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Concrete Pump Manufacturers Association

for

Concrete Pumps, Placing Booms, and Delivery System

CPMA27-2000

Version:

4.0.6

Safety Standard

CPMA 27-2000

Version:

4.0.6

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 Association 2310 S. Green Bay Rd. Suite C PMB #174 Racine, WI 53406 copyright 2002, 2003 by the Concrete Pump Manufacturers Association All Rights Reserved Printed in U.S.A.

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Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Chapter 27-0 Scope, Definitions, and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Section 27-0.1 Section 27-0.2 Section 27-0.3 -

Scope of CPMA27 - 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 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 27-1.1.1 27-1.1.2 27-1.1.3 27-1.1.4 27-1.1.5 27-1.1.6 27-1.1.7 Section 27-1.2 27-1.2.1 27-1.2.2 27-1.2.3 Section 27-1.3 Section 27-1.4 Section 27-1.5 Section 27-1.6 Section 27-1.7 Section 27-1.8 27-1.8.1 27-1.8.2 27-1.8.3 27-1.8.4 Section 27-1.9 Section 27-1.10 Section 27-1.11 27-1.11.1 27-1.11.2 Section 27-1.12 27-1.12.1 27-1.12.2

Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Concrete Pump Rating and Identification Markings . . . . . . . . . . . . . . . . . . . . . . 9 Air Compressor Rating Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Placing Boom Rating and Identification Markings . . . . . . . . . . . . . . . . . . . . . . . 9 Straight Delivery Pipes and Concrete Delivery Hose Rating and Identification Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Delivery System Elbow Rating and Identification Marking . . . . . . . . . . . . . . . 10 Delivery System Accessory Identification Marking . . . . . . . . . . . . . . . . . . . . . 10 Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Concrete Pump Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Lifting Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Work Places, Access Walkways and Gangways . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Noise Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Emergency Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 General Control Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Standardized Joystick Movements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pump Pressure Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Reversible Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Non-reversible Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Mobile and Stationary Placing Booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Outriggers and Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Placing Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Safety Standard

Section 27-1.13 Section 27-1.14 27-1.14.1 27-1.14.2 Section 27-1.15 Section 27-1.16 Section 27-1.17 Section 27-1.18 27-1.18.1 27-1.18.2 Section 27-1.19 Chapter 27-2

Boom Tip Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Delivery Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Delivery System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remote Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Standardized Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Minimum Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 User Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Fuel and Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection, Testing, and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Section 27-2.1 27-2.1.1 27-2.1.2 27-2.1.3 27-2.1.4 Section 27-2.2 27-2.2.1 27-2.2.2 Section 27-2.3 27-2.3.1 27-2.3.2 27-2.3.3 Section 27-2.4 27-2.4.1 27-2.4.2
Chapter 27-3

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Inspection Classifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inspection Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Theoretical Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Material Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Factory Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Stability Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Post Maintenance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Section 27-3.1 27-3.1.1 27-3.1.2 27-3.1.3 27-3.1.4 27-3.1.5 27-3.1.6 27-3.1.7 Section 27-3.2 Section 27-3.3 27-3.3.1 27-3.3.2 27-3.3.3 27-3.3.4

Qualifications For and Conduct of Operators and Operating Practices. . . . . . . 23 Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Qualifications for Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Physical Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Conduct of Operators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Operating Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Operating Near Electric Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Knowledge of Manual Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Concrete Pump Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Standard Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Special Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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List of Figures

FIG. 1 FIG. 2 FIG. 3 FIG. 4 FIG. 5 FIG. 6 FIG. 7 FIG. 8 FIG. 9 FIG. 10 FIG. 11

Mechanical pea gravel concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic pea gravel and/or concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Trailer mounted concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Truck mounted concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Truck mounted concrete pump with integral placing boom . . . . . . . . . . . . . . . . . . . . . . . . . 8 Separate placing boom with electric power pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Standardized joystick movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Specifications for minimum and maximum hopper grate spacing . . . . . . . . . . . . . . . . . . . 13 Standardized safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Area of extended outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Concrete Pumping Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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

Introduction General

This document is being drafted for the purpose of setting safety standards for the concrete pumping industry. One purpose of the Standard is to serve as a guide to governmental authorities having jurisdiction over subjects within the scope of the Standard. It is expected however, that the Standard will nd a major application in industry, serving as a guide to manufacturers, purchasers, and users of the equipment. If adopted for governmental use, the references to other national codes and standards in the specic volumes may be changed to refer to the corresponding regulations of the governmental authorities. The use of concrete pumps, placing booms, concrete delivery systems, and the related accessories is subject to certain hazards that cannot be met by mechanical means but only by the exercise of intelligence, care, and common sense. It is therefore essential to have personnel involved in the use and operation of equipment who are competent, careful, physically and mentally qualied, and trained in the safe operation of the equipment. Serious hazards include overloading of the boom, blockages in the delivery system, and using equipment for a purpose for which it was not intended or designed. The Standards Committee fully realizes the importance of proper design factors, minimum or maximum sizes, and other limiting dimensions covered by the Standard, all of which are closely connected with safety. Sizes, strengths, and similar criteria are dependent on many different factors, often varying with the installation and uses. These factors depend on the condition of the equipment or material; on the loads; on the acceleration or speed of the material being con-

veyed; on the type of attachments; on the number, size, and arrangement of boom sections or other parts; on environmental conditions causing corrosion or wear; on the material being transported, and on many variables that must be considered in each individual case. The rules given in the Standard must be interpreted accordingly, and judgment used in determining their application. The Standards Committee will be glad to receive criticisms of this Standards requirements and suggestions for its improvement, especially those based on actual experience in application of the rules. Suggestions for changes to the Standard should be submitted to the Secretary of The Concrete Pump Manufacturers Association, 2310 S. Green Bay Rd., Suite C, PMB #174, Racine, WI 53406 and should be in accordance with the following format: (a) cite the specic paragraph designation of the pertinent volume; (b) indicate the suggested change (addition, deletion, revision, etc.); (c) briey state the reason and/or evidence for the suggested change; (d) submit suggested changes to more than one paragraph in the order that the paragraphs appear in the volume. The Manufacturers Association will consider each suggested change in a timely manner in accordance with its procedures.

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Safety Standard

Section I - Scope

This Standard applies to the construction, installation, operation, inspection, and maintenance of reversible and non-reversible pumps for concrete distribution, wet mix shotcreting machines, concrete placing booms, and concrete pumping accessories including pipeline, hoses, clamps, gaskets, concrete diversion valves, concrete shut-off valves, pipeline blow-out heads and attachments. This Standard does not apply to mortar conveying or spraying machines, dry mix shotcreting machines, or any crane used for lifting, or equipment coming within the scope of the following Committees: A10, A17, A90, A120, B20, B30, B56, and B77.
Section II - Purpose

The request for interpretation should be clear and unambiguous. It is further recommended that the inquirer submit his request utilizing the following format.
Subject: Edition: Cite the applicable paragraph number(s) and provide a concise description. Cite the applicable edition (version) of the pertinent volume for which the interpretation is being requested. Phrase the question as a request for an interpretation of a specic requirement suitable for general understanding and use, not as a request for approval of a proprietary design or situation. The inquirer may also include any plans or drawings which are necessary to explain the question; however, they should not contain any proprietary names or information.

Question:

This standard is designed to: (a) guard against and minimize injury to workers, and otherwise provide for the protection of life, limb, and property by prescribing safety requirements; (b) provide direction to owners, employers, supervisors, and others concerned with, or responsible for, its application; and (c) guide governments and other regulatory bodies in the development, promulgation, and enforcement of appropriate safety directives.
Section III - Interpretations

Requests that are not in this format will be rewritten in this format by the Committee prior to being answered, which could change the intent of the original request. CPMA procedures provide for reconsideration of any interpretation when or if additional information which might affect an interpretation is available. Further, persons aggrieved by an interpretation may appeal to the cognizant CPMA Committee or Subcommittee. CPMA does not approve, certify, rate, or endorse any item, construction, proprietary device, or activity.
Section IV - New and Existing Installations

Upon request, the standards Committee will render an interpretation of any requirement of the Standard. Interpretations can only be rendered in response to a written request sent to:

(a) Effective Date. The effective date of this volume for the purpose of dening new and existing installations is 1 year after its date of issuance. (b) New Installations. Construction, installation, inspection, testing, maintenance, and operation of equipment manufactured and facilities constructed after the effective date of this volume shall conform with the mandatory requirements of this volume.

Secretary,
The Concrete Pump Manufacturers Association 2310 S. Green Bay Rd. Suite C PMB #174 Racine, WI 53406

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(c) Existing Installations. Inspection, testing, maintenance, and operation of equipment manufactured and facilities constructed prior to the effective date of this volume shall be done, as applicable, in accordance with the requirements of this volume. It is not the intent of this volume to require retrotting of existing equipment. However, when an item is being modied, the need to meet the construction and installation requirements of the current standard shall be evaluated by a qualied person selected by the owner (user). If there is a substantial difference between the performance of the item and the construction and installation requirement(s) stated in this standard, which can cause a hazardous condition, changes recommended by the qualied person shall be made by the owner (user) within one year.
Section V - Mandatory and Advisory Rules

Mandatory rules of this volume are characterized by use of the word shall. If a provision is of an advisory nature, it is indicated by use of the word should and is a recommendation to be considered, the advisability of which depends on the facts in each situation.
Section VI - Metric Conversions

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

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CPMA 27-2000

CONCRETE PUMPS AND PLACING BOOMS

Chapter 27-0
Scope, Denitions, and References

Section 27-0.1 -Scope of CPMA27 - 2000 Standard CPMA27 - 2000 includes provisions which apply to the construction, installation, operation, inspection, and maintenance of mechanical pea gravel, hydraulic pea gravel, trailer mounted, truck mounted (with or without integral placing boom) concrete pumps; and separate placing booms (see Figure 1 through Figure 6). The requirements for mortar conveying and spraying machines are not included in this standard. Section 27-0.2 -Denitions additives material which is added to concrete or mortar to change the properties of the mix. concrete and grout homogenous mix of cement, graded aggregate and water, to which nontoxic additives may be added. concrete delivery hose a exible concrete delivery hose which has two end couplings. control panel the control panel is considered to be the place where the control actuating devices for the operation of the machine are located. A distinction shall be made between the control panel on the machine and the remote control, and between the control panel and the manual valve overrides. delivery systems delivery lines, hoses, and their components, as well as transfer valves are lines through which the material to be transported is pumped. designated selected or assigned by the employer or the employers representative as being competent to perform specic duties.

designated person a person selected or assigned by the employer or the employers representative as being competent to perform specic duties. end hose a exible concrete delivery hose which has only one end coupling. grooved connection a type of pipe connection where a groove is machined or rolled directly into the outside of the pipe wall, creating a ange height of less than 0.15 inches. hopper a receptacle for the material to be transported, which can include an agitator, a mixer, or both. manual valve overrides are mechanical valve actuators that can be used to operate a valve in emergency or breakdown situations. Manual valve overrides are not to be considered control panels unless the manual valve override handle is the primary means of valve actuation. metric connection a type of pipe connection where the raised ange diameter, shape, and thickness are manufactured to metric specications. mobile and stationary concrete and wet mix shotcrete pumps These are construction machines that pump and spray concrete, with or without agitator, whereby the material to be transported is conveyed to the placing position through delivery systems. The conveyance is carried out mechanically. These mobile and stationary concrete and wet mix shotcrete pumps may be mounted on trucks, trailers, or special vehicles. normal operating conditions conditions during which a concrete pump is performing functions within the scope of the original design.

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placing booms placing units and placing booms are manual or power driven, slewable working devices, consisting of one or more extendable or foldable parts which support the concrete delivery system, and which direct the discharge into the desired location. Placing booms may be mounted on trucks, trailers, or special vehicles. qualied person a person who, by possession of a recognized degree or certicate of professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work. raised-end connection a type of pipe connection where the raised ange is tapered and self aligning. remote control a control device for the machine that is portable and may be connected to the machine by a wire cable or linked by radio or other wireless means. A distinction shall be made between the control panel and the remote control. Section 27-0.3 -Reference to Other Codes and Standards Within the text reference is made to the following publications, copies of which may be obtained from one of the European Standard clearinghouses, such as Global Engineering, or from the publishers, as indicated. For dated references, subsequent amendments to or revisions of any of these publications apply to this Standard only when incorporated in it by amendment or provisions. For undated references, the latest edition of the publication referred to applies.
ANSI Z-244.1-1982 Lockout/Tagout of Energy Sources Minimum Safety Requirements ANSI Z-535.1 -.4 Product Safety Signs and Labels EN 292-2: 1991 Safety of machinery; Basic concepts, general principles for design part 2: Technical principles and specications.

EN 418

Safety of machinery; Emergency stop equipment, functional aspects; Principles for design SAE J185 Platforms SAE J833 Ergonomics UNITED STATES FEDERAL CODE OF REGULATIONS PART 1910.95. Chapter XVII of Title 29 (39 F.R. 7006) Noise Exposure

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Examples of types of concrete pumps and placing booms

peagrvpmp.eps

FIG. 1 Mechanical pea gravel concrete pump

Control panel
hydpgrvl.eps

Remote control

FIG. 2 Hydraulic pea gravel and/or concrete pump

trlr

iso

.ep

FIG. 3 Trailer mounted concrete pump

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trkmntcp.eps

FIG. 4 Truck mounted concrete pump

tkmtcpPB.eps

FIG. 5 Truck mounted concrete pump with integral placing boom

SPB.eps

FIG. 6 Separate placing boom with electric power pack

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Chapter 27-1

Construction and Installation

Section 27-1.1 -Markings 27-1.1.1 Concrete Pump Rating and Identication Markings The following information shall be legibly marked on a durable identication plate on the concrete pump: (a) (b) (c) (d) (e) manufacturer, supplier, or importer; year of construction; fabrication (serial) number; type or model; maximum working pressure in the hydraulic system; (f) maximum material pressure; (g) power rating for high voltage electrical equipment (voltage, frequency, power, amperage draw).

(2) volume of the pressure vessel (e.g. in gallons); (3) the construction identication for pressure vessels. Note. This requirement does not apply to any part of the air system installed by the chassis manufacturer. 27-1.1.3 Placing Boom Rating and Identication Markings If the unit is equipped with a placing boom, the following information shall be legibly marked on a durable identication plate on the placing boom: (a) On the boom identication plate: (1) manufacturer, supplier or importer; (2) year of fabrication; (3) fabrication (serial) number; (4) type or model; (5) maximum working pressure in the hydraulic system; (6) maximum weight per foot of delivery system, 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 system components; (2) Three examples of allowable size and length combinations.

27-1.1.2 Air Compressor Rating Markings If the machine is equipped with an air compressor, the following information shall be legibly marked on a durable identication 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 pressure vessel;

CPMAv4.0.6

CPMA 27-2000

Safety Standard

27-1.1.4 Straight Delivery Pipes and Concrete Delivery Hose Rating and Identication Marking The following information shall be legibly and durably marked on straight delivery pipes longer than 12 inches and concrete delivery hoses: (a) (b) (c) (d) manufacturer or supplier (name or code); nominal diameter; maximum working pressure, when new; weight of pipe (without ends) per foot, lled with concrete at 150 lbs/ft3.

and the materials used in the construction conrm that the machine is constructed for its intended purpose. (b) The manufacturers of the chassis and the concrete pump should comply with the construction and use regulations applicable to the country of use, taking into consideration the stress caused by on and off road use and the ability of the chassis to handle the strains imposed. 27-1.2.2 Stability (a) The stability of the truck mounted concrete pump with integral placing boom shall be determined by calculation of the static load imposed by the boom and its systems and mountings, plus the maximum allowable load imposed on the boom by the material in the delivery system, including end hose, and the boom rotated to the least stable position. The calculation 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 chassis in each intended operating conguration shall be tested to verify the calculated stability. See paragraph 27-2.3.2 on page 21 for testing requirements. (c) Stability may be inuenced by such additional factors as wind, ground conditions, boom lengths, and proper operating speeds. 27-1.2.3 Lifting Attachments (a) Machines or their parts which are intended to be moved at building sites by cranes or other lifting devices shall be equipped with suitable attachment points. (b) Any component weighing more than 500 pounds and having lifting attachments shall have the component weight legibly and durably marked on the component. Section 27-1.3 -Work Places, Access Walkways and Gangways (a) Work places, access walkways and gangways shall be designed to minimize slip, trip and fall hazards during operation.

27-1.1.5 Delivery System Elbow Rating and Identication Marking The following information shall be legibly and durably marked on delivery system elbows: (a) manufacturer or supplier (name or code); (b) maximum working pressure, when new; (c) weight of elbow, lled with concrete at 150 lbs/ft3. 27-1.1.6 Delivery System Accessory Identication Marking The following information will be legibly and durably marked on the following delivery system components: End hoses, shut-off valves, clamps, and reducers. (a) manufacturer or supplier (name or code); (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 ANSI Z-535. Section 27-1.2 -Concrete Pump Construction 27-1.2.1 Structural (a) A design review shall be performed by the manufacturer to verify that the stability and stress calculations, the construction drawings,

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(b) Access for maintenance, assembly, dismantling, and testing should be considered. (c) The machine designer should consider weather conditions in the design phase. (d) Access on and off of the concrete pump decks shall be designed per SAE J185. Section 27-1.4 -Electrical Installations Electrical installations above 100 volts shall be in compliance with the appropriate National Electric Code. The equipment shall be connected via a ground fault circuit interrupter or system that provides an equivalent level of protection. Section 27-1.5 -Noise Exposure The machine designer shall consider Part 1910.95 of the United States Federal Code of Regulations, Chapter XVII of Title 29 (39 F.R. 7006) in machine design, construction, operation, and maintenance. Section 27-1.6 -Ergonomics Control panels, manual override levers, access doors and covers shall be located to provide access to accommodate human physical dimensions as outlined in SAE J833. Section 27-1.7 -Outriggers (a) The machine shall be constructed so the operator can see the area of movement. (b) The machine shall be constructed so the outriggers are securable when in the transport position. Section 27-1.8 -Controls 27-1.8.1 Emergency Stops (a) Each machine shall be equipped with an emergency stop system. (b) The emergency stop system shall be visible, accessible and easy to operate. (c) The machine may be tted with several emergency stop controls.

(d) Emergency stops shall: (1) cause the machinery to stop instantaneously, taking into account stored energy; (2) prevent the automatic restart of the machine. The machine will have to be started intentionally; (3) be constructed according to EN 418. (e) The machine shall be equipped with emergency stop devices at the control panels and at the remote control device. 27-1.8.2 Outriggers (a) Control devices for slewable, telescopic, and adjustable outriggers shall be self resetting. (b) Control devices for outriggers shall be situated outside of the area of movement, or access to the area of movement shall be otherwise restricted. (c) Control circuits for the outriggers shall be independent of each other. (d) When implemented, the lockout/tagout procedure must make the outrigger controls nonfunctional. 27-1.8.3 General Control Requirements (a) If there are several control panels, the same operation (e.g. start, close, open) shall only be possible from one panel at any one time. Priority switching (either manual or automatic) shall be made between panels to transfer the controls. (b) The control devices must be safeguarded against unintentional operation. (c) When implemented, the lockout/tagout procedure must make the control devices nonfunctional. (d) The control devices shall be constructed, arranged and marked in such a way that the function is indicated. (e) The control devices which activate boom and outrigger movements shall be self resetting.

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27-1.8.4 Standardized Joystick Movements Joystick movements shall be consistent with the standardized movements shown in gure 7.

LEFT JOYSTICK
TIP RETRACT PLUS NTT EXTEND NTT EXTEND TIP RETRACT TIP RETRACT PLUS NTT RETRACT NTT RETRACT

RIGHT JOYSTICK
#1 DOWN PLUS SLEWING CCW SLEWING COUNTERCLOCKWISE (CCW) #1 UP PLUS SLEWING CCW #1 UP #1 DOWN #1 DOWN PLUS SLEWING CW

OFF

OFF

SLEWING CLOCKWISE (CW) #1 UP PLUS SLEWING CW

NTT EXTEND PLUS TIP EXTEND

TIP EXTEND

NTT RETRACT PLUS TIP EXTEND

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

Section 27-1.9 -Guards Any hazard that is inaccessible because of its location is considered guarded by location. (a) A xed guard shall be installed to prevent unintentional access to the moving parts in the waterbox. (b) If not guarded by location, a xed guard shall be installed to prevent unintentional contact with the material valve switching mechanism. (c) A xed guard shall be installed over rotating shafts. The underside of mobile truck chassis mounted concrete pumps are considered guarded by location. (d) A xed guard shall be installed over V-belts and drive pulleys. (e) Hot machinery parts shall be guarded. Engine exhaust gases shall be piped to the outside of the cab and discharged in a direction away from the operator. All exhaust pipes shall be

guarded, located, or insulated to prevent contact with personnel when performing normal duties. Section 27-1.10 -Hoppers (a) Grates on hoppers of reversible pumps, which can be opened without a tool or which have to be opened more than once a day shall be congured in such a way that when they are opened operation of the concrete pump and agitator is stopped, and they shall be secured against restarting while the grate remains open. (b) A valve mechanism capable of crushing, tearing, or cutting shall be guarded by a cover grate on the opening of the charging hopper within the dimensions shown in Figure 8 on page 13, or the machine may be constructed in such a way that the crushing points are inaccessible.

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(c) Agitators or screw conveyors located inside of hoppers shall be guarded with a cover grate constructed within the dimensions shown in Figure 8 on page 13. (d) Power operated hopper cover grates or hopper covers shall have a control device with self acting reset. The location of the control levers

shall be far enough away from the crushing points to prevent contact with the moving parts. (e) A grate or cover which can be raised shall be securable in the open position or constructed in such a way that it will not close unintentionally.

bar type grate

mesh type grate

b a b d

h
bar type grate

a
2
3 4

h
4

mesh type grate

both types

c
1
3 8

d
1
3 16

3 1

1 8 9 16

4 3
1 2

all sizes in inches

hopperart5.eps

FIG. 8 Specications for minimum and maximum hopper grate spacing

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Section 27-1.11 -Pump Pressure Release 27-1.11.1 Reversible Pumps Reversible pumps shall be constructed so pressure caused by blockages in the delivery system can be removed by reversing pumping, but it must be understood that reverse pumping cannot release static pressure such as in a vertical standpipe. 27-1.11.2 Non-reversible Pumps Non-reversible pumps shall be constructed so personnel are not endangered by the forceful ejection of concrete when removing the pressure caused by blockages. This can be accomplished by: (a) a restraining device allowing the pump manifold to be opened safely; (b) a pressure release gate in the manifold; (c) any other pressure release mechanism that will not endanger personnel when used. Section 27-1.12 -Mobile and Stationary Placing Booms 27-1.12.1 Outriggers and Support Structure The outriggers and pedestal assembly of placing booms shall be constructed so the maximum existing support force can be transferred to the subsoil. The maximum support force shall be marked at the outriggers. 27-1.12.2 Placing Boom (a) A remote control device with sufcient range to reach the end of the boom shall be supplied. (b) The lifting and lowering speed at the end of a xed speed or single speed boom shall not exceed 3 feet per second when activating any one section. With proportional control boom systems, it shall be possible to operate at or below the specied speed. (c) The lifting and lowering speed at the end of a xed speed or single speed boom shall not exceed 10 feet per second when activating all boom functions simultaneously. With proportional control boom systems, it shall be possible to operate at or below the specied speed.

(d) The horizontal slewing speed of the end of a xed speed or single speed boom shall not exceed 5 feet per second. With proportional control boom systems, it shall be possible to operate at or below the specied speed. (e) Placing booms shall be clearly marked with the maximum allowable hanging weight per the instruction at paragraph 27-1.1.3 b on page 9, and a label afxed near the tip elbow warning about the use of improper diameter delivery system. (f) The placing boom shall not be used as a hoist. A warning label shall be placed on the machine to this effect. Section 27-1.13 -Boom Tip Attachments Provisions shall be made so attachments suspended from the boom tip can be restrained. Section 27-1.14 -Delivery Systems 27-1.14.1 Delivery Line Delivery system components supplied with a machine shall have a working pressure rating at least equal to the maximum pressure of the machine as delivered. 27-1.14.2 Delivery System Components (a) New delivery system components shall meet the following minimum ratios of burst pressure 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 units shall have a minimum of 85 bar (1233 PSI) working pressure, when new. Any boom unit capable of exceeding 85 bar material pressure shall have the delivery system's working pressure requirements clearly marked on the boom. (c) Pipeline couplings shall be constructed to minimize the possibility of inadvertent opening.

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(d) Delivery systems with grooved connections shall not be used on placing booms, or on slickline, or hoses. (e) Air blow out caps shall be equipped with a separate bleed off valve to allow the operator to relieve pressure in the system. Section 27-1.15 -Loss of Power Interruption of power to the machine shall not cause a hazardous situation. Section 27-1.16 -Remote Starting A machine which is powered by the vehicle engine shall be designed such that the engine cannot be started from a remote location unless the drive axles are disengaged. Section 27-1.17 -Standardized Safety Labels When applicable, concrete pump manufacturers shall furnish each machine with safety labels as shown in gure 9 as a minimum. Units not equipped with booms would not need boom specic safety labels, units not equipped with outriggers would not need outrigger specic safety labels, etcetera. Section 27-1.18 -Manuals 27-1.18.1 Minimum Contents The concrete pump manufacturer shall furnish with each machine at least one copy of a manual(s). The manual(s) shall include information applicable to the following: (a) (b) (c) (d) (e) (f) (g) (h) (i) installation operation inspection testing lubrication maintenance parts wiring diagram (may be supplied separately) hydraulic diagram (may be supplied separately)

27-1.18.2 User Publications In general, there are 4 different types of user publications: operation manuals; safety manuals; maintenance manuals; spare parts lists. 27-1.18.2.1 The operation manual should be written in a clear and understandable manner. The operation manual shall comply with 5.5 of EN 292-2. In addition to the requirements in EN 292, the following specic requirements shall be described in the operation manual: (a) It shall give information if personal protective equipment is necessary; (b) The independent use or maintenance of concrete pumping machines shall be carried out by designated persons; (c) It shall be stated how to lockout or tagout the control devices against unauthorized use; (d) Instructions for frequency and method of regular inspections according to paragraphs 272.1.1 and 27-2.1.2 and instructions to record the results on the machine specication sheet, with instructions regarding notifying the manufacturer. 27-1.18.2.2 The following operator information shall be contained in the operation manual as a minimum requirement: (a) For all units: (1) Operation of this machine requires training. You must read all warning labels on the unit; (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 structural malfunctions, failures or faults occur. Do not restart until repaired; (5) Machine should not be operated with the emergency stop equipment bypassed;

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010

WARNING

011

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

012

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

013

WARNING

Clear area before activating outriggers

015
SAFETY

WARNING
Do not operate this machine without training. Understand the warnings in safety manuals and on decals.

016

WARNING

017

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

MANUAL

014

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

019
WARNING
Use retaining pins in all delivery system clamps.

WARNING

020

WARNING

021

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

018

Stand clear of outriggers when activating.

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

022

IMPORTANT
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))

023

WARNING

024

WARNING
Safety guard is missing.

025

WARNING

026

WARNING

027

30355887

Do not stand on hopper grates.

028

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

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

029

WARNING
Do not use the boom as a crane or hoist.

030

WARNING
OK

031

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

032

EXTEND OUTRIGGER TO HERE BEFORE UNFOLDING BOOM

Cement dust is toxic. Use lung protection when exposed.

#035 refers to the striped decal #032.

035 034

WARNING
Unit will tip if outriggers are not fully extended.

033*

SAFETY INSTRUCTIONS
1. Operation of this machine requires training. You must read all warning labels on the unit items covered on specic warning labels are not covered here. There are other hazards and safety rules that are ONLY covered in the safety manual or operation manual. Only the operator may authorize access to the unit or surrounding area. Safety devices and guards must NOT be altered or removed. Stop the operation if any malfunctions, failures or structural faults occur. DO NOT restart until repaired. NEVER try to nish the operation with the emergency stop dump valves bypassed. 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. Ensure the stability of the unit. Use adequate outrigger cribbing for soil conditions. Level the unit to within 3. Check for obstructions before unfolding or slewing the boom or outriggers. DO NOT unfold the boom unless the outriggers are fully extended and properly jacked. Shortrigging is NEVER allowed on the side of the pour. 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). Never retract the outriggers until the boom is folded into the transport position. Be sure outriggers are retracted and pinned before driving the unit. NEVER drive the unit with extended outriggers or an unfolded placing boom! Not even a few feet. The supplied safety cable MUST be used to secure the discharge hose or reducer to the tip section. 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. In the event of a thunderstorm or high winds (over 48 MPH), the boom must be folded into the transport position. Any and all clamps, hoses and pipe connected to the unit MUST be able to withstand the maximum concrete pressure of the unit. 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. 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. Wear a hardhat, safety goggles, ear protection, gloves, steel toed shoes and tight tting clothes when working on or near a concrete pump. 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. Lift the main boom to vertical to release the transport hook when unfolding. The hook 2. 3. 4. 5. 6.

SAFETY INSTRUCTIONS

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

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

7. 8. 9. 10. 11. 12. 13. 14. 15.

037

16. 17. 18. 19.

20. 21. 22.

036

DANGER
Electrocution hazard. Stay back from high voltage wires at least 17 feet (5 meters).

038

* For reference only. Each manufacturer to make a similar decal applicable to their models and features.

rev:08/04/03 file:CPMAstddecals.eps

FIG. 9 Standardized safety labels

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(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; (8) Wear a hard hat, safety goggles, and snug tting clothes when working on or near a concrete pump. Wear hearing protection, gloves, and steel toed shoes when required; (9) Never leave the unit unattended when it is running or ready to operate, especially around children. Turn off the remote control box before setting it down; (10) Personnel should be cleared from the area of the end hose when starting or restarting the pump; (11) Never remove the fuel cap or refuel the unit near hot surfaces, sparks, or open ames. The fuel may explode. (b) For units with integrated placing booms: (1) Use adequate outrigger cribbing for soil conditions. Level the unit to the manufacturers specication; (2) A minimum of 17 feet (5 meters) must be maintained between the machine and electrical power lines at all times; (3) Check for obstructions before unfolding or slewing the boom or outriggers; (4) Do not unfold the boom unless the outriggers are fully extended and properly jacked. Shortrigging is never allowed on the side of the pour; (5) Maintain a safe distance from excavations or cliffs. Stay as far back from the bottom edge as the depth of the excavation or cliff. (This is the one to one rule); (6) Never retract the outriggers until the boom is folded into the transport position; (7) Be sure outriggers are retracted and locked before driving the unit; (8) Never drive the unit with extended outriggers or an unfolded placing boom; (9) All delivery system attached to the end of the boom shall be secured with a a strap or cable;

(10) Do not overload the boom. The maximum allowable weight from hose or reducer/hose combination on units shall be documented, and examples given to aid the operator; (11) In the event of a thunderstorm or high winds (over 48 MPH), the boom must be folded into the transport position; (12) 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; (13) Cleaning the boom or a separately laid pipeline with compressed air should only be done under the supervision of a qualied person. All hoses must be removed, unless specically designed by the manufacturer to remain in place during the blow out process (e.g. a boom delivery system with a permanently attached and restrained hose), and the discharge end must be controlled. Use of a ball catcher is recommended; (14) The operator and/or laborer assigned to the pump should not allow unauthorized personnel around the machine, nor in the boom placing area; (15) Do not extend the placing boom beyond the manufacturers design specication; (16) Do not use the boom to drag delivery system sideways. 27-1.18.2.3 The spare part list shall contain all relevant safety related spare parts with an unambiguous identication and information of the location of the part to be replaced. 27-1.18.2.4 The Safety Manual shall address the common hazards found in the concrete pumping industry and shall be included with the machine. Section 27-1.19 -Fuel and Exhaust Systems (a) The machines fuel system components shall be compatible with the fuel used. (b) The fuel system lling area shall be located away from hot machinery components.

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(c) The machines fuel and exhaust systems shall conform to applicable state and federal regulations.

(d) The machines shall be constructed so control devices are not situated near the engine exhaust.

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Chapter 27-2

Inspection, Testing, and Maintenance

Section 27-2.1 -Inspection 27-2.1.1 Inspection Classications (a) Initial Inspection. Prior to initial use, all concrete pumps which are new, altered, or returned from major repair shall be inspected by a designated person to verify that the equipment is in compliance with the provisions of this standard. (b) Regular Inspection. The inspection procedure for concrete pumps in regular service is divided into two general classications based upon the intervals at which the inspections are to be performed. The inspection intervals are dependent upon the nature of the components and the degree of safety, exposure to wear, malfunction, or deterioration. The two general classications of regular inspection are designated as frequent and periodic with respective intervals as follows: (1) Frequent Inspection. Daily, weekly, and monthly intervals. Frequent Inspections shall be done by a designated person. (2) Periodic Inspection. Intervals in excess of one month, based on time, hours of operation, or cubic yards pumped, or as specically recommended by the manufacturer. Periodic Inspections shall be done by a qualied person. 27-2.1.2 Frequent Inspection (a) Frequent inspection shall include observations during operation. (b) Any deciencies discovered shall be carefully examined and a determination made as to whether they constitute a hazard.

(c) The following items on the pump or boom shall be inspected: (1) Safety devices for proper operation; (2) Pump and boom controls for proper operation 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 deformations, cracks, and damage; (8) Tires for sufcient tread, proper ination, cuts, and loose lug nuts; (9) Proper loading of accessories to prevent loss while traveling; (10) Proper lubrication of moving parts. (d) The following items of the delivery system components shall be inspected: (1) Inspect boom delivery system for: (a) Sufcient 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 misplaced reinforcement; (d) Presence of old concrete. (3) Inspect couplings:

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(a) For cracked, broken, distorted, or missing components; (b) For proper operation of the adjusting nut, if so equipped; (c) For concrete in the gasket cavity that would prevent proper operation; (d) That the clamp and gasket were designed to be used with the designated system. (4) Inspect separately laid pipeline components for: (a) Sufcient wall thickness to withstand the maximum 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 performed 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, whichever occurs rst. (b) Any deciencies discovered shall be carefully examined and a determination made as to whether they constitute a hazard. (c) The inspection shall include the items listed in paragraph 27-2.1.2 (c), and the following items, as applicable: (1) Deformed structural members on the boom or outrigger assembly; (2) Cracks on the boom, outrigger assembly, or any structural member; (3) Corrosion which could cause a weakening of any structural member; (4) Loose or missing fasteners including pins or pin 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 recommended by the manufacturer); (11) Hydraulic hoses for rubbing, cracking, and leaks; (12) Relief valve settings; (13) Hydraulic leaks at rod seals on hydraulic cylinders and shaft seals on hydraulic motors; (14) Warning and operational labels are present, attached in the appropriate place, and readable. 27-2.1.4 Inspection Records Dated inspection records should be maintained under the supervision of an appointed person. Section 27-2.2 -Specications 27-2.2.1 Theoretical Output Each model of concrete pump shall have its output rated by the following calculation: Actual strokes per minute times calculated material cylinder displacement. 27-2.2.2 Material Pressure Each model of concrete pump shall have the maximum material pressure rated by applying the ratio of effective hydraulic cylinder area versus material cylinder area to the maiximum hydraulic system pressure. Section 27-2.3 -Testing 27-2.3.1 Factory Testing All new concrete pumps shall be tested by the manufacturer after nal assembly to verify: (a) Proper operation of all safety devices; (b) Proper operation of all controls; (c) Proper positioning of all boom sections in all intended operational positions; (d) Proper positioning of outriggers in all intended operational positions; (e) Proper setting of hydraulic pressures and relief settings; (f) That there are no unusual vibrations or noise;

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CPMA 27-2000

(g) That the boom will support the intended load without seeping down in excess of the manufacturers specication; (h) Proper operation and engaging of latching and locking devices. 27-2.3.2 Stability Test The stability test shall comply with these guidelines as a minimum: (a) The margin of stability shall be determined by calculation of the static load imposed by the boom and its systems and mountings, plus the maximum allowable load imposed on the boom by the material in the delivery system, including end hose, and the boom rotated to the least stable position. The calculation of the material load shall be based on material with a bulk density of 150 pounds per cubic foot; (b) A representative unit of each model and chassis in each intended operation conguration shall be tested to verify compliance. If having the outriggers, stabilizers, extendable axles, or other stability enhancing means in use is part of the normal conguration to meet the stability requirements, they shall be extended and set per manufacturers instructions. A written test report shall be kept of le; (c) The test load equivalent to 125% of the rated load (1.25 times) shall be applied to the boom to verify its stability. The manufacturer shall determine the most critical conguration(s) of the unit for this test. Ballast may be applied to the unit which is equivalent to the weight of material in the hopper (lled to the top of delivery cylinder opening), one delivery cylinder (lled 75%), and the deck delivery line; (d) None of the stability testing shall produce instability of the unit or cause permanent deformation to any component. During the stability test, the lifting of an outrigger or wheel on the opposite side of the load does not necessarily indicate a condition of instability.

27-2.3.3 Post Maintenance Test The concrete pump or placing boom shall be tested for proper operation before being returned to service after maintenance is performed. Section 27-2.4 -Maintenance 27-2.4.1 Preventive Maintenance (a) The manufacturer shall provide a recommended preventative maintenance schedule to minimize the possibility of mechanical failures and excessive and unnecessary wear. (b) A preventive maintenance program based on the machine manufacturers and truck manufacturers recommendations should be established for working concrete pumps. (c) Preventive maintenance schedules shall be based on hours operated, cubic yards pumped, or time lapsed. (d) Written records of maintenance performed should be maintained. (e) Under severe conditions or if excessive wear is noted, scheduled intervals should be adjusted to prevent breakdowns and excessive wear. (f) Maintenance shall be performed by a designated person familiar with the safe operation of the concrete pump or placing boom. (g) Maintenance should be performed only after the power source has been removed from the system using an approved lockout/tagout procedure. (h) All guards shall be reinstalled, all safety devices reactivated and maintenance equipment removed after maintenance is performed. (i) Welding on the boom, outrigger, or structural member shall be performed in accordance with the recommendations of the manufacturer by a certied welder. (j) Replacement parts should meet or exceed the manufacturers specications. (k) Missing or unreadable warning and operational labels should be replaced.

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27-2.4.2 Lubrication (a) All moving parts of the concrete pump and placing boom for which lubrication is specied should be regularly lubricated. Lubricating means should be checked for delivery of lubricant. Care should be taken to follow recommendations stated in the manufacturers manual as to points and frequency of lubrication, maintenance of lubricant levels, and types of lubricant to be used. (b) Machinery shall be stationary while lubricants are being applied, unless equipped for automatic or remote lubrication, or unless the lubrication point specically requires movement for the lubricating procedure.

intesmntCPMA401

22

Safety Standard

CPMA 27-2000

Chapter 27-3

Operation

Section 27-3.1 -Qualications For and Conduct of Operators and Operating Practices 27-3.1.1 Operators 27-3.1.1.1 The operation of concrete pumps shall be limited to personnel with the following qualications: (a) Persons designated as qualied concrete pump operators; (b) Mechanics and trainees under the direct supervision of a qualied concrete pump operator. 27-3.1.1.2 During concrete pumping operations, no one other than the personnel specied in 27-3.1.1.1 above shall enter into the immediate area of the pump, or climb up on the pump, with the exception of supervisors, those specied persons authorized by supervisors whose duties require them to do so in the performance of their duties, or concrete truck drivers, and then only with the knowledge and permission of the concrete pump operator. 27-3.1.2 Qualications for Operators (a) Operators shall be considered qualied when they have completed a program of training and supervised operation of concrete pumps and have passed a practical operating examination of their ability to operate a specic model and type of equipment and their understanding of the controls and operating procedures. (b) Operators shall possess knowledge of emergency procedures and implementation of the same.

(c) Operators shall possess knowledge regarding the systems deactivated by the emergency stop, and other procedures required to completely disable the pump and boom. (d) Operators shall possess knowledge regarding the restart procedure after emergency stop has been activated. (e) Operators shall possess the proper class of drivers license to drive the concrete pump truck as required by local authorities. (f) Operators shall be drug and alcohol free. (g) Operators shall be of legal age to perform the duties required according to local authorities. (h) Operators shall demonstrate the ability to comprehend and interpret machine markings, warning labels, and operators manuals. (i) Operators shall be familiar with the applicable requirements of this standard. 27-3.1.3 Physical Qualications (a) Have vision of at least 20/30 Snellen, with or without corrective lenses. (b) Have the ability to distinguish colors, regardless of position, if color differentiation is required for operation. (c) Have adequate hearing with or without a hearing aid, for the specic operation. (d) Be free of physical defects, emotional instability or seizures which could render a hazard to the operator or to others, or which, in the opinion of the examiner, interfere with the operators performance. Specialized medical tests may be required to determine these conditions.

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(e) Have normal depth perception, eld of vision, reaction time, manual dexterity and coordination. (f) Have no tendencies to dizziness or similar undesirable characteristics. 27-3.1.4 Conduct of Operators 27-3.1.4.1 The operator shall not divert his attention from the operation of the concrete pump while operating the concrete pump. 27-3.1.4.2 The operator is responsible for the operation of the concrete pump. The operators supervisor shall be consulted before proceeding, if there is any doubt as to the safety of the situation. 27-3.1.4.3 The operator shall not knowingly set up the pump or unfold the boom when it results in a hazardous condition. 27-3.1.4.4 The operator shall not knowingly violate any of the warning labels on the concrete pump. 27-3.1.4.5 The operator shall not operate a piece of equipment he knows to be malfunctioning, when the malfunction results in a hazardous condition. 27-3.1.4.6 The operator shall report the need for adjustments or repairs or hazardous conditions to a designated person. 27-3.1.5 Operating Practices 27-3.1.5.1 Concrete pump placing booms shall:

(e) Not be operated unless the outriggers are properly shored and supported on level pads; (f) Not be used to drag hose or separately laid delivery system; (g) Not be operated without a sling or safety cable attaching each piece of hanging delivery system to the boom; (h) Not be moved to different locations with the boom or outriggers not secured; (i) Not be operated in any manner inconsistent with the manufacturers operating manual; (j) Not be operated when lightning is present in the immediate area; (k) Not be operated when wind force exceeds the manufacturers recommendation for safe operation. 27-3.1.5.2 Material delivery systems shall not be cleaned out with compressed air unless all of the following conditions have been met: (a) The procedure is under the supervision of a qualied person; (b) The system to be cleaned has been secured against movement; (c) All hoses at the discharge end have been removed; (d) On mobile boom trucks, only when no other clean out method is practical, or as recommended by the manufacturer; (e) Only in specialized applications, such as high rise buildings and tunnel jobs, and then only as pre-planned and supervised by a qualied person; (f) Only when the discharge is controlled. A ball catcher is recommended. 27-3.1.5.3 Persons shall not attempt to remove a blockage in a material delivery system with compressed air. 27-3.1.6 Operating Near Electric Power Lines 27-3.1.6.1 Concrete placing booms shall not be operated within 17 feet of electrical wires unless:

(a) Not be used as cranes or hoists to lift material or other loads; (b) Not be loaded beyond the rated load as specied by the manufacturer; (c) Not be operated when outside of the manufacturers specication for level; (d) Not be operated beyond the area of extended outriggers, when all outriggers are not fully extended and jacked. See gure 10;

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CPMA 27-2000

NO! OK Material to be Placed

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. NO! OK NO!

Material to be Placed

OK NO!
FIG. 10 Area of extended outriggers

shrtrigFRNT/RR.eps

NO!

OK

Material to be Placed

OK

NO!

NO!

OK

Material to be Placed

OK NO!

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Safety Standard

(a) Conrmation by a representative of the power line company that the electrical lines have been de-energized and visibly grounded or (b) The wires have been insulated (booted) and a representative of the power line company conrms the sufciency of the insulation. 27-3.1.6.2 If a concrete pump is positioned such that the placing boom is capable of coming within 17 feet of electrical power lines, the operator should appoint a spotter to observe the clearance and give a warning if the boom approaches the 17 foot minimum clearance distance. 27-3.1.6.3 If electric power lines are in the area of the pour and the operator cannot be positioned to observe the clearance between the boom and the wires, the operator shall appoint a spotter to observe the clearance and give a warning if the boom approaches the 17 foot minimum clearance distance. 27-3.1.6.4 Warning labels shall be installed at the operators panel and on the boom warning that electrocution may occur unless a minimum of 17 feet is maintained from electrical lines. 27-3.1.7 Knowledge of Manual Content Personnel responsible for the supervision, installation, operation, inspection or maintenance of the concrete pump shall be familiar with the applicable contents of the manual(s). Section 27-3.2 -Concrete Pump Lockout/ Tagout (a) A lockout/tagout policy and procedure shall be developed, documented, and implemented by the owner or user of the concrete pump.

(b) The lockout/tagout policy and procedure shall comply with the requirements of ANSI Z244.1. (c) The policy shall give consideration to the following 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 accordance with 27-3.3.2 unless voice communication equipment (telephone, radio, or equivalent) is utilized. Signals shall be discernible or audible at all times. No response shall be made unless signals are clearly understood. 27-3.3.2 Hand Signals Hand signals shall be in accordance with gure 11, and shall be posted conspicuously on the concrete pump or placing boom. 27-3.3.3 Special Signals For operations not covered by para. 27-3.3.2, or for special conditions that occur from time to time, additions to or modications of the standard signals may be required. In all such cases, these special signals shall be agreed upon in advance by both the operator and the signal person, and should not be in conict with standard signals. 27-3.3.4 Instructions If it is desired to give instructions to the operator, other than those provided by established signal system, the boom or pump movements shall be stopped.

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CPMA 27-2000

Units with booms


ACPAhndsig2.eps

(2 taps)

1. START PUMP SPEED UP

2. SLOW PUMP DOWN

3. STOP PUMP

4. LITTLE BIT

5. RELIEVE PRESSURE

6. ADD WATER 4-GALLONS

7. ALL DONE CLEAN UP

8. BOOM UP

9. BOOM DOWN

10. BOOM LEFT

11. BOOM RIGHT

13. 12. 14. CLOSE OR OPEN OR STOP BOOM EXTEND BOOM RETRACT BOOM

Units without booms

(2 taps)

START PUMP SPEED UP

SLOW PUMP DOWN

RELIEVE PRESSURE

FIG. 11 Concrete Pumping Hand Signals

27

CPMAv4.0.6

ACPAhndsig4.eps

1.

2.

3. STOP PUMP

4. LITTLE BIT

5.

6. ADD WATER 4-GALLONS

7. ALL DONE CLEAN UP

CPMA 27-2000

Safety Standard

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CPMA 27-2000

Alphabetical Index

Access walkways . . . . . . . . . . . . . . . . . . . . . . 10 ACPA hand signals . . . . . . . . . . . . . . . . . . . . 26 Additives defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ANSI Z-535 . . . . . . . . . . . . . . . . . . . . . . . . . . 10


B

Boom, see placing boom Bulk density of material . . . . . . . . . . . . . . . . . 21


C

Concrete defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Concrete delivery hose defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Concrete pump construction . . . . . . . . . . . . . 10 controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 delivery systems . . . . . . . . . . . . . . . . . . . . 14 electrical installations . . . . . . . . . . . . . . . . 11 emergency stops . . . . . . . . . . . . . . . . . . . . 11 ergonomics . . . . . . . . . . . . . . . . . . . . . . . . 11 fuel and exhaust systems . . . . . . . . . . . . . 17 general control requirements . . . . . . . . . . 11 guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 loss of power . . . . . . . . . . . . . . . . . . . . . . 15 manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 15 mobile and stationary placing booms . . . 14 noise exposure . . . . . . . . . . . . . . . . . . . . . 11

non-reversible pumps . . . . . . . . . . . . . . . . 14 outriggers . . . . . . . . . . . . . . . . . . . . . . . . . 11 placing boom tip attachments . . . . . . . . . . . . . . . . . . 14 pressure release . . . . . . . . . . . . . . . . . . . . 14 remote starting . . . . . . . . . . . . . . . . . . . . . 15 safety labels . . . . . . . . . . . . . . . . . . . . . . . 10 stability . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Structural . . . . . . . . . . . . . . . . . . . . . . . . . 10 Concrete pumps defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . 11 defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 boom and outrigger movements . . . . . . . . 11 control panel requirements . . . . . . . . . . . . 11 emergency stops . . . . . . . . . . . . . . . . . . . . 11 general requirements . . . . . . . . . . . . . . . . 11 lockout/tagout . . . . . . . . . . . . . . . . . . . . . 11 marking . . . . . . . . . . . . . . . . . . . . . . . . . . 11 outriggers . . . . . . . . . . . . . . . . . . . . . . . . . 11
D

Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 15 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 concrete and grout . . . . . . . . . . . . . . . . . . . 5 concrete delivery hose . . . . . . . . . . . . . . . . 5 control panel . . . . . . . . . . . . . . . . . . . . . . . . 5
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delivery systems . . . . . . . . . . . . . . . . . . . . . 5 designated . . . . . . . . . . . . . . . . . . . . . . . . . 5 designated person . . . . . . . . . . . . . . . . . . . . 5 end hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 grooved connection . . . . . . . . . . . . . . . . . . 5 hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 manual valve override . . . . . . . . . . . . . . . . 5 metric connection . . . . . . . . . . . . . . . . . . . . 5 mobile and stationary concrete pumps . . . . 5 normal operating conditions . . . . . . . . . . . 5 placing boom . . . . . . . . . . . . . . . . . . . . . . . 6 qualified person . . . . . . . . . . . . . . . . . . . . . 6 raised-end connection . . . . . . . . . . . . . . . . 6 remote control . . . . . . . . . . . . . . . . . . . . . . 6 Delivery hose defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Delivery system . . . . . . . . . . . . . . . . . . . . . . . 14 defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 delivery line . . . . . . . . . . . . . . . . . . . . . . . 14 marking . . . . . . . . . . . . . . . . . . . . . . . . . . 10 pressure ratios . . . . . . . . . . . . . . . . . . . . . 14 Designated defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Designated person defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E

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


G

Gangways . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Grooved connection defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Grout defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


H

Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5


I

Emergency stops . . . . . . . . . . . . . . . . . . . . . . 11 EN 418 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 End hose defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Exhaust and fuel system . . . . . . . . . . . . . . . . . 17 Existing installations . . . . . . . . . . . . . . . . . . . . 3
F

Initial inspection defined . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 classifications . . . . . . . . . . . . . . . . . . . . . . 19 frequent . . . . . . . . . . . . . . . . . . . . . . . . . . 19 frequent, defined . . . . . . . . . . . . . . . . . . . 19 initial, defined . . . . . . . . . . . . . . . . . . . . . 19 periodic . . . . . . . . . . . . . . . . . . . . . . . . . . 20 periodic, defined . . . . . . . . . . . . . . . . . . . 19 records . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 regular, defined . . . . . . . . . . . . . . . . . . . . 19 Interpretations request for . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
J

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


K

Factory testing requirements . . . . . . . . . . . . . . . . . . . . . . . 20 stability . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Frequent inspection . . . . . . . . . . . . . . . . . . . . 19 defined . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Knowledge of Manuals who must have . . . . . . . . . . . . . . . . . . . . . 26


L

Labels, safety . . . . . . . . . . . . . . . . . . . . . . 10, 15 Lifting attachments . . . . . . . . . . . . . . . . . . . . 10 Lockout/tagout . . . . . . . . . . . . . . . . . . . . . . . . 11 general requirements . . . . . . . . . . . . . . . . 26

CPMA401bookIOM.fm

30

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CPMA 27-2000

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


M

Machine construction . . . . . . . . . . . . . . . . . . . . 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 21 manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 preventive . . . . . . . . . . . . . . . . . . . . . . . . . 21 lubrication . . . . . . . . . . . . . . . . . . . . . 22 testing after . . . . . . . . . . . . . . . . . . . . . . . . 21 Manual valve override defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 knowledge of . . . . . . . . . . . . . . . . . . . . . . 26 maintenance . . . . . . . . . . . . . . . . . . . . . . . 15 minimum contents . . . . . . . . . . . . . . . . . . 15 types of . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 user publications . . . . . . . . . . . . . . . . . . . 15 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 air compressor . . . . . . . . . . . . . . . . . . . . . . 9 concrete pump identification . . . . . . . . . . . 9 concrete pump ratings . . . . . . . . . . . . . . . . 9 controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 elbow identification . . . . . . . . . . . . . . . . . 10 elbow rating . . . . . . . . . . . . . . . . . . . . . . . 10 placing boom identification . . . . . . . . . . . . 9 placing boom rating . . . . . . . . . . . . . . . . . . 9 safety labels . . . . . . . . . . . . . . . . . . . . . . . 10 straight delivery pipe identification . . . . . 10 straight delivery pipe rating . . . . . . . . . . . 10 Material bulk density of . . . . . . . . . . . . . . . . . . . . . 21 Metric connection defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Metric conversions . . . . . . . . . . . . . . . . . . . . . . 3 Mobile and stationary concrete pumps defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Mobile and stationary placing booms outriggers and support structure . . . . . . . . 14
N

Operating practices . . . . . . . . . . . . . . . . . 23, 24 Operation maximum wind force . . . . . . . . . . . . . . . . 24 near electric lines . . . . . . . . . . . . . . . . . . . 24 near lightning . . . . . . . . . . . . . . . . . . . . . . 24 Operation Manual . . . . . . . . . . . . . . . . . . . . . 15 requirements . . . . . . . . . . . . . . . . . . . . . . . 15 Operator conduct . . . . . . . . . . . . . . . . . . . . . . . . 23, 24 qualifications general . . . . . . . . . . . . . . . . . . . . . . . . 23 physical . . . . . . . . . . . . . . . . . . . . . . . 23 specific . . . . . . . . . . . . . . . . . . . . . . . . 23 Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . 11, 14 controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 shortrigging . . . . . . . . . . . . . . . . . . . . . . . 25
P

Panels control . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Periodic inspection defined . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 procedure . . . . . . . . . . . . . . . . . . . . . . . . . 20 Placing boom . . . . . . . . . . . . . . . . . . . . . . . . . 14 defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 maximum lifting speed . . . . . . . . . . . . . . 14 maximum slewing speed . . . . . . . . . . . . . 14 support structure . . . . . . . . . . . . . . . . . . . . 14 tip attachments . . . . . . . . . . . . . . . . . . . . . 14 Pressure release non-reversible pumps . . . . . . . . . . . . . . . . 14 reversible pumps . . . . . . . . . . . . . . . . . . . 14 Preventive maintenance . . . . . . . . . . . . . . . . . 21 lubrication . . . . . . . . . . . . . . . . . . . . . . . . 22
Q

Qualified person defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6


R

New installations . . . . . . . . . . . . . . . . . . . . . . . 2 Normal operating conditions defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Raised-end connection defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Regular inspection defined . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Remote control defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remote starting . . . . . . . . . . . . . . . . . . . . . . . 15


S

Safety labels . . . . . . . . . . . . . . . . . . . . . . . 10, 15 Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . 15 Self-resetting controls . . . . . . . . . . . . . . . . . . 11 Setup outriggers . . . . . . . . . . . . . . . . . . . . . . . . . 25 shortrigging . . . . . . . . . . . . . . . . . . . . . . . 25 Shall, defined . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Shortrigging . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Should, defined . . . . . . . . . . . . . . . . . . . . . . . . 3 Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ACPA hand signals . . . . . . . . . . . . . . . . . 26 special . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 special instructions . . . . . . . . . . . . . . . . . . 26 standard . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . 15 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Standard as applied to existing installations . . . . . . . 3 as applied to new installations . . . . . . . . . . 2 definitions . . . . . . . . . . . . . . . . . . . . . . . . . 5 effective date . . . . . . . . . . . . . . . . . . . . . . . 2

purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 references to other standards . . . . . . . . . . . 6 scope . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 5 Standardized hand signals . . . . . . . . . . . . . . . . . . . . . . . 26 joystick movements . . . . . . . . . . . . . . . . . 12 safety labels . . . . . . . . . . . . . . . . . . . . . . . 15
T

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


U

User publications . . . . . . . . . . . . . . . . . . . . . . 15
V

Voltage, high operation near . . . . . . . . . . . . . . . . . . . . . . 24


W

Walkways . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Warning labels, see Safety labels Wind force, maximum . . . . . . . . . . . . . . . . . . 24 Work places . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Z

Z-535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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