Concrete Demolition Ultra High Water Pressure Safe Work Method Statement

Ultra-high pressure water jetting operators require specialised training that goes well beyond general construction competency. While Australia does not currently mandate a specific high-risk work license for UHP water jetting operations, industry best practice and insurance requirements typically require operators to complete comprehensive training programs covering hydraulic principles and pressure-energy relationships, equipment operation including startup, operation, shutdown, and emergency procedures, hazard recognition specific to UHP systems, inspection and maintenance procedures, PPE selection and use, and emergency response including first aid for high-pressure injection injuries. Training should include minimum 40 hours of theoretical and practical content delivered by experienced UHP contractors, equipment manufacturers, or recognised training providers. Practical competency assessment should require operators to demonstrate safe equipment setup and connection procedures, correct operating technique and lance control, emergency shutdown response achieving system stop within 2 seconds, identification of equipment defects during inspection, appropriate PPE selection and use, and understanding of exclusion zones and work area controls. Many major contractors and equipment hire companies require operators to hold formal certification from equipment manufacturers demonstrating completion of approved training programs. Insurance policies covering UHP water jetting often specify minimum training requirements, with claims potentially denied if operators lack documented competency. Given the catastrophic injury potential, employers should implement training standards exceeding minimum requirements and maintain detailed training records for all operators. Refresher training should occur annually at minimum, with immediate additional training if operators demonstrate unsafe work practices or if near-miss incidents occur. Never permit untrained or inadequately supervised personnel to operate UHP equipment regardless of project schedule pressures—the injury consequences are too severe to accept any compromise on operator competency.

High-pressure hose condition is absolutely critical to safe UHP water jetting operations because hose failures at 2,000+ bar pressure are catastrophic and can cause severe injuries or death. Hoses should be inspected thoroughly before every use following systematic inspection procedures. Visual inspection should identify external damage including cuts, abrasion, or impact marks that penetrate beyond outer cover, bulging or blisters indicating internal failure of reinforcement layers or hose structure, kinking or sharp bends that have damaged hose structure, and signs of chemical attack or degradation including unusual surface appearance or softening. End fitting inspection should verify threaded fittings show no backing off, cross-threading, or stripped threads, ferrules are not displaced or showing corrosion, and fittings show no cracks or deformation. Functional testing should include visual confirmation of secure connection with full thread engagement, torque verification using calibrated torque wrench confirming fittings are tightened to manufacturer specification (typically 200-300 Nm for UHP fittings), and pressure hold test where system is pressurised to operating pressure and held for 60 seconds while inspecting for any leaks or weeping. Hoses must be immediately removed from service if any of the following conditions exist: any cut or abrasion exposing reinforcement wire, any bulging or blisters regardless of size, any visible kinking or permanent deformation, end fittings showing any cracks or deformation, any leakage at any pressure, hoses that have been kinked or run over by vehicles even if no external damage is visible (internal damage may be present), or hoses that exceed manufacturer's recommended service life (typically 2-5 years depending on usage). Additionally, track hose operating hours and replace at manufacturer's specified pressure cycle limits—typical UHP hoses are rated for 10,000-20,000 pressure cycles. Never attempt field repairs on ultra-high pressure hoses as these repairs are ineffective and extremely dangerous—damaged hoses must be returned to manufacturer-authorised service centres or replaced. The cost of hose replacement is insignificant compared to catastrophic injury consequences if failed hoses cause operators to lose control or if whipping hoses strike workers.

High-pressure water injection injuries are medical emergencies requiring immediate hospital treatment and must never be dismissed as minor injuries regardless of small external wound appearance. If a worker suffers water stream contact during UHP operations, implement the following emergency response immediately: activate emergency stop button or dead-man trigger release immediately to stop further injury, call emergency services (000) stating clearly 'high-pressure water cutting injury with penetrating wound and potential severe internal damage', implement severe bleeding control using direct pressure with clean dressings—if bleeding is severe, use maximum pressure and do not release pressure even to examine wound, elevate injured limb above heart level while maintaining pressure if possible without aggravating injury, keep injured worker still and lying down if possible to minimise blood pressure and reduce bleeding, reassure injured worker while awaiting emergency services, do not attempt to clean or examine penetrating wounds as this may increase bleeding and contaminate deeper tissues, do not remove any embedded debris or foreign material from wounds as this may worsen bleeding, keep injured worker warm using blankets or shelter to prevent shock, monitor for signs of shock including pale skin, rapid pulse, confusion, or loss of consciousness, and document exact time injury occurred and mechanism of injury for emergency services. Critical information for emergency services includes the water pressure (typically 2,000-3,000 bar for UHP equipment), the body part injured and approximate injection site, whether water stream contained contaminants from concrete slurry, and any immediate first aid provided. High-pressure injection injuries require immediate surgical treatment to remove injected fluids and debris, extensive debridement of damaged tissue, and aggressive antibiotic treatment to prevent infection. Even injuries that appear minor externally often involve massive internal tissue damage requiring emergency surgery. Workers who suffer injection injuries should be transported to hospital immediately even if they resist or claim injury is minor—the delayed presentation of internal damage can lead to loss of limbs or life if treatment is delayed. After any high-pressure injection injury, implement work stop order and conduct comprehensive incident investigation identifying how operator contacted water stream and what additional controls are required to prevent recurrence.

Regular high-pressure cleaning equipment operating at typical pressures of 100-300 bar is completely inadequate for concrete demolition and attempting to use such equipment for this purpose will fail to remove concrete while exposing operators to extended hazardous conditions. Concrete demolition requires ultra-high pressure equipment operating at minimum 1,000 bar and typically 1,500-3,000 bar to achieve the water velocity and impact energy necessary to fragment concrete matrix. The physics of water jetting dictate that impact force increases with the square of velocity, meaning that doubling pressure roughly quadruples cutting effectiveness. Regular high-pressure equipment lacks the pressure capability to exceed concrete's compressive strength (typically 20-50 MPa for structural concrete) and will merely clean concrete surfaces rather than remove material. Additionally, UHP equipment differs fundamentally from high-pressure cleaners in several critical aspects: UHP pumps use specialised intensifier technology or ultra-high pressure plunger pumps designed for continuous operation at extreme pressures, UHP hoses incorporate multiple layers of steel wire reinforcement capable of containing 2,000+ bar pressure, UHP lance assemblies include sophisticated trigger mechanisms, safety interlocks, and guards preventing operator contact with water stream, and UHP nozzles are precision-engineered with specific orifice geometries optimised for concrete cutting. Attempting to modify regular high-pressure equipment for concrete demolition is extremely dangerous as standard components will fail catastrophically at ultra-high pressures. Furthermore, UHP concrete demolition contractors require substantial capital investment in equipment, specialised training for operators, and comprehensive safety systems—factors that explain why this work is typically performed by specialised subcontractors rather than general construction personnel. If your project requires concrete demolition using water jetting techniques, engage a specialised UHP contractor with appropriate equipment, trained operators, insurance coverage, and demonstrated safety performance. Do not attempt to perform this work with regular pressure cleaning equipment regardless of project budget constraints—the equipment inadequacy will prevent effective concrete removal while creating unacceptable safety risks.

UHP concrete demolition generates substantial water discharge containing high concentrations of suspended solids, elevated pH from cement dissolution, and potential contaminants from existing concrete requiring comprehensive environmental controls and potential regulatory approvals. Under Australian environmental protection legislation, all water discharge to stormwater systems, waterways, or ground must comply with Environmental Protection Authority requirements which vary by jurisdiction but generally prohibit discharge of contaminated water without treatment and approval. For most UHP concrete demolition projects, water discharge will require pH adjustment to neutral range (typically pH 6.5-8.5), removal of suspended solids to meet concentration limits (often <50 mg/L), testing for potential contaminants including heavy metals if demolishing old concrete that may contain hazardous materials, and documentation proving discharge meets EPA approval conditions. Project planning must include water management systems addressing these requirements including primary settlement tanks allowing suspended solids to settle before discharge, pH adjustment using acid dosing systems bringing alkaline concrete water to neutral pH, filtration systems removing fine particles if settlement alone is inadequate, and water quality testing confirming compliance before any discharge occurs. For projects where site discharge is prohibited or impractical, implement closed-loop systems recycling water through filtration and settlement, minimising fresh water consumption and waste volumes, or engage licensed liquid waste contractors for regular pump-out and offsite disposal of contaminated water and concrete slurry at approved facilities. Before commencing any UHP demolition work, contact relevant EPA authority to determine discharge approval requirements—many jurisdictions require formal environmental approval applications particularly for large-scale demolition generating substantial water volumes. Penalties for non-compliant discharge are severe, with fines reaching tens of thousands of dollars and potential prosecution if contamination of waterways occurs. Project budgets must include adequate water treatment systems, ongoing water quality testing, and disposal costs as these are mandatory compliance requirements not optional considerations. Document all water management activities including volumes used and discharged, water quality test results, and disposal records as regulators frequently inspect construction sites for environmental compliance and inadequate documentation compounds penalties if violations are found.