated outside of the area of movement, or ac-cess to the area of movement shall beotherwise restricted.

(c) Control circuits for the outriggers shall be in-dependent of each other.

(d) When implemented, the lockout/tagout proce-dure must make the outrigger controls non-functional.

27-1.8.3 General Control Requirements

(a) If there are several control panels, the sameoperation (e.g. start, close, open) shall only bepossible from one panel at any one time. Pri-ority switching (either manual or automatic)shall be made between panels to transfer thecontrols.

(b) The control devices must be safeguardedagainst unintentional operation.

(c) When implemented, the lockout/tagout proce-dure must make the control devices nonfunc-tional.

(d) The control devices shall be constructed, ar-ranged and marked in such a way that thefunction is indicated.

(e) The control devices which activate boom andoutrigger movements shall be self resetting.

11 CPMAv4.0.6


27-1.8.4 Standardized Joystick Movements

Joystick movements shall be consistent with thestandardized movements shown in figure 7.

Section 27-1.9 -Guards

Any hazard that is inaccessible because of its loca-tion is considered guarded by location.

(a) A fixed guard shall be installed to prevent un-intentional access to the moving parts in thewaterbox.

(b) If not guarded by location, a fixed guard shallbe installed to prevent unintentional contactwith the material valve switching mechanism.

(c) A fixed guard shall be installed over rotatingshafts. The underside of mobile truck chassismounted concrete pumps are consideredguarded by location.

(d) A fixed guard shall be installed over V-beltsand drive pulleys.

(e) Hot machinery parts shall be guarded. Engineexhaust gases shall be piped to the outside ofthe cab and discharged in a direction awayfrom the operator. All exhaust pipes shall be

guarded, located, or insulated to prevent con-tact with personnel when performing normalduties.

Section 27-1.10 -Hoppers

(a) Grates on hoppers of reversible pumps, whichcan be opened without a tool or which have tobe opened more than once a day shall be con-figured in such a way that when they areopened operation of the concrete pump andagitator is stopped, and they shall be securedagainst restarting while the grate remainsopen.

(b) A valve mechanism capable of crushing, tear-ing, or cutting shall be guarded by a covergrate on the opening of the charging hopperwithin the dimensions shown in Figure 8 onpage 13, or the machine may be constructed insuch a way that the crushing points are inac-cessible.

OFF

#1DOWN#1 DOWN

PLUSSLEWING CCW

#1 DOWNPLUS

SLEWING CW

#1 UPPLUS

SLEWING CCW

#1 UPPLUS

SLEWING CW

SLEWINGCOUNTER-

CLOCKWISE(CCW)

SLEWINGCLOCKWISE(CW)

#1UP

OFF

TIPRETRACTTIP RETRACT

PLUSNTT EXTEND

TIP RETRACTPLUS

NTT RETRACT

NTT EXTENDPLUS

TIP EXTEND

NTT RETRACTPLUS

TIP EXTEND

NTTEXTEND

NTTRETRACT

TIPEXTEND

LEFT JOYSTICK RIGHT JOYSTICK

NTT = Next To Tip. It means the section of boom attached to the tip section. For example, on a 4 section boom NTT would be number 3. On a 3 section boom, NTT would be number 2. Each remote box will show the configuration correctly for the unit it will run. There is no standard for any sections not listed, meaning that extra sections may have pushbuttons, additional joysticks, or some other configuration.

joystickstandard.eps

FIG. 7 Standardized joystick movements

con&charCPMA401 12


(c) Agitators or screw conveyors located inside ofhoppers shall be guarded with a cover grateconstructed within the dimensions shown inFigure 8 on page 13.

(d) Power operated hopper cover grates or hoppercovers shall have a control device with selfacting reset. The location of the control levers

shall be far enough away from the crushingpoints to prevent contact with the movingparts.

(e) A grate or cover which can be raised shall besecurable in the open position or constructedin such a way that it will not close uninten-tionally.

h

c

d

b h

³4

²19

16 ³31

2

²318

mesh type grate

a h

²234 ³4

bar type grate

³13

16

c d

²138

both types

all sizes in incheshopperart5.eps

mesh type grate

b

b

bar type grate

a

FIG. 8 Specifications for minimum and maximum hopper grate spacing

13 CPMAv4.0.6


Section 27-1.11 -Pump Pressure Release

27-1.11.1 Reversible Pumps

Reversible pumps shall be constructed so pressurecaused by blockages in the delivery system can beremoved by reversing pumping, but it must beunderstood that reverse pumping cannot releasestatic pressure such as in a vertical standpipe.

27-1.11.2 Non-reversible Pumps

Non-reversible pumps shall be constructed so per-sonnel are not endangered by the forceful ejectionof concrete when removing the pressure caused byblockages. This can be accomplished by:

(a) a restraining device allowing the pump mani-fold to be opened safely;

(b) a pressure release gate in the manifold;

(c) any other pressure release mechanism thatwill not endanger personnel when used.

Section 27-1.12 -Mobile and Stationary Plac-ing Booms

27-1.12.1 Outriggers and Support Structure

The outriggers and pedestal assembly of placingbooms shall be constructed so the maximum exist-ing support force can be transferred to the subsoil.The maximum support force shall be marked at theoutriggers.

27-1.12.2 Placing Boom

(a) A remote control device with sufficient rangeto reach the end of the boom shall be supplied.

(b) The lifting and lowering speed at the end of afixed speed or single speed boom shall not ex-ceed 3 feet per second when activating anyone section. With proportional control boomsystems, it shall be possible to operate at orbelow the specified speed.

(c) The lifting and lowering speed at the end of afixed speed or single speed boom shall not ex-ceed 10 feet per second when activating allboom functions simultaneously. With propor-tional control boom systems, it shall be possi-ble to operate at or below the specified speed.

(d) The horizontal slewing speed of the end of afixed speed or single speed boom shall not ex-ceed 5 feet per second. With proportional con-trol boom systems, it shall be possible tooperate at or below the specified speed.

(e) Placing booms shall be clearly marked withthe maximum allowable hanging weight perthe instruction at paragraph 27-1.1.3 b onpage 9, and a label affixed near the tip elbowwarning about the use of improper diameterdelivery system.

(f) The placing boom shall not be used as a hoist.A warning label shall be placed on the ma-chine to this effect.

Section 27-1.13 -Boom Tip Attachments

Provisions shall be made so attachments suspendedfrom the boom tip can be restrained.

Section 27-1.14 -Delivery Systems

27-1.14.1 Delivery Line

Delivery system components supplied with amachine shall have a working pressure rating atleast equal to the maximum pressure of themachine as delivered.

27-1.14.2 Delivery System Components

(a) New delivery system components shall meetthe following minimum ratios of burst pres-sure versus working pressure:

(1) end hoses . . . . . . . . . . . . . . . . . . . . . . . 2:1;(2) boom pipes and boom couplings. . . . . . 2:1;(3) other concrete placing line and accessories,

including concrete delivery hose, slickline,valves and couplings . . . . . . . . . . . . . . . 2:1.

(b) Delivery system components for boom unitsshall have a minimum of 85 bar (1233 PSI)working pressure, when new. Any boom unitcapable of exceeding 85 bar material pressureshall have the delivery system's working pres-sure requirements clearly marked on theboom.

(c) Pipeline couplings shall be constructed tominimize the possibility of inadvertent open-ing.

con&charCPMA401 14


(d) Delivery systems with grooved connectionsshall not be used on placing booms, or onslickline, or hoses.

(e) Air blow out caps shall be equipped with aseparate bleed off valve to allow the operatorto relieve pressure in the system.

Section 27-1.15 -Loss of Power

Interruption of power to the machine shall notcause a hazardous situation.

Section 27-1.16 -Remote Starting

A machine which is powered by the vehicle engineshall be designed such that the engine cannot bestarted from a remote location unless the driveaxles are disengaged.

Section 27-1.17 -Standardized Safety Labels

When applicable, concrete pump manufacturersshall furnish each machine with safety labels asshown in figure 9 as a minimum. Units notequipped with booms would not need boom spe-cific safety labels, units not equipped with outrig-gers would not need outrigger specific safetylabels, etcetera.

Section 27-1.18 -Manuals

27-1.18.1 Minimum Contents

The concrete pump manufacturer shall furnish witheach machine at least one copy of a manual(s). Themanual(s) shall include information applicable tothe following:

(a) installation

(b) operation

(c) inspection

(d) testing

(e) lubrication

(f) maintenance

(g) parts

(h) wiring diagram (may be supplied separately)

(i) hydraulic diagram (may be supplied sepa-rately)

27-1.18.2 User Publications

In general, there are 4 different types of user publi-cations:• operation manuals;• safety manuals;• maintenance manuals;• spare parts lists.

27-1.18.2.1 The operation manual should bewritten in a clear and understandable man-ner. The operation manual shall comply with5.5 of EN 292-2. In addition to the require-ments in EN 292, the following specificrequirements shall be described in the opera-tion manual:

(a) It shall give information if personal protectiveequipment is necessary;

(b) The independent use or maintenance of con-crete pumping machines shall be carried outby designated persons;

(c) It shall be stated how to lockout or tagout thecontrol devices against unauthorized use;

(d) Instructions for frequency and method of reg-ular inspections according to paragraphs 27-2.1.1 and 27-2.1.2 and instructions to recordthe results on the machine specification sheet,with instructions regarding notifying the man-ufacturer.

27-1.18.2.2 The following operator informationshall be contained in the operation manual asa minimum requirement:

(a) For all units:(1) Operation of this machine requires training.

You must read all warning labels on theunit;

(2) Only the operator may authorize access tothe unit or surrounding area;

(3) Safety devices and guards must not be al-tered or removed;

(4) Stop the operation if any structural mal-functions, failures or faults occur. Do notrestart until repaired;

(5) Machine should not be operated with theemergency stop equipment bypassed;

15 CPMAv4.0.6


file:CPMAstddecals.epsrev:08/04/03

WARNING

DANGERElectrocution hazard.Stay back fromhigh voltage wiresat least 17 feet(5 meters).

WARNINGDo not use the boom as a crane or hoist.

SAFETY INSTRUCTIONS1. Operation of this machine requires training. You must read all warning labels on the unit -

items covered on specific warning labels are not covered here. There are other hazards and safety rules that are ONLY covered in the safety manual or operation manual.

2. Only the operator may authorize access to the unit or surrounding area.

3. Safety devices and guards must NOT be altered or removed.

4. Stop the operation if any malfunctions, failures or structural faults occur. DO NOT restart until repaired.

5. NEVER try to finish the operation with the emergency stop dump valves bypassed.

6. You must always be able to see the point of discharge. If this is impossible, an assistant (spotter) MUST be used. The spotter must be positioned to see both the operator and point of discharge for the purpose of giving instructions to the operator.

7. Ensure the stability of the unit. Use adequate outrigger cribbing for soil conditions. Level the unit to within 3°.

8. Check for obstructions before unfolding or slewing the boom or outriggers.

9. DO NOT unfold the boom unless the outriggers are fully extended and properly jacked. Shortrigging is NEVER allowed on the side of the pour.

10. Maintain a safe distance from excavations or cliffs. Stay as far back from the edge as the depth of the excavation or cliff. (This is the one to one rule).

11. Never retract the outriggers until the boom is folded into the transport position.

12. Be sure outriggers are retracted and pinned before driving the unit.

13. NEVER drive the unit with extended outriggers or an unfolded placing boom! Not even a few feet.

14. The supplied safety cable MUST be used to secure the discharge hose or reducer to the tip section.

15. DO NOT overload the boom. The maximum allowable weight from hose or reducer/hose combination is 376 pounds, which is equivalent to one 12 foot long 5 inch hose, OR a 5 inch to 4 inch reducer and one 12 foot long 4 inch hose. NEVER use the boom as a hoist or crane. NEVER attach a structural extension to the boom.

16. In the event of a thunderstorm or high winds (over 48 MPH), the boom must be folded into the transport position.

17. Any and all clamps, hoses and pipe connected to the unit MUST be able to withstand the maximum concrete pressure of the unit.

18. If the boom will be connected to a separately laid pipeline a hose MUST be used between them. DO NOT allow the hose to kink. DO NOT allow the boom to rest on the deck.

19. Cleaning the boom or a separately laid pipeline with compressed air should only be done under the supervision of an expert. All hoses must be removed, and a ball catcher MUST be attached to the discharge.

20. Wear a hardhat, safety goggles, ear protection, gloves, steel toed shoes and tight fitting clothes when working on or near a concrete pump.

21. Never leave the unit unattended when it is running or ready to operate, especially around children. Turn off the remote control box with the kill switch before setting it down.

22. Lift the main boom to vertical to release the transport hook when unfolding. The hook

DANGERStay clear.Contact will result in death or serious injury if the unit becomes electrically charged.

WARNINGBefore opening a blocked pipeline, relieve pressure by reversing pump.See manual.

WARNING

Keep hands out of hopper and valve assembly. See operation manual if access is required.

Keep hands out of waterbox.Stop engine/motor if access is required. Keep covers closed.

WARNING

WARNINGUse retaining pins in all delivery system clamps.

WARNINGDo not operate this machine without training. Understandthe warnings in safety manuals and on decals.

SAFETY

MANUAL

WARNINGSafety guard is missing.

WARNING

This machine is remote controlled and may start at any time. Stop engine before servicing unit.

WARNING

WARNING

OK

WARNING

Cement dust is toxic. Use lung protection when exposed.

EXTEND OUTRIGGER TO HERE BEFORE UNFOLDING BOOM

Unit will tip if outriggers are not fully extended.

WARNING

SAFETY INSTRUCTIONSExtend outriggers until striped decals are visible, as shown in illustrations.

WARNINGClear discharge area when first starting the pump, restarting after moving, or whenever air is present in the delivery system. See Safety Manual.

WARNING

Do not touch hydraulic oil leaks. Get immediate medical attention if oil penetrates skin.

30355887

You can order additional operation manuals, spare parts books, safety manuals and decal sets by contacting us at:

(Manufacturer Name)(Phone number to call to order parts)

(Business hours (i.e. 9 - 5 M-F))

IMPORTANT

WARNING

Stand clear of outriggers when activating.

WARNING

Do not stand on hopper grates.

Clear area before activating outriggers

WARNINGTipping hazard. Additional cribbing required for many soil types See Operation Manual.

WARNING

Do not operate at pressures exceeding the rating of the entire material delivery system.

WARNING

WARNINGDo not exceed the maximum total weight limit for system hanging from the boom.Boom cracking hazard.

026

036

029

033*

017

031

025

014

013

034

018

010

021

024

012

015

027

019

038

037

023

016

022

035

032

028

020

030

011

* For reference only. Each manufacturer to make a similar decal applicable to

their models and features.

#035 refers to the striped decal #032.

FIG. 9 Standardized safety labels

con&charCPMA401 16


(6) You must always be able to see the point ofdischarge. If this is impossible, an assistant(spotter) must be used. The spotter must bepositioned to see both the operator andpoint of discharge for the purpose of givinginstructions to the operator;

(7) Ensure the stability of the unit;(8) Wear a hard hat, safety goggles, and snug

fitting clothes when working on or near aconcrete pump. Wear hearing protection,gloves, and steel toed shoes when required;

(9) Never leave the unit unattended when it isrunning or ready to operate, especiallyaround children. Turn off the remote controlbox before setting it down;

(10) Personnel should be cleared from the areaof the end hose when starting or restartingthe pump;

(11) Never remove the fuel cap or refuel the unitnear hot surfaces, sparks, or open flames.The fuel may explode.

(b) For units with integrated placing booms:(1) Use adequate outrigger cribbing for soil

conditions. Level the unit to the manufac-turer’s specification;

(2) A minimum of 17 feet (5 meters) must bemaintained between the machine and elec-trical power lines at all times;

(3) Check for obstructions before unfolding orslewing the boom or outriggers;

(4) Do not unfold the boom unless the outrig-gers are fully extended and properly jacked.Shortrigging is never allowed on the side ofthe pour;

(5) Maintain a safe distance from excavationsor cliffs. Stay as far back from the bottomedge as the depth of the excavation or cliff.(This is the one to one rule);

(6) Never retract the outriggers until the boomis folded into the transport position;

(7) Be sure outriggers are retracted and lockedbefore driving the unit;

(8) Never drive the unit with extended outrig-gers or an unfolded placing boom;

(9) All delivery system attached to the end ofthe boom shall be secured with a a strap orcable;

(10) Do not overload the boom. The maximumallowable weight from hose or reducer/hosecombination on units shall be documented,and examples given to aid the operator;

(11) In the event of a thunderstorm or highwinds (over 48 MPH), the boom must befolded into the transport position;

(12) If the boom will be connected to a sepa-rately laid pipeline a hose must be used be-tween them. Do not allow the hose to kink.Do not allow the boom to rest on the deck;

(13) Cleaning the boom or a separately laidpipeline with compressed air should only bedone under the supervision of a qualifiedperson. All hoses must be removed, unlessspecifically designed by the manufacturer toremain in place during the blow out process(e.g. a boom delivery system with a perma-nently attached and restrained hose), andthe discharge end must be controlled. Useof a ball catcher is recommended;

(14) The operator and/or laborer assigned to thepump should not allow unauthorized per-sonnel around the machine, nor in the boomplacing area;

(15) Do not extend the placing boom beyond themanufacturers design specification;

(16) Do not use the boom to drag delivery sys-tem sideways.

27-1.18.2.3 The spare part list shall contain allrelevant safety related spare parts with anunambiguous identification and informationof the location of the part to be replaced.

27-1.18.2.4 The Safety Manual shall address thecommon hazards found in the concretepumping industry and shall be included withthe machine.

Section 27-1.19 -Fuel and Exhaust Systems

(a) The machine’s fuel system components shallbe compatible with the fuel used.

(b) The fuel system filling area shall be locatedaway from hot machinery components.

17 CPMAv4.0.6


(c) The machine’s fuel and exhaust systems shallconform to applicable state and federal regula-tions.

(d) The machines shall be constructed so controldevices are not situated near the engine ex-haust.

con&charCPMA401 18


Chapter 27-2

Inspection, Testing, and Maintenance

Section 27-2.1 -Inspection

27-2.1.1 Inspection Classifications

(a) Initial Inspection. Prior to initial use, all con-crete pumps which are new, altered, or re-turned from major repair shall be inspected bya designated person to verify that the equip-ment is in compliance with the provisions ofthis standard.

(b) Regular Inspection. The inspection procedurefor concrete pumps in regular service is di-vided into two general classifications basedupon the intervals at which the inspections areto be performed. The inspection intervals aredependent upon the nature of the componentsand the degree of safety, exposure to wear,malfunction, or deterioration. The two generalclassifications of regular inspection are desig-nated as “frequent” and “periodic” with re-spective intervals as follows:

(1) Frequent Inspection. Daily, weekly, andmonthly intervals. Frequent Inspectionsshall be done by a designated person.

(2) Periodic Inspection. Intervals in excess ofone month, based on time, hours of opera-tion, or cubic yards pumped, or as specifi-cally recommended by the manufacturer.Periodic Inspections shall be done by aqualified person.

27-2.1.2 Frequent Inspection

(a) Frequent inspection shall include observationsduring operation.

(b) Any deficiencies discovered shall be carefullyexamined and a determination made as towhether they constitute a hazard.

(c) The following items on the pump or boomshall be inspected:

(1) Safety devices for proper operation;(2) Pump and boom controls for proper opera-

tion and engagement;(3) Boom and outrigger hooks and latches for

proper operation and engagement;(4) Hydraulic hoses for wear, rubbing, and

cracking;(5) Hydraulic oil level;(6) Remote control boxes and cables for proper

operation, exposed wires, broken controls,or broken plugs;

(7) Boom and outrigger structures for deforma-tions, cracks, and damage;

(8) Tires for sufficient tread, proper inflation,cuts, and loose lug nuts;

(9) Proper loading of accessories to preventloss while traveling;

(10) Proper lubrication of moving parts.

(d) The following items of the delivery systemcomponents shall be inspected:

(1) Inspect boom delivery system for:(a) Sufficient wall thickness to withstand the

maximum material pressure of the pump;(b) Dents or cracks;(c) Missing locking pins;(d) Leaking gaskets.

(2) Inspect delivery system hoses for:(a) Excessive internal wear;(b) Separation of the ferrule from the hose;(c) Bulges, kinks, soft spots, cuts, or abraded

areas which may indicate broken or mis-placed reinforcement;

(d) Presence of old concrete.(3) Inspect couplings:

19 CPMAv4.0.6


(a) For cracked, broken, distorted, or missingcomponents;

(b) For proper operation of the adjusting nut,if so equipped;

(c) For concrete in the gasket cavity thatwould prevent proper operation;

(d) That the clamp and gasket were designedto be used with the designated system.

(4) Inspect separately laid pipeline componentsfor:

(a) Sufficient wall thickness to withstand themaximum material pressure of the pump;

(b) Dents, holes, or deformed ends;(c) The presence of old concrete inside the

pipeline.

27-2.1.3 Periodic Inspections

(a) Complete inspections of the concrete pump,boom, and outrigger assembly shall be per-formed at the following intervals:

(1) First 5 years – at least once per year;(2) Five to ten years – every 6 months;(3) Ten years and older – every 500 working

hours, or at least once per year, whicheveroccurs first.

(b) Any deficiencies discovered shall be carefullyexamined and a determination made as towhether they constitute a hazard.

(c) The inspection shall include the items listed inparagraph 27-2.1.2 (c), and the followingitems, as applicable:

(1) Deformed structural members on the boomor outrigger assembly;

(2) Cracks on the boom, outrigger assembly, orany structural member;

(3) Corrosion which could cause a weakeningof any structural member;

(4) Loose or missing fasteners including pins orpin retainers;

(5) Boom pin wear;(6) Proper operation of emergency stops;(7) Proper lubrication;(8) Mounting bolts to the carrier chassis;(9) Truck chassis (as recommended by the

manufacturer);

(10) Concrete pump components (as recom-mended by the manufacturer);

(11) Hydraulic hoses for rubbing, cracking, andleaks;

(12) Relief valve settings;(13) Hydraulic leaks at rod seals on hydraulic

cylinders and shaft seals on hydraulic mo-tors;

(14) Warning and operational labels are present,attached in the appropriate place, and read-able.

27-2.1.4 Inspection Records

Dated inspection records should be maintainedunder the supervision of an appointed person.

Section 27-2.2 -Specifications

27-2.2.1 Theoretical Output

Each model of concrete pump shall have it’s outputrated by the following calculation:

Actual strokes per minute times calculated materialcylinder displacement.

27-2.2.2 Material Pressure

Each model of concrete pump shall have the maxi-mum material pressure rated by applying the ratioof effective hydraulic cylinder area versus materialcylinder area to the maiximum hydraulic systempressure.

Section 27-2.3 -Testing

27-2.3.1 Factory Testing

All new concrete pumps shall be tested by themanufacturer after final assembly to verify:

(a) Proper operation of all safety devices;

(b) Proper operation of all controls;

(c) Proper positioning of all boom sections in allintended operational positions;

(d) Proper positioning of outriggers in all in-tended operational positions;

(e) Proper setting of hydraulic pressures and re-lief settings;

(f) That there are no unusual vibrations or noise;

intesmntCPMA401 20


(g) That the boom will support the intended loadwithout seeping down in excess of the manu-facturer’s specification;

(h) Proper operation and engaging of latching andlocking devices.

27-2.3.2 Stability Test

The stability test shall comply with these guide-lines as a minimum:

(a) The margin of stability shall be determined bycalculation of the static load imposed by theboom and its systems and mountings, plus themaximum allowable load imposed on theboom by the material in the delivery system,including end hose, and the boom rotated tothe least stable position. The calculation of thematerial load shall be based on material with abulk density of 150 pounds per cubic foot;

(b) A representative unit of each model and chas-sis in each intended operation configurationshall be tested to verify compliance. If havingthe outriggers, stabilizers, extendable axles, orother stability enhancing means in use is partof the normal configuration to meet the stabil-ity requirements, they shall be extended andset per manufacturer’s instructions. A writtentest report shall be kept of file;

(c) The test load equivalent to 125% of the ratedload (1.25 times) shall be applied to the boomto verify its stability. The manufacturer shalldetermine the most critical configuration(s) ofthe unit for this test. Ballast may be applied tothe unit which is equivalent to the weight ofmaterial in the hopper (filled to the top of de-livery cylinder opening), one delivery cylinder(filled 75%), and the deck delivery line;

(d) None of the stability testing shall produce in-stability of the unit or cause permanent defor-mation to any component. During the stabilitytest, the lifting of an outrigger or wheel on theopposite side of the load does not necessarilyindicate a condition of instability.

27-2.3.3 Post Maintenance Test

The concrete pump or placing boom shall be testedfor proper operation before being returned to ser-vice after maintenance is performed.

Section 27-2.4 -Maintenance

27-2.4.1 Preventive Maintenance

(a) The manufacturer shall provide a recom-mended preventative maintenance schedule tominimize the possibility of mechanical fail-ures and excessive and unnecessary wear.

(b) A preventive maintenance program based onthe machine manufacturer’s and truck manu-facturer’s recommendations should be estab-lished for working concrete pumps.

(c) Preventive maintenance schedules shall bebased on hours operated, cubic yards pumped,or time lapsed.

(d) Written records of maintenance performedshould be maintained.

(e) Under severe conditions or if excessive wearis noted, scheduled intervals should be ad-justed to prevent breakdowns and excessivewear.

(f) Maintenance shall be performed by a desig-nated person familiar with the safe operationof the concrete pump or placing boom.

(g) Maintenance should be performed only afterthe power source has been removed from thesystem using an approved lockout/tagout pro-cedure.

(h) All guards shall be reinstalled, all safety de-vices reactivated and maintenance equipmentremoved after maintenance is performed.

(i) Welding on the boom, outrigger, or structuralmember shall be performed in accordancewith the recommendations of the manufac-turer by a certified welder.

(j) Replacement parts should meet or exceed themanufacturer’s specifications.

(k) Missing or unreadable warning and opera-tional labels should be replaced.

21 CPMAv4.0.6


27-2.4.2 Lubrication

(a) All moving parts of the concrete pump andplacing boom for which lubrication is speci-fied should be regularly lubricated. Lubricat-ing means should be checked for delivery oflubricant. Care should be taken to follow rec-ommendations stated in the manufacturer’smanual as to points and frequency of lubrica-tion, maintenance of lubricant levels, andtypes of lubricant to be used.

(b) Machinery shall be stationary while lubricantsare being applied, unless equipped for auto-matic or remote lubrication, or unless the lu-brication point specifically requires movementfor the lubricating procedure.

intesmntCPMA401 22


Chapter 27-3

Operation

Section 27-3.1 -Qualifications For and Con-duct of Operators and Oper-ating Practices

27-3.1.1 Operators

27-3.1.1.1 The operation of concrete pumpsshall be limited to personnel with the follow-ing qualifications:

(a) Persons designated as qualified concrete pumpoperators;

(b) Mechanics and trainees under the direct super-vision of a qualified concrete pump operator.

27-3.1.1.2 During concrete pumping opera-tions, no one other than the personnel speci-fied in 27-3.1.1.1 above shall enter into theimmediate area of the pump, or climb up onthe pump, with the exception of supervisors,those specified persons authorized by super-visors whose duties require them to do so inthe performance of their duties, or concretetruck drivers, and then only with the knowl-edge and permission of the concrete pumpoperator.

27-3.1.2 Qualifications for Operators

(a) Operators shall be considered qualified whenthey have completed a program of training andsupervised operation of concrete pumps andhave passed a practical operating examinationof their ability to operate a specific model andtype of equipment and their understanding ofthe controls and operating procedures.

(b) Operators shall possess knowledge of emer-gency procedures and implementation of thesame.

(c) Operators shall possess knowledge regardingthe systems deactivated by the emergencystop, and other procedures required to com-pletely disable the pump and boom.

(d) Operators shall possess knowledge regardingthe restart procedure after emergency stop hasbeen activated.

(e) Operators shall possess the proper class ofdriver’s license to drive the concrete pumptruck as required by local authorities.

(f) Operators shall be drug and alcohol free.

(g) Operators shall be of legal age to perform theduties required according to local authorities.

(h) Operators shall demonstrate the ability tocomprehend and interpret machine markings,warning labels, and operators manuals.

(i) Operators shall be familiar with the applicablerequirements of this standard.

27-3.1.3 Physical Qualifications

(a) Have vision of at least 20/30 Snellen, with orwithout corrective lenses.

(b) Have the ability to distinguish colors, regard-less of position, if color differentiation is re-quired for operation.

(c) Have adequate hearing with or without a hear-ing aid, for the specific operation.

(d) Be free of physical defects, emotional insta-bility or seizures which could render a hazardto the operator or to others, or which, in theopinion of the examiner, interfere with the op-erator’s performance. Specialized medicaltests may be required to determine these con-ditions.

23 CPMAv4.0.6


(e) Have normal depth perception, field of vision,reaction time, manual dexterity and coordina-tion.

(f) Have no tendencies to dizziness or similar un-desirable characteristics.

27-3.1.4 Conduct of Operators

27-3.1.4.1 The operator shall not divert hisattention from the operation of the concretepump while operating the concrete pump.

27-3.1.4.2 The operator is responsible for theoperation of the concrete pump. The opera-tor’s supervisor shall be consulted beforeproceeding, if there is any doubt as to thesafety of the situation.

27-3.1.4.3 The operator shall not knowingly setup the pump or unfold the boom when itresults in a hazardous condition.

27-3.1.4.4 The operator shall not knowinglyviolate any of the warning labels on the con-crete pump.

27-3.1.4.5 The operator shall not operate apiece of equipment he knows to be malfunc-tioning, when the malfunction results in ahazardous condition.

27-3.1.4.6 The operator shall report the needfor adjustments or repairs or hazardous con-ditions to a designated person.

27-3.1.5 Operating Practices

27-3.1.5.1 Concrete pump placing booms shall:

(a) Not be used as cranes or hoists to lift materialor other loads;

(b) Not be loaded beyond the rated load as speci-fied by the manufacturer;

(c) Not be operated when outside of the manufac-turers specification for level;

(d) Not be operated beyond the area of extendedoutriggers, when all outriggers are not fullyextended and jacked. See figure 10;

(e) Not be operated unless the outriggers areproperly shored and supported on level pads;

(f) Not be used to drag hose or separately laid de-livery system;

(g) Not be operated without a sling or safety cableattaching each piece of hanging delivery sys-tem to the boom;

(h) Not be moved to different locations with theboom or outriggers not secured;

(i) Not be operated in any manner inconsistentwith the manufacturer’s operating manual;

(j) Not be operated when lightning is present inthe immediate area;

(k) Not be operated when wind force exceeds themanufacturers recommendation for safe oper-ation.

27-3.1.5.2 Material delivery systems shall notbe cleaned out with compressed air unless allof the following conditions have been met:

(a) The procedure is under the supervision of aqualified person;

(b) The system to be cleaned has been securedagainst movement;

(c) All hoses at the discharge end have been re-moved;

(d) On mobile boom trucks, only when no otherclean out method is practical, or as recom-mended by the manufacturer;

(e) Only in specialized applications, such as highrise buildings and tunnel jobs, and then onlyas pre-planned and supervised by a qualifiedperson;

(f) Only when the discharge is controlled. A ballcatcher is recommended.

27-3.1.5.3 Persons shall not attempt to removea blockage in a material delivery system withcompressed air.

27-3.1.6 Operating Near Electric Power Lines

27-3.1.6.1 Concrete placing booms shall not beoperated within 17 feet of electrical wiresunless:

oprtionCPMA401 24


NO!

OK

shrtrigFRNT/RR.eps

NO!

OKMaterialto be Placed

NO! NO!OK OKMaterial

to be Placed

NO!OK

NO!

OK

NO!OK

NO!

OK

TIPPING HAZARD! The boom can be moved safely ONLY between the centerlines of the extended outriggers as represented by the shading. Use of the boom outside the centerlines (the unshaded areas) could cause tipping.

Materialto be Placed

Materialto be Placed

FIG. 10 Area of extended outriggers

25 CPMAv4.0.6


(a) Confirmation by a representative of the powerline company that the electrical lines havebeen de-energized and visibly grounded or

(b) The wires have been insulated (booted) and arepresentative of the power line company con-firms the sufficiency of the insulation.

27-3.1.6.2 If a concrete pump is positionedsuch that the placing boom is capable ofcoming within 17 feet of electrical powerlines, the operator should appoint a spotter toobserve the clearance and give a warning ifthe boom approaches the 17 foot minimumclearance distance.

27-3.1.6.3 If electric power lines are in the areaof the pour and the operator cannot be posi-tioned to observe the clearance between theboom and the wires, the operator shallappoint a spotter to observe the clearanceand give a warning if the boom approachesthe 17 foot minimum clearance distance.

27-3.1.6.4 Warning labels shall be installed atthe operator’s panel and on the boom warn-ing that electrocution may occur unless aminimum of 17 feet is maintained from elec-trical lines.

27-3.1.7 Knowledge of Manual Content

Personnel responsible for the supervision, installa-tion, operation, inspection or maintenance of theconcrete pump shall be familiar with the applicablecontents of the manual(s).

Section 27-3.2 -Concrete Pump Lockout/Tagout

(a) A lockout/tagout policy and procedure shallbe developed, documented, and implementedby the owner or user of the concrete pump.

(b) The lockout/tagout policy and procedure shallcomply with the requirements of ANSI Z-244.1.

(c) The policy shall give consideration to the fol-lowing areas:

(1) Concrete pump power disconnection means;(2) Work to be done on the concrete pump.

Section 27-3.3 -Signals

27-3.3.1 Standard Signals

Standard signals to the operator shall be in accor-dance with 27-3.3.2 unless voice communicationequipment (telephone, radio, or equivalent) is uti-lized. Signals shall be discernible or audible at alltimes. No response shall be made unless signalsare clearly understood.

27-3.3.2 Hand Signals

Hand signals shall be in accordance with figure 11,and shall be posted conspicuously on the concretepump or placing boom.

27-3.3.3 Special Signals

For operations not covered by para. 27-3.3.2, or forspecial conditions that occur from time to time,additions to or modifications of the standard sig-nals may be required. In all such cases, these spe-cial signals shall be agreed upon in advance byboth the operator and the signal person, and shouldnot be in conflict with standard signals.

27-3.3.4 Instructions

If it is desired to give instructions to the operator,other than those provided by established signalsystem, the boom or pump movements shall bestopped.

oprtionCPMA401 26


AC

PAhn

dsig

2.ep

s

(2 taps)

9.BOOM DOWN

10.BOOM LEFT

11.BOOM RIGHT

12.OPEN OR

EXTEND BOOM

13.CLOSE OR

RETRACT BOOM

8.BOOM UP

6.ADD WATER4-GALLONS

7.ALL DONECLEAN UP

5.RELIEVE

PRESSURE

4.LITTLE BIT

3.STOP PUMP

2.SLOW PUMP

DOWN

1.START PUMP

SPEED UP

14.STOP BOOM

AC

PAhn

dsig

4.ep

s

(2 taps)

6.ADD WATER4-GALLONS

7.ALL DONECLEAN UP

5.RELIEVE

PRESSURE

4.LITTLE BIT

3.STOP PUMP

2.SLOW PUMP

DOWN

1.START PUMP

SPEED UP

FIG. 11 Concrete Pumping Hand Signals

Units with booms

Units without booms

27 CPMAv4.0.6


oprtionCPMA401 28


Alphabetical Index

AAccess walkways . . . . . . . . . . . . . . . . . . . . . . 10ACPA hand signals . . . . . . . . . . . . . . . . . . . . 26Additives

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5ANSI Z-535 . . . . . . . . . . . . . . . . . . . . . . . . . . 10

BBoom, see placing boomBulk density of material . . . . . . . . . . . . . . . . . 21

CConcrete

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Concrete delivery hose

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Concrete pump construction . . . . . . . . . . . . . 10

controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 11delivery systems . . . . . . . . . . . . . . . . . . . . 14electrical installations . . . . . . . . . . . . . . . . 11emergency stops . . . . . . . . . . . . . . . . . . . . 11ergonomics . . . . . . . . . . . . . . . . . . . . . . . . 11fuel and exhaust systems . . . . . . . . . . . . . 17general control requirements . . . . . . . . . . 11guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . 12loss of power . . . . . . . . . . . . . . . . . . . . . . 15manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 15mobile and stationary placing booms . . . 14noise exposure . . . . . . . . . . . . . . . . . . . . . 11

non-reversible pumps . . . . . . . . . . . . . . . . 14outriggers . . . . . . . . . . . . . . . . . . . . . . . . . 11placing boom

tip attachments . . . . . . . . . . . . . . . . . . 14pressure release . . . . . . . . . . . . . . . . . . . . 14remote starting . . . . . . . . . . . . . . . . . . . . . 15safety labels . . . . . . . . . . . . . . . . . . . . . . . 10stability . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Structural . . . . . . . . . . . . . . . . . . . . . . . . . 10

Concrete pumpsdefined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Control panel . . . . . . . . . . . . . . . . . . . . . . . . . 11

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

boom and outrigger movements . . . . . . . . 11control panel requirements . . . . . . . . . . . . 11emergency stops . . . . . . . . . . . . . . . . . . . . 11general requirements . . . . . . . . . . . . . . . . 11lockout/tagout . . . . . . . . . . . . . . . . . . . . . 11marking . . . . . . . . . . . . . . . . . . . . . . . . . . 11outriggers . . . . . . . . . . . . . . . . . . . . . . . . . 11

DDecals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 15Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5concrete and grout . . . . . . . . . . . . . . . . . . . 5concrete delivery hose . . . . . . . . . . . . . . . . 5control panel . . . . . . . . . . . . . . . . . . . . . . . . 5

29 CPMAv4.0.6


delivery systems . . . . . . . . . . . . . . . . . . . . . 5designated . . . . . . . . . . . . . . . . . . . . . . . . . 5designated person . . . . . . . . . . . . . . . . . . . . 5end hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 5grooved connection . . . . . . . . . . . . . . . . . . 5hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5manual valve override . . . . . . . . . . . . . . . . 5metric connection . . . . . . . . . . . . . . . . . . . . 5mobile and stationary concrete pumps . . . . 5normal operating conditions . . . . . . . . . . . 5placing boom . . . . . . . . . . . . . . . . . . . . . . . 6qualified person . . . . . . . . . . . . . . . . . . . . . 6raised-end connection . . . . . . . . . . . . . . . . 6remote control . . . . . . . . . . . . . . . . . . . . . . 6

Delivery hosedefined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Delivery system . . . . . . . . . . . . . . . . . . . . . . . 14defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5delivery line . . . . . . . . . . . . . . . . . . . . . . . 14marking . . . . . . . . . . . . . . . . . . . . . . . . . . 10pressure ratios . . . . . . . . . . . . . . . . . . . . . 14

Designateddefined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Designated persondefined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

EEmergency stops . . . . . . . . . . . . . . . . . . . . . . 11EN 418 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11End hose

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . 11Exhaust and fuel system . . . . . . . . . . . . . . . . . 17Existing installations . . . . . . . . . . . . . . . . . . . . 3

FFactory testing

requirements . . . . . . . . . . . . . . . . . . . . . . . 20stability . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Frequent inspection . . . . . . . . . . . . . . . . . . . . 19defined . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fuel and exhaust systems . . . . . . . . . . . . . . . . 17

GGangways . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Grooved connection

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Grout

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

HHand signals . . . . . . . . . . . . . . . . . . . . . . . . . . 26Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

IInitial inspection

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

classifications . . . . . . . . . . . . . . . . . . . . . . 19frequent . . . . . . . . . . . . . . . . . . . . . . . . . . 19frequent, defined . . . . . . . . . . . . . . . . . . . 19initial, defined . . . . . . . . . . . . . . . . . . . . . 19periodic . . . . . . . . . . . . . . . . . . . . . . . . . . 20periodic, defined . . . . . . . . . . . . . . . . . . . 19records . . . . . . . . . . . . . . . . . . . . . . . . . . . 20regular, defined . . . . . . . . . . . . . . . . . . . . 19

Interpretationsrequest for . . . . . . . . . . . . . . . . . . . . . . . . . 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

JJacking, outriggers . . . . . . . . . . . . . . . . . . . . . 24Joystick movements, standardized . . . . . . . . . 12

KKnowledge of Manuals

who must have . . . . . . . . . . . . . . . . . . . . . 26

LLabels, safety . . . . . . . . . . . . . . . . . . . . . . 10, 15Lifting attachments . . . . . . . . . . . . . . . . . . . . 10Lockout/tagout . . . . . . . . . . . . . . . . . . . . . . . . 11

general requirements . . . . . . . . . . . . . . . . 26

CPMA401bookIOM.fm 30


Loss of power . . . . . . . . . . . . . . . . . . . . . . . . . 15Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

MMachine construction . . . . . . . . . . . . . . . . . . . . 9Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 21

manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 15preventive . . . . . . . . . . . . . . . . . . . . . . . . . 21

lubrication . . . . . . . . . . . . . . . . . . . . . 22testing after . . . . . . . . . . . . . . . . . . . . . . . . 21

Manual valve overridedefined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15knowledge of . . . . . . . . . . . . . . . . . . . . . . 26maintenance . . . . . . . . . . . . . . . . . . . . . . . 15minimum contents . . . . . . . . . . . . . . . . . . 15types of . . . . . . . . . . . . . . . . . . . . . . . . . . . 15user publications . . . . . . . . . . . . . . . . . . . 15

Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9air compressor . . . . . . . . . . . . . . . . . . . . . . 9concrete pump identification . . . . . . . . . . . 9concrete pump ratings . . . . . . . . . . . . . . . . 9controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 11decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10elbow identification . . . . . . . . . . . . . . . . . 10elbow rating . . . . . . . . . . . . . . . . . . . . . . . 10placing boom identification . . . . . . . . . . . . 9placing boom rating . . . . . . . . . . . . . . . . . . 9safety labels . . . . . . . . . . . . . . . . . . . . . . . 10straight delivery pipe identification . . . . . 10straight delivery pipe rating . . . . . . . . . . . 10

Materialbulk density of . . . . . . . . . . . . . . . . . . . . . 21

Metric connectiondefined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Metric conversions . . . . . . . . . . . . . . . . . . . . . . 3Mobile and stationary concrete pumps

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Mobile and stationary placing booms

outriggers and support structure . . . . . . . . 14

NNew installations . . . . . . . . . . . . . . . . . . . . . . . 2Normal operating conditions

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

OOperating practices . . . . . . . . . . . . . . . . . 23, 24Operation

maximum wind force . . . . . . . . . . . . . . . . 24near electric lines . . . . . . . . . . . . . . . . . . . 24near lightning . . . . . . . . . . . . . . . . . . . . . . 24

Operation Manual . . . . . . . . . . . . . . . . . . . . . 15requirements . . . . . . . . . . . . . . . . . . . . . . . 15

Operatorconduct . . . . . . . . . . . . . . . . . . . . . . . . 23, 24qualifications

general . . . . . . . . . . . . . . . . . . . . . . . . 23physical . . . . . . . . . . . . . . . . . . . . . . . 23specific . . . . . . . . . . . . . . . . . . . . . . . . 23

Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . 11, 14controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 11jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . 24shortrigging . . . . . . . . . . . . . . . . . . . . . . . 25

PPanels

control . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Periodic inspection

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . 19procedure . . . . . . . . . . . . . . . . . . . . . . . . . 20

Placing boom . . . . . . . . . . . . . . . . . . . . . . . . . 14defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6maximum lifting speed . . . . . . . . . . . . . . 14maximum slewing speed . . . . . . . . . . . . . 14support structure . . . . . . . . . . . . . . . . . . . . 14tip attachments . . . . . . . . . . . . . . . . . . . . . 14

Pressure releasenon-reversible pumps . . . . . . . . . . . . . . . . 14reversible pumps . . . . . . . . . . . . . . . . . . . 14

Preventive maintenance . . . . . . . . . . . . . . . . . 21lubrication . . . . . . . . . . . . . . . . . . . . . . . . 22

QQualified person

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

RRaised-end connection

defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

31 CPMAv4.0.6


Regular inspectiondefined . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Remote controldefined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Remote starting . . . . . . . . . . . . . . . . . . . . . . . 15

SSafety labels . . . . . . . . . . . . . . . . . . . . . . . 10, 15Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . 15Self-resetting controls . . . . . . . . . . . . . . . . . . 11Setup

outriggers . . . . . . . . . . . . . . . . . . . . . . . . . 25shortrigging . . . . . . . . . . . . . . . . . . . . . . . 25

Shall, defined . . . . . . . . . . . . . . . . . . . . . . . . . . 3Shortrigging . . . . . . . . . . . . . . . . . . . . . . . . . . 25Should, defined . . . . . . . . . . . . . . . . . . . . . . . . 3Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

ACPA hand signals . . . . . . . . . . . . . . . . . 26special . . . . . . . . . . . . . . . . . . . . . . . . . . . 26special instructions . . . . . . . . . . . . . . . . . . 26standard . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . 15Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Standard

as applied to existing installations . . . . . . . 3as applied to new installations . . . . . . . . . . 2definitions . . . . . . . . . . . . . . . . . . . . . . . . . 5effective date . . . . . . . . . . . . . . . . . . . . . . . 2

purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2references to other standards . . . . . . . . . . . 6scope . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 5

Standardizedhand signals . . . . . . . . . . . . . . . . . . . . . . . 26joystick movements . . . . . . . . . . . . . . . . . 12safety labels . . . . . . . . . . . . . . . . . . . . . . . 15

TTesting

factory, requirements . . . . . . . . . . . . . . . . 20general info . . . . . . . . . . . . . . . . . . . . . . . 20post maintenance . . . . . . . . . . . . . . . . . . . 21stability . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

UUser publications . . . . . . . . . . . . . . . . . . . . . . 15

VVoltage, high

operation near . . . . . . . . . . . . . . . . . . . . . . 24

WWalkways . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Warning labels, see Safety labelsWind force, maximum . . . . . . . . . . . . . . . . . . 24Work places . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ZZ-535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CPMA401bookIOM.fm 32

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Safety Standard Concrete Pumps