Safe Work Method Statement for Concrete Washout Collection and Disposal

Concrete Washout Collection Safe Work Method Statement

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Concrete washout collection is a critical environmental and safety management activity on construction sites involving concrete placement operations. This work encompasses the establishment, maintenance, and servicing of designated concrete washout facilities where concrete trucks, pumps, chutes, and tools are cleaned to prevent environmental contamination from highly alkaline concrete waste. Concrete wash water contains Portland cement with pH levels exceeding 12, substantial chromium concentrations, and suspended cement particles that can severely damage soil, waterways, and stormwater systems if released into the environment. The collection process involves operating specialized vacuum trucks or pump-out equipment to remove liquid and solid concrete waste from containment bunds, transporting waste to approved treatment facilities, and maintaining washout bay functionality throughout project duration. This Safe Work Method Statement addresses the specific hazards associated with concrete washout collection including exposure to alkaline substances causing chemical burns, manual handling of heavy equipment, working with vacuum and pumping systems under pressure, environmental contamination risks, and coordination with ongoing concrete operations. Compliance with Australian environmental protection legislation, WHS regulations, and local council requirements for concrete waste management is essential to prevent prosecution and environmental harm.

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Overview

What this SWMS covers

Concrete washout collection represents an essential environmental protection service required on all construction sites conducting concrete placement operations. The work involves establishing and maintaining designated concrete washout areas where concrete delivery vehicles, pumping equipment, wheelbarrows, tools, and boots are cleaned after concrete operations. These washout facilities typically consist of either temporary above-ground bunds constructed from hay bales and plastic lining, prefabricated steel or plastic washout bins, or permanent in-ground concrete containment pits designed to capture all wash water and prevent any discharge to the environment. The collection process requires specialized equipment including vacuum trucks capable of extracting both liquid slurry and solidified concrete waste, high-pressure water cleaning systems to break down hardened concrete residues, and appropriate containment and transport vessels meeting environmental protection requirements. Collection frequency depends on washout facility capacity and site concrete usage, ranging from daily service on large commercial projects to weekly or as-needed collection on smaller residential sites. Concrete washout waste contains extremely high pH levels (typically 12-13) due to calcium hydroxide in cement, hexavalent chromium which is both toxic and carcinogenic, and high concentrations of suspended solids that can smother aquatic ecosystems if released to waterways. Washout collection operators must coordinate closely with site management and concrete placement crews to schedule collection that minimizes disruption to construction activities while ensuring containment capacity is never exceeded. The work often occurs in confined or awkward locations where washout facilities have been positioned away from main traffic routes and stormwater drains. Operators must navigate site conditions including uneven ground, muddy areas following rain, overhead services, and active construction work occurring simultaneously. The collected concrete waste must be transported to facilities licensed to receive and treat alkaline industrial waste, with appropriate manifests and records maintained to demonstrate environmental compliance. Regulatory requirements for concrete washout management stem from state Environmental Protection Acts, local council development approvals often containing specific concrete washout conditions, and WHS regulations addressing chemical exposure and manual handling. Recent prosecutions of building companies and concrete suppliers for discharge of concrete waste to stormwater have resulted in fines exceeding $100,000, highlighting the critical importance of proper washout management and collection procedures. Site Environmental Management Plans typically mandate concrete washout locations, containment specifications, maintenance requirements, and collection protocols that must be strictly followed.

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Why this SWMS matters

Concrete washout collection is mandated under Australian environmental protection legislation to prevent pollution of waterways, soils, and stormwater systems from highly alkaline concrete waste. Concrete wash water has pH levels of 12-13, well above the typical environmental discharge limit of pH 6.5-8.5, and contains hexavalent chromium at concentrations that can exceed environmental quality guidelines by factors of 100 or more. When concrete washout is discharged to stormwater drains or directly onto soil, it causes immediate environmental harm including fish kills in receiving waters, destruction of aquatic insect populations, damage to riparian vegetation from high pH exposure, and long-term soil contamination requiring expensive remediation. State Environmental Protection Agencies actively investigate concrete washout pollution incidents, with prosecutions of construction companies resulting in fines up to $250,000 plus cleanup costs and adverse publicity damaging company reputation. The chemical hazards present in concrete washout create serious risks to workers performing collection activities. Portland cement is classified as a hazardous substance due to its extreme alkalinity and chromium content. Direct skin contact with concrete wash water causes chemical burns that develop over hours of exposure, initially presenting as reddening and irritation but progressing to painful cracking, bleeding, and ulceration of affected skin. Eyes are particularly vulnerable, with splashes of concrete wash water causing severe pain, corneal damage, and potential permanent vision impairment if not immediately flushed with clean water for at least 15 minutes. Chromium in concrete is present primarily as hexavalent chromium (chromium VI), a known human carcinogen causing lung cancer through inhalation exposure and skin sensitization leading to allergic contact dermatitis that can permanently prevent workers from handling cement products. Manual handling injuries are common in washout collection work due to the physical demands of operating vacuum hoses weighing 20-30kg when filled with concrete slurry, positioning and securing heavy washout bins for transport (prefabricated units can weigh 200-400kg empty and over 2 tonnes when full), and working in awkward postures when accessing washout facilities located in confined site areas. Collection operators frequently work alone without spotters or assistants, increasing both manual handling injury risk and the potential for serious incidents to occur without immediate aid. Lower back injuries, shoulder strains from sustained overhead hose positioning, and knee damage from working in kneeling or squatting positions represent the most frequent manual handling outcomes. The combination of environmental sensitivity, chemical hazards, manual handling demands, and equipment operation risks makes concrete washout collection a moderate-risk construction support activity requiring detailed safe work method statements. Beyond legal compliance, comprehensive SWMS documentation provides essential worker protection, demonstrates due diligence in environmental management, and establishes clear accountability for this critical site environmental control measure. For principal contractors and developers, requiring detailed washout collection SWMS from service providers ensures consistent safety and environmental standards across all project sites.

Reinforce licensing, insurance, and regulator expectations for Concrete Washout Collection Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Chemical Burns from Alkaline Concrete Waste

High

Concrete wash water is extremely alkaline with pH levels of 12-13 due to calcium hydroxide in Portland cement. Workers performing washout collection operations experience direct exposure through splashes during vacuum hose connection and disconnection, spray-back when high-pressure water is used to break down hardened concrete in washout bays, and contact with contaminated equipment surfaces. Unlike acid burns that cause immediate pain, alkaline burns from concrete develop gradually over hours, often resulting in workers not recognizing exposure until serious tissue damage has occurred. The high pH dissolves skin proteins and fats, creating deep penetrating burns particularly severe on hands, forearms, face, and eyes. Collection operators working with concrete washout daily face cumulative exposure that can cause chronic dermatitis and permanent skin sensitization even with PPE use.

Consequence: Severe chemical burns requiring medical treatment, permanent skin damage and scarring, chronic dermatitis ending careers in construction, corneal damage and vision loss from eye exposure, and sensitization preventing future work with cement products.

Hexavalent Chromium Exposure from Concrete Waste

High

Portland cement contains chromium which partially exists as hexavalent chromium (Cr VI), classified as a Group 1 carcinogen by the International Agency for Research on Cancer. Concrete wash water contains dissolved hexavalent chromium at concentrations that create both acute skin sensitization risk and long-term cancer risk through repeated exposure. Skin contact causes allergic contact dermatitis in sensitized individuals, creating itchy, weeping rashes that persist even after exposure ceases and may prevent workers from continuing in construction trades. Inhalation of dried concrete dust from washout areas or spray mist during high-pressure cleaning creates lung cancer risk through cumulative exposure. The risk is heightened because hexavalent chromium readily penetrates skin and respiratory barriers, and Australian workplace exposure limits for chromium VI are very stringent (0.05 mg/m³) reflecting the serious health impacts.

Consequence: Allergic contact dermatitis requiring job change, long-term lung cancer risk from inhalation exposure, skin sensitization preventing future work with cement, and potential respiratory system damage from repeated exposure to chromium compounds.

Manual Handling Injuries During Collection Operations

Medium

Washout collection requires substantial manual handling including operating heavy vacuum hoses that weigh 20-30kg when filled with concrete slurry and must be positioned, moved, and controlled during pumping operations. Workers must manually position and secure washout bins weighing 200-400kg empty using forklift or truck-mounted crane attachments, with improper rigging or unstable positioning creating crush hazards. Accessing washout facilities often requires working in confined spaces, kneeling, squatting, or bending for extended periods to connect vacuum equipment or scrape out hardened concrete residues. The combination of heavy loads, awkward postures, repetitive movements, and often working alone without assistance creates significant musculoskeletal injury risk. Vacuum hose operation requires workers to maintain grip and control for sustained periods, causing hand and forearm strain.

Consequence: Lower back injuries requiring extended time off work, shoulder and rotator cuff damage from overhead hose positioning, knee damage from prolonged kneeling on hard surfaces, hand and wrist strains from gripping heavy hoses, and chronic musculoskeletal conditions from repeated exposure to poor manual handling tasks.

Vacuum Equipment Pressurization and Burst Hazards

Medium

Vacuum trucks operate under significant negative pressure to extract concrete slurry and solids from washout facilities. Blocked hoses, closed valves, or excessive material density can cause pressure spikes that burst hoses or fittings, releasing concrete slurry under pressure that can strike workers. Vacuum hose connections use cam-lock or threaded fittings that can separate under pressure if not properly secured, causing hose whip that can strike operators or bystanders with significant force. The concrete slurry being collected contains solids and hardened chunks that can block hoses mid-operation, requiring workers to release pressure and clear blockages while managing spray-back of alkaline material. Vacuum tank overfilling creates spillage risks when tanks are opened for discharge at treatment facilities.

Consequence: Impact injuries from hose whip or fitting separation, chemical burns from pressurized concrete slurry spray, eye injuries from material discharge, lacerations from failed equipment components, and environmental contamination from uncontrolled waste discharge during equipment failure.

Slips, Trips and Falls in Washout Areas

Medium

Concrete washout areas are inherently slippery due to wet concrete residue, mud created by wash water overflow, and contaminated ground surfaces. Workers must navigate uneven ground around temporary bund walls constructed from hay bales and timber, step over hoses and equipment while carrying or operating heavy vacuum equipment, and work on potentially unstable ground where heavy concrete trucks have previously operated. Washout facilities are often positioned in less-developed site areas to keep them away from stormwater drains, meaning access paths may be rough, muddy, or obstructed. Concrete slurry spills create extremely slippery surfaces similar to ice, with minimal warning and very low slip resistance. Night work or early morning collection when lighting is poor increases trip hazards from equipment, bund structures, and ground irregularities that are not clearly visible.

Consequence: Falls resulting in impact injuries, fractures from falling onto hard concrete surfaces or equipment, chemical burns from falling into concrete waste, soft tissue injuries from stepping in holes or on uneven ground, and head injuries from striking equipment or structures during falls.

Mobile Plant Interaction and Reversing Vehicles

Medium

Washout collection requires positioning vacuum trucks in areas with limited space, often while concrete delivery trucks, pumps, and other construction vehicles are operating nearby. Reversing vacuum trucks to access washout facilities creates struck-by hazards for workers on foot, particularly in busy site areas with multiple simultaneous activities. Site ground conditions around washout areas may be soft or unstable from wet concrete overflow, creating risk of vacuum trucks bogging or tipping when positioned for collection. Workers on foot connecting hoses and operating equipment may not be clearly visible to plant operators, particularly when working at the rear of vacuum trucks or in blind spots. Other construction vehicles may not be aware of collection operations occurring and could strike workers, hoses, or equipment.

Consequence: Serious crush injuries or fatalities from being struck by reversing vehicles, entrapment between vehicles and fixed objects, equipment damage from vehicle collisions, hose damage requiring emergency equipment shutdown, and environmental contamination from equipment damaged by vehicle strikes.

Environmental Contamination from Spills During Collection

Medium

Collection operations involve transferring liquid and semi-solid concrete waste from containment facilities to transport tanks, creating spill and overflow risks. Overfilled vacuum tanks can discharge when opened at disposal facilities, contaminating site surfaces and potentially entering stormwater systems. Hose disconnection before vacuum pressure is fully released causes spray discharge of alkaline waste. Damaged or deteriorated washout containment can fail during or after collection, releasing residual concrete waste to surrounding areas. Heavy vacuum trucks can damage temporary bund walls or crack concrete washout pits when positioning too close to containment edges. Equipment cleaning at unsuitable locations after collection can create new contamination points. These spills trigger environmental incident reporting requirements and can result in regulatory enforcement action.

Consequence: Environmental prosecution and fines up to $250,000, ecosystem damage requiring expensive remediation, pollution of waterways causing fish kills and aquatic habitat destruction, soil contamination requiring excavation and disposal, stormwater system damage, and permanent site access restrictions from environmental authorities.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Designated Washout Facility Design and Positioning

Elimination

Properly designed and positioned concrete washout facilities eliminate environmental contamination by preventing any discharge of alkaline concrete waste to surrounding areas. Washout facilities must be located minimum 50 metres from any waterway, wetland, or stormwater inlet, positioned on level or gently sloping ground to prevent runoff, and sized to contain expected volumes including provision for rainfall collection. Facilities use either prefabricated steel or plastic bins with sealed bases and minimum 600mm high walls, or temporary bunds constructed from double-layer hay bales secured with stakes and lined with heavy-duty plastic sheeting with all joints overlapped and sealed. Adequate capacity must be provided based on project concrete usage, with typical rule of thumb being 1 cubic metre of washout capacity for every 20 cubic metres of concrete placement planned per week. Secondary containment around permanent washout pits prevents overflow impacts. Clear signage marks washout locations and prohibits discharge of any other materials including paint washout, equipment fuels, or general waste. Design eliminates the possibility of environmental contamination by ensuring all concrete waste is captured within designated containment.

Implementation

1. Review site layout plans and identify suitable washout facility locations meeting minimum 50m setback from waterways and stormwater infrastructure 2. Calculate required washout capacity based on project concrete volumes and planned pour schedule 3. Install washout facilities using either prefabricated containment bins or construct temporary bunds from double-layer hay bales with 200-micron plastic liner 4. Ensure washout facilities have minimum 600mm containment height and adequate base area to prevent overflow 5. Install weather protection covers over washout facilities to minimize rainwater collection 6. Erect clear signage identifying concrete washout only use and prohibiting other waste discharge 7. Mark washout locations on site induction maps and include in site environmental management plans 8. Inspect washout facilities weekly for damage, deterioration, or capacity reduction and repair immediately 9. Monitor containment capacity during concrete pours and arrange collection before 75% capacity reached 10. Document washout facility locations, capacities, and inspection records in site environmental files

Comprehensive Skin and Eye Protection Program

PPE

Concrete washout contains extremely alkaline materials requiring comprehensive personal protective equipment to prevent chemical burns. Workers must wear waterproof gloves rated for alkaline substance protection (not standard cotton or leather work gloves which absorb alkaline water and worsen exposure). Chemical-resistant gauntlet-style gloves extending to mid-forearm provide optimal protection for collection operations involving direct handling of concrete waste. Full-face shields or safety glasses with side shields protect eyes from splashes during hose connection and high-pressure cleaning. Waterproof overalls or chemical-resistant aprons protect body and clothing from contamination. Safety gumboots with steel toe caps provide foot protection from alkaline water and dropped equipment. Immediate washing facilities must be available including eyewash stations for emergency eye flushing, clean water and soap for skin decontamination, and emergency shower access for major exposure incidents. PPE must be inspected before each use for damage or deterioration, with alkaline-damaged items replaced immediately. The combination of proper PPE selection, correct usage, and emergency washing access provides essential worker protection from alkaline burns.

Implementation

1. Procure chemical-resistant gauntlet gloves rated for high pH substances (pH 12-14) with minimum 400mm length 2. Provide full-face shields or safety glasses with side shields to all workers performing washout collection 3. Supply waterproof overalls or chemical-resistant aprons for use during collection operations 4. Ensure all workers wear safety gumboots when working in or around washout facilities 5. Install portable eyewash station at washout collection vehicle accessible within 10 seconds travel time 6. Provide adequate clean water supply and soap for immediate washing of skin exposure 7. Train workers on proper PPE donning and doffing procedures to avoid self-contamination 8. Inspect all PPE before use and replace damaged items immediately 9. Establish PPE cleaning procedures using clean water to remove concrete residue after each use 10. Monitor PPE condition and replace gloves monthly or when deterioration observed

Vacuum Equipment Pre-Operation Inspection and Testing

Administrative

Systematic pre-operation inspection and testing of vacuum collection equipment prevents equipment failures that could cause worker injury or environmental contamination. Inspections verify all hose cam-lock or threaded fittings are undamaged with seals in good condition, vacuum hoses have no cuts, abrasion damage, or weak spots that could burst under pressure, pressure relief valves are functional and set to correct operating pressures, and tank level indicators are operational to prevent overfilling. Testing involves operating vacuum system at low pressure before connecting to washout facility, verifying all connections seal properly without leaks, confirming pressure controls respond correctly, and checking discharge valves operate smoothly. Defects identified during inspection must be repaired before collection commences, with defective hoses, fittings, or pressure control components replaced rather than temporarily repaired. Inspection records document equipment condition and provide evidence of systematic maintenance for regulatory compliance and incident investigation. Regular equipment inspection combined with operator training in correct operating procedures prevents the majority of vacuum equipment incidents.

Implementation

1. Develop pre-operation inspection checklist covering vacuum pump, hoses, fittings, pressure controls, and tank integrity 2. Inspect all vacuum hoses for cuts, abrasion, chemical damage, or soft spots indicating internal deterioration 3. Check cam-lock or threaded fittings for cracks, damaged sealing surfaces, or worn locking mechanisms 4. Test pressure relief valves operate freely and verify correct pressure settings per manufacturer specifications 5. Confirm tank level indicators are functional and visible from operator position 6. Inspect discharge valves for proper sealing and smooth operation 7. Start vacuum pump and operate at low pressure to verify normal operation before connecting to washout facility 8. Test all hose connections for air leaks using soap solution or listening for air ingress sounds 9. Document inspection results on daily equipment checklist with operator signature 10. Remove defective equipment from service and arrange repairs or replacement before recommencing collection operations

Traffic Management and Exclusion Zones During Collection

Engineering

Establishing exclusion zones and traffic controls during washout collection operations separates workers on foot from moving vehicles and mobile plant. Temporary fencing or barrier mesh creates physical separation between collection work area and active vehicle routes, preventing vehicles from entering areas where collection hoses are deployed or workers are operating equipment. Traffic control includes designated parking positions for vacuum trucks marked with witches hats or delineator posts, reversing spotter requirements for all vacuum truck movements in confined areas, and temporary stop/go traffic control when collection operations require temporary road closure. Audible reversing alarms on vacuum trucks warn workers of vehicle movements. High-visibility clothing for all collection workers ensures they remain visible to plant operators. Radio communication between collection crew and site traffic controller coordinates collection activities with concrete deliveries and other vehicle movements. Physical barriers prevent the possibility of workers being struck by vehicles through engineered separation of people and plant.

Implementation

1. Install temporary fencing or barrier mesh to create exclusion zone around washout collection work area 2. Position witches hats or delineator posts to mark vacuum truck parking position and create vehicle-free zone 3. Assign trained spotter for all vacuum truck reversing in confined site areas 4. Implement stop/go traffic control using trained traffic controllers when collection requires temporary road closure 5. Ensure vacuum truck has functional reversing alarm and directional indicators 6. Require all collection workers wear high-visibility clothing meeting AS/NZS 4602.1 Class D/N requirements 7. Establish radio communication between collection crew, spotter, and site traffic controller 8. Coordinate collection schedule with concrete deliveries to avoid simultaneous vehicle movements in same area 9. Install temporary speed limit signs (10 km/h maximum) in areas where collection operations occur 10. Conduct toolbox talk with all workers in area explaining collection operations and exclusion zones before work commences

Environmental Spill Response and Containment Equipment

Administrative

Immediate spill response capability prevents environmental contamination when collection equipment failures or operational errors cause concrete waste discharge. Spill response kits contain materials to rapidly contain and neutralize alkaline concrete spills including absorbent materials (spill pads, loose absorbent granules), pH neutralization agents (weak acid solutions or specialized neutralizing compounds), temporary containment barriers (sand bags, containment booms), and collection tools (shovels, brooms, waste collection bags). Response procedures establish immediate actions including stopping the spill source, containing spread using absorbent materials or temporary berms, preventing entry to stormwater drains, and neutralizing pH before disposal. Workers receive training in spill response procedures during site induction and practice response using simulated spill scenarios. Environmental incident reporting procedures ensure regulatory authorities are notified of reportable environmental harm as required under state environmental legislation. Pre-positioned spill response equipment combined with trained workers enables rapid containment that prevents minor operational spills from becoming major environmental incidents.

Implementation

1. Position spill response kit on vacuum truck containing minimum 20kg absorbent material, pH neutralizing agent, sand bags, and collection tools 2. Train all collection workers in spill response procedures during site induction 3. Establish spill response procedure card displayed in vacuum truck cab outlining immediate response steps 4. Conduct monthly spill response practice scenario with collection crew 5. Pre-position sand bags near washout facilities to enable rapid drain protection if spills occur 6. Ensure vacuum truck carries adequate clean water supply for emergency dilution and cleaning 7. Establish environmental incident notification procedure including contact details for environmental manager and regulatory authorities 8. Stock pH test strips or pH meter to assess spill severity and verify neutralization effectiveness 9. Designate suitable temporary waste storage area for spill cleanup materials pending proper disposal 10. Review and update spill response procedures following any spill incident or near-miss occurrence

Download complete control procedures

Personal protective equipment

Chemical-Resistant Gauntlet Gloves

Requirement: Nitrile or PVC gauntlet gloves rated for pH 12-14 alkaline substances, minimum 400mm length, meeting AS/NZS 2161 chemical protective gloves standard

When: Required for all workers performing washout collection operations, connecting vacuum hoses, operating high-pressure cleaning equipment, or any direct contact with concrete wash water or contaminated surfaces. Must be worn continuously during collection operations.

Full-Face Shield or Safety Glasses with Side Shields

Requirement: Face shield meeting AS/NZS 1337 with clear polycarbonate lens providing full-face protection, or safety glasses meeting AS/NZS 1336 with side shields and clear lenses suitable for chemical splash protection

When: Required during all washout collection operations particularly when connecting/disconnecting vacuum hoses, operating high-pressure cleaning equipment, or working around concrete waste where splash exposure can occur. Face shields preferred over safety glasses for operations with high splash risk.

Waterproof Safety Gumboots

Requirement: PVC or rubber safety gumboots with steel toe caps meeting AS/NZS 2210 (safety footwear) with waterproof construction and chemical-resistant materials, minimum 300mm height

When: Required for all workers entering washout facility areas or performing collection operations. Must be worn when standing on wet or contaminated ground, operating around concrete wash water, or handling contaminated equipment.

Chemical-Resistant Apron or Waterproof Overalls

Requirement: PVC or heavy-duty rubber apron providing coverage from chest to knees, or full waterproof overalls, both resistant to alkaline substances pH 12-14

When: Required during operations with high contamination risk including pump-out of heavily contaminated washout facilities, high-pressure cleaning of hardened concrete residues, or any work requiring extended contact with concrete waste materials.

High-Visibility Clothing

Requirement: Class D/N high-visibility vest, shirt or jacket meeting AS/NZS 4602.1 with minimum 0.2m² combined fluorescent and reflective material

When: Required at all times when performing washout collection on active construction sites where mobile plant and vehicles are operating. Must be worn over all other protective clothing to ensure visibility to plant operators.

Inspections & checks

Before work starts

  • ✓Verify washout facility location, capacity status, and structural integrity before positioning collection equipment
  • ✓Inspect vacuum truck including pump, hoses, fittings, pressure controls, and tank for damage or defects
  • ✓Check all cam-lock or threaded hose fittings for cracks, damaged seals, or worn locking mechanisms
  • ✓Test vacuum pump operation at low pressure and verify pressure relief valves function correctly
  • ✓Confirm spill response equipment present on vacuum truck including absorbents, neutralizers, and containment materials
  • ✓Verify eyewash station is filled and functional with clean water available for emergency use
  • ✓Inspect all required PPE for damage, deterioration, or contamination from previous use
  • ✓Check traffic management equipment including witches hats, barriers, and communication radios are available and functional
  • ✓Confirm site environmental manager has authorized collection operation and scheduled timing

During work

  • ✓Monitor vacuum tank level indicator continuously during collection to prevent overfilling
  • ✓Check hose connections for leaks or air ingress during initial pump operation
  • ✓Observe vacuum pressure gauges for abnormal readings indicating blockages or equipment problems
  • ✓Monitor work area for unauthorized entry of personnel or vehicles into exclusion zone
  • ✓Watch for signs of washout facility damage or failure during collection including liner tears or bund deterioration
  • ✓Verify workers maintain proper use of PPE particularly gloves and eye protection during splash-risk operations
  • ✓Assess ground stability around washout facility for vacuum truck positioning safety
  • ✓Check for concrete waste spills or contamination occurring during collection operations

After work

  • ✓Inspect washout facility after collection for residual capacity, structural integrity, and any required repairs
  • ✓Clean and inspect all vacuum hoses and fittings, checking for chemical damage or deterioration requiring replacement
  • ✓Decontaminate vacuum truck external surfaces removing concrete residue using clean water wash-down
  • ✓Document waste volumes collected and transport destination in environmental records
  • ✓Complete post-operation inspection checklist for vacuum equipment noting any maintenance requirements
  • ✓Clean and store all PPE removing concrete contamination and inspecting for damage requiring replacement
  • ✓Dispose of any contaminated spill response materials or damaged equipment according to waste management procedures
  • ✓Report any environmental incidents, spills, or equipment failures to site environmental manager

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready
1

Pre-Collection Site Assessment and Preparation

Begin by conducting comprehensive site assessment of washout facility location, access routes, and current capacity status. Contact site environmental manager to confirm collection is scheduled and authorized. Assess access route from site entrance to washout facility, identifying overhead services, ground stability issues, and available turning space for vacuum truck positioning. Inspect washout containment facility visually from outside to estimate fill level and identify any obvious structural damage requiring repair before collection. Verify concrete placement operations are not scheduled during collection timeframe to avoid conflicts. Check weather forecast for rainfall that could complicate collection or create additional liquid volume. Identify suitable temporary vehicle parking area if washout facility access is restricted. Prepare traffic management equipment and ensure communication radios are charged and functional.

Safety considerations

Access route assessment prevents vacuum truck becoming bogged in soft ground or striking overhead services. Verifying concrete operations are not occurring prevents simultaneous vehicle movements creating struck-by hazards. Weather check enables planning for rain protection and managing increased liquid volumes. Communication equipment ensures coordination with site management.

2

Vacuum Equipment Pre-Operational Inspection

Conduct detailed pre-operation inspection of vacuum truck and associated equipment before traveling to site. Inspect vacuum pump for oil levels, belt condition, and any signs of mechanical problems. Check all vacuum hoses for cuts, abrasion damage, or soft spots indicating deterioration. Examine cam-lock or threaded fittings for cracks, damaged sealing surfaces, or worn locking mechanisms that could fail under pressure. Test pressure relief valves operate freely and verify correct pressure settings matching manufacturer specifications. Confirm tank level indicators are functional and visible from operator position. Inspect discharge valves for proper sealing when closed and smooth operation. Start vacuum pump and run at low pressure listening for unusual noises or vibrations indicating mechanical problems. Verify spill response kit is stocked with absorbents, neutralizers, sand bags, and collection tools. Check eyewash station contains clean water and is accessible. Document inspection completion on daily equipment checklist. Do not proceed with collection if any defects are identified until repairs completed.

Safety considerations

Thorough pre-operation inspection prevents equipment failures during collection that could cause pressurized hose burst, fitting separation, or uncontrolled waste discharge. Defect identification before mobilization avoids emergency repairs in field conditions. Functional pressure relief valves prevent tank over-pressurization. Spill kit verification ensures response capability if incidents occur.

3

Site Access and Traffic Management Setup

Travel to construction site following designated access routes and report to site office for sign-in and current site hazard briefing. Position vacuum truck at designated parking area and conduct site-specific hazard identification including active work areas, mobile plant movements, overhead services, and ground conditions. Establish traffic management by installing temporary fencing or barrier mesh to create exclusion zone around washout facility. Position witches hats or delineator posts marking vacuum truck parking location and creating vehicle-free work zone. Assign trained spotter if reversing vacuum truck in confined area is required. Install temporary signage warning other site users that collection operations are occurring. Establish radio communication with site traffic controller. Conduct toolbox meeting with any site workers in immediate area explaining collection operations, exclusion zones, and expected timeframe. Don all required PPE including chemical-resistant gloves, safety glasses or face shield, gumboots, and high-visibility vest before approaching washout facility.

Safety considerations

Traffic management prevents workers being struck by vehicles during collection operations. Exclusion zones separate people from operating equipment. Spotter assignment ensures safe reversing movements. Communication with site workers prevents unexpected entry to work area. PPE donning before approaching contaminated washout facility prevents alkaline exposure during setup activities.

4

Washout Facility Inspection and Access Preparation

Approach washout facility and conduct detailed visual inspection from outside containment area before entering. Assess liquid and solid waste volumes to estimate collection requirements and verify capacity is not exceeded requiring emergency measures. Inspect containment structure including plastic liner, hay bale bunds, or concrete pit walls for damage, tears, or deterioration that could cause failure during collection. Check ground stability around washout facility ensuring vacuum truck can be positioned safely without creating collapse or subsidence risks. Identify locations of hardened concrete chunks requiring mechanical breaking before vacuum collection possible. Note any contamination outside containment requiring cleanup. Remove any debris, tools, or materials placed in washout facility that should not be there. If washout facility contains excessive hardened concrete, use jackhammer or breaking equipment to reduce large chunks to sizes that will pass through vacuum hose (typically 50-75mm maximum). Position vacuum truck at safe distance from washout facility edge ensuring stable ground conditions and adequate hose reach.

Safety considerations

External inspection before entry identifies structural failures that could create fall or immersion hazards. Volume assessment prevents over-collection attempts that could overflow vacuum tank creating environmental contamination. Ground stability check prevents vacuum truck rollover or subsidence during collection. Debris removal prevents foreign objects from damaging vacuum equipment or creating blockages. Breaking hardened concrete before vacuum collection prevents hose blockages requiring emergency pressure release.

5

Vacuum Equipment Connection and Collection Operations

Select appropriate vacuum hose length to reach washout facility from truck parking position, choosing shortest practical hose to minimize weight and pressure losses. Connect vacuum hose to truck suction connection using cam-lock or threaded fitting, ensuring fitting seats properly and locking mechanism fully engages. Check connection by hand to verify secure attachment before applying vacuum pressure. Position hose end near edge of liquid concrete waste, avoiding direct immersion in thick slurry that could cause immediate blockage. Start vacuum pump at low power and gradually introduce hose end into waste material while monitoring pressure gauges. Progressively increase vacuum power as material flow established. Manage hose position to optimize collection of liquid waste before attempting collection of thicker slurry or solid materials. Monitor vacuum tank level indicator continuously, ceasing collection before tank reaches 90% capacity to allow adequate air space. If blockage occurs during collection, shut down vacuum pump immediately, release pressure through relief valve, and clear blockage using rodding equipment or water jetting. For heavily contaminated washout facilities, multiple collection visits may be required to fully clean facility.

Safety considerations

Proper hose connection prevents fitting separation under pressure causing hose whip and worker strike injuries. Low power startup with gradual pressure increase reduces blockage risk. Tank level monitoring prevents overfilling creating spillage during transport or discharge. Immediate shutdown on blockage prevents pressure buildup causing hose burst. Pressure release before blockage clearing prevents alkaline waste spray when blockage clears. Multiple collection approach prevents overloading vacuum system.

6

Hose Disconnection and Equipment Decontamination

When collection complete, shut down vacuum pump and verify all pressure released from system before disconnecting hoses. Close vacuum tank inlet valve preventing waste discharge during hose disconnection. Raise vacuum hose from washout facility allowing residual waste to drain back into containment, reducing hose weight and contamination. Disconnect hose from vacuum truck connection by releasing cam-lock handles or unscrewing threaded fittings, controlling hose end to prevent contact with ground or splashing residual waste. Flush vacuum hose with clean water if facility available, removing concrete residues that could harden and create blockages. Coil hoses neatly and secure on truck for transport. Inspect washout facility condition after collection, noting residual capacity and any required maintenance. Use clean water to wash down vacuum truck external surfaces removing concrete splash contamination. Clean boots and gloves before removing PPE to avoid self-contamination. Remove and properly store all PPE, inspecting for damage requiring replacement. Remove traffic management equipment and witches hats, restoring normal site access. Complete collection documentation including waste volumes, transport destination, and any equipment issues requiring maintenance.

Safety considerations

Pressure release before disconnection prevents hose contents discharging under pressure causing chemical burns and environmental contamination. Hose draining reduces manual handling loads during disconnection. Controlled hose end management prevents alkaline splash exposure. Clean water flushing prevents concrete hardening in hoses creating equipment damage and future blockage risks. External decontamination removes chemical hazards before transport. Proper PPE removal sequence prevents chemical transfer to skin and clothing. Traffic management removal restores site normal operations safely.

7

Waste Transport and Disposal at Licensed Facility

Transport collected concrete washout waste to facility licensed to receive and treat alkaline industrial waste. Ensure waste transport manifest or consignment note completed documenting waste type, volume, origin site, transport details, and destination facility. Drive carefully to disposal facility as liquid waste creates vehicle stability considerations and spills during transport have serious environmental consequences. On arrival at disposal facility, follow site procedures for vehicle positioning and waste discharge. Ensure discharge area has appropriate containment preventing overflow creating environmental contamination. Open vacuum tank discharge valves gradually allowing controlled waste flow to disposal facility receiving tank or treatment area. Monitor discharge process for blockages or overflow. Once discharge complete, close all valves and verify tank is empty. Clean tank interior using facility wash-down if available, removing residual concrete waste. Obtain signed manifest or receipt from disposal facility operator confirming waste acceptance and volumes. Complete environmental records documenting collection and disposal chain of custody. Report any transport incidents, spills, or disposal facility issues to site environmental manager immediately.

Safety considerations

Licensed disposal facility selection ensures legal waste disposal and prevents environmental prosecution. Transport manifest documentation creates legal record demonstrating proper waste management. Careful transport prevents liquid waste spills from vehicle movements or sudden stops. Controlled discharge prevents overflow at disposal facility. Tank cleaning prevents concrete hardening in transport tank creating permanent capacity reduction and future collection problems. Documentation completion demonstrates environmental compliance and due diligence.

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Frequently asked questions

Why is concrete washout collection a legal requirement on construction sites?

Concrete washout collection is mandated under state Environmental Protection Acts and local council development approval conditions to prevent pollution of waterways and stormwater systems from highly alkaline concrete waste. Concrete wash water has pH levels of 12-13, contains hexavalent chromium classified as a carcinogen, and carries high suspended solids concentrations that cause severe environmental harm if discharged. Australian environmental regulators actively investigate concrete washout pollution with prosecutions resulting in fines exceeding $100,000 plus cleanup costs. Recent cases in Victoria, NSW, and Queensland have led to significant penalties for building companies allowing concrete washout discharge to stormwater. Beyond legal requirements, proper washout collection demonstrates environmental responsibility, protects company reputation, and ensures development approval conditions are met. Site Environmental Management Plans typically mandate specific washout containment and collection procedures that become legal obligations once approved by regulatory authorities.

What personal protective equipment is required for workers collecting concrete washout waste?

Workers performing concrete washout collection require comprehensive PPE due to extreme alkalinity of concrete waste causing chemical burns. Essential PPE includes chemical-resistant gauntlet gloves rated for pH 12-14 substances with minimum 400mm length protecting forearms (standard cotton or leather work gloves are inadequate and actually worsen exposure by absorbing alkaline water). Full-face shields or safety glasses with side shields protect eyes from alkaline splash that can cause permanent vision damage if not immediately flushed. Waterproof safety gumboots with steel toe caps prevent foot exposure to alkaline water and protect from dropped equipment. Chemical-resistant aprons or waterproof overalls provide body protection during high-contamination operations. High-visibility clothing worn over protective equipment ensures visibility to plant operators. Immediate washing facilities including eyewash stations must be available for emergency decontamination. PPE must be inspected before each use with alkaline-damaged items replaced immediately. Training in proper PPE donning and removal prevents self-contamination.

How often should concrete washout facilities be serviced and emptied?

Collection frequency depends on washout facility capacity and site concrete usage intensity. General guideline is to arrange collection when facility reaches 75% capacity, providing safety margin to prevent overflow before collection service arrives. High-volume commercial sites conducting daily concrete pours may require weekly or even twice-weekly collection. Smaller residential sites might need monthly collection or collection timed to coincide with project completion. Washout facility capacity must be monitored by site supervisors with collection scheduled proactively rather than waiting for overflow emergencies. Rain events significantly increase liquid volumes requiring more frequent collection during wet weather. Sites should establish maximum service intervals (typically 30 days) even if capacity not reached, preventing concrete from fully hardening in containment making collection difficult or impossible. Environmental Management Plans often specify maximum service intervals as approval conditions. Collection should be scheduled allowing buffer before major concrete pours to ensure adequate containment capacity available.

What should happen if concrete washout is accidentally discharged to stormwater?

Concrete washout discharge to stormwater constitutes a reportable environmental incident requiring immediate action. First priority is stopping the discharge source by containing the spill using sand bags across drains and absorbent materials. Site environmental manager and principal contractor must be notified immediately. State environmental protection authority must be notified within 24 hours for serious or material environmental harm, which concrete washout discharge typically constitutes. Report must include incident details, volumes discharged, receiving environment affected, and immediate response actions taken. Environmental consultant may need to assess downstream impacts and recommend remediation measures. Water quality testing of affected waterways documents contamination extent. Cleanup may require vacuum collection of contaminated stormwater, pH neutralization of affected areas, and monitoring until environmental values restored. Incident investigation determines root causes and implements corrective actions preventing recurrence. Environmental prosecutions often result from inadequate incident response rather than the initial discharge, making proper notification and documentation essential.

Can concrete washout waste be reused or recycled?

Concrete washout waste can be recycled through several methods depending on local facility availability and waste composition. Liquid concrete slurry can be returned to concrete batching plants where solids are recovered and aggregates reused in future concrete mixes, though this requires specialized treatment equipment not available at all plants. Water from washout after solids removal can be used for concrete mixing once pH is neutralized and chromium concentrations meet specifications. Hardened concrete removed from washout facilities can be crushed and used as fill material or road base subject to environmental approval and testing confirming no leachate concerns. Some waste management facilities operate concrete recycling operations accepting washout waste for processing. However, many areas lack convenient recycling facilities requiring disposal to landfill licensed for alkaline industrial waste. Transport costs often determine whether recycling is economically viable versus disposal. Regardless of disposal method, waste transport manifests documenting legal disposal pathway are required. Sites should investigate recycling options during project planning to minimize environmental impacts and disposal costs.

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