4d (edited) • Planning & Pre-Lift Failures
Tower Crane & Concrete Pump Interface
A tower crane was carrying out lifting operations while a mobile concrete pump was operating within or close to the crane’s working area.
The concrete pump is not a fixed object. Its boom can slew, raise, lower and reposition, while the vehicle itself may also need to move.
If the pump operator is concentrating only on the concrete pour and the lifting team is concentrating only on the crane, the two operations can quickly conflict.
What Are the Hazards?
- Crane load passing above or close to the concrete pump.
- Tower crane jib, hook block or lifting accessories conflicting with the pump boom.
- Concrete pump boom moving unexpectedly into the crane’s operating area.
- Pump operator unaware of a suspended load approaching.
- Personnel working around the pump exposed to suspended loads.
- Poor radio communication between the two operations.
- Crane and pump movements occurring simultaneously.
- Concrete delivery vehicles creating additional plant movements and blind spots.
What Should Be Avoided?
The pump operator should never assume the airspace above is clear simply because the concrete pour is continuing.
Likewise, the lifting team should not assume:
The pump will stay where it is.
Where the operations could conflict, movements should be coordinated.
For example:
Crane requires access→ Pump movement stops→Crane load passes and clears→Positive confirmation→Pump operation resumes.
No guessing. No racing each other.
Coordination & Supervision
Before work starts, establish:
- Who controls the interface.
- Crane and pump operating zones.
- Restricted/no-go areas.
- Communication arrangements.
- What happens when the crane requires access above or near the pump.
- Who has authority to call STOP.
If either operator loses communication or cannot confirm the other’s position:
STOP ALL MOVEMENTS.
Safety Recommendations
- Include the concrete pump in the lifting-operation interface assessment.
- Brief the crane and concrete-pump teams together where their operations interact.
- Maintain suitable exclusion zones.
- Prevent suspended loads passing over personnel.
- Establish clear priorities for conflicting movements.
- Use agreed radio communication/signals.
- Reassess the arrangement whenever the pump is repositioned.
- Never rely solely on either operator seeing the other machine.
Incident Source
Safety-learning scenario based on tower crane operations taking place alongside a mobile concrete pump on an active construction site.
Regulatory Mapping
● LOLER Reg. 8 – Lifting operations must be properly planned, appropriately supervised and carried out safely.
● PUWER – Work equipment and its interaction with surrounding activities must be safely managed.
● CDM 2015 – Contractors must plan, manage and monitor their work and coordinate activities with others.
● BS 7121 principles – Effective communication, supervision and management of crane interfaces.
Key Point
The concrete pump is moving plant, not part of the scenery.
The crane operator watches the lift.
The pump operator watches the pour.
Someone must make sure they are also watching each other.
When the two operating areas conflict:
One moves. One holds. One clears. Then the other continues.
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Tower Crane & Concrete Pump Interface
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