Static Plant
pre-use check

The 8 things to look at before the key turns on generator, compressor, pump, concrete pump.

Every item below says what good looks like, when it passes, the regulation or manufacturer's standard it rests on and the defects that usually fail it. That guidance is the difference between a tick and a check.

1. 1.

   Visual inspection — no damage or leaks
   What to look forWalk round the unit. Check the canopy/skid for damage from forklift contact, doors closing flush, lifting eye(s) intact, no fluid pooling under the engine or pump end. Check pipework lagging on concrete pumps for damage. Examine the chassis where it sits on the ground — any rocking suggests a bent skid.
   Acceptable whenNo drips on the ground after 24h stand. Canopy locks shut. Lifting eyes free of cracks, paint not flaking from a deformation. Skid sitting flat. All decals legible.
   StandardPUWER 1998 reg.5/6. Manufacturer's daily check. CDM 2015 reg.13.
   Common defectsForklift damage to the canopy door — no longer closes, weatherproofing lostDiesel weep at the day tank gauge — pooling under the unitConcrete pump pipework cracked at a clamp — high-pressure failure riskSkid bent from a poor lift — unit no longer sits stableLifting eye repainted hiding a crack — survey before next move
2. 2.

   Fuel / oil levels correct
   What to look forEngine oil between MIN and MAX with the unit on level ground, cool. Coolant in expansion tank between marks. Diesel fuel level adequate for the planned shift, no water in the fuel-water separator (drain tap cleared until clean). Hydraulic level (concrete pumps) at the sight glass.
   Acceptable whenAll fluids between marks per handbook. Fuel-water separator drained dry of water. Correct grade per filler-cap label.
   StandardPUWER 1998 reg.6. Manufacturer's daily check schedule.
   Common defectsWater in the fuel — bug growth in tanks left part-full overnightCoolant low — slow leak at the radiator core, top-up masking the issueWrong oil grade topped up by the previous userFuel level instrument stuck — false full readingDiesel bug in a long-stored unit — filter blocking within an hour of run
3. 3.

   Connections secure (hoses, cables, pipes)
   What to look forAll hoses and cables secured at fittings, no chafing against sharp edges, strain reliefs intact at glands. Quick-couplers (compressor, pump) seated and locked. Concrete pump pipe couplers with both clip and safety pin engaged. Electrical connections via CEE plugs, not "twist-and-tape".
   Acceptable whenNo leaks at any joint. Strain reliefs intact. Pipe couplers both clipped and pinned. Electrical connections via 16/32A CEE form (or equivalent), no exposed conductors.
   StandardPUWER 1998 reg.5. Electricity at Work Regs 1989. BS 7671 (where it applies). DSEAR (LPG/petrol). HSG47 (services).
   Common defectsAir hose coupler missing safety clip — whip risk on disconnectConcrete delivery pipe coupler clip in place but no R-pin — vibrates loosePower cable taped to the chassis with abrasion already startingGenerator output connected via screw terminals into a domestic plug — non-compliantWelder return clamp on rusty steel — bad earth, arc-strike on the gas line
4. 4.

   Guards in place
   What to look forBelt/flywheel guards on engines, fan guards, coupling guards on pump drives, agitator grilles on concrete pump hoppers. All present, secured with the correct fasteners, not removed for "easier access".
   Acceptable whenAll guards present per manufacturer drawing. Fasteners match originals (e.g. shoulder bolts not generic M8). Interlocked guards, where fitted, kill drive when opened.
   StandardPUWER 1998 reg.11 (dangerous parts of machinery). BS EN ISO 14120 (guards general). Manufacturer's drawings.
   Common defectsBelt guard left off after an inspection — mesh leaning looseFan guard with a gap to fit a hand into — substandard repairConcrete pump hopper grille interlock bridged with a magnetCoupling guard cracked from a knock and tied with cable tiesGenerator alternator end cover missing — fan exposed
5. 5.

   Emergency stop working
   What to look forTest E-stop function before the work starts. Push (palm-style mushroom button) — engine cuts immediately. Pull/twist to reset. On concrete pumps, all auxiliary E-stops (hopper, hose end, remote) tested in turn.
   Acceptable whenEngine/pump cuts within seconds of E-stop activation. Reset only via deliberate twist/pull, not by moving a control lever. All remote E-stops effective.
   StandardPUWER 1998 reg.15 (stop controls). BS EN ISO 13850. Manufacturer's daily check.
   Common defectsMushroom seized in — either always activated or unable to activateE-stop wired to a relay that doesn't cut fuel solenoid — engine continuesRemote E-stop on concrete pump cable broken at the strain reliefReset by simply moving the throttle — non-compliant logic
6. 6.

   Exhaust fumes vented away from occupied areas
   What to look forExhaust outlet directed away from cabins, intakes, doorways, stairwells, basements, and trenches. CO and NOx accumulate in low/enclosed spaces. Where the unit is in a courtyard or partially enclosed area, ducted exhaust extension fitted. CO monitor in the area where work is ongoing.
   Acceptable whenExhaust ≥3m from any opening, never venting into enclosed space. Ducting (where used) heat-rated, secure, no cracks. CO monitor active where the unit runs near occupants.
   StandardCOSHH 2002 (exhaust as substance hazardous to health). HSG258 controlling airborne contaminants. Manufacturer's installation guidance.
   Common defectsGenerator parked outside a site cabin door — fumes drawn in by extract fanExhaust extension cracked — fumes leak inside the canopyConcrete pump in a basement — no forced ventilationCO monitor battery flat — no warning of accumulationSite rule of "10m setback" not enforced when space is tight
7. 7.

   Drip tray / bunding in place
   What to look forIntegral bund (modern canopies) sealed and clean — capacity ≥110% of the largest tank. Removable drip tray under any external connection (fuel cap, hose). No standing water in the bund (will reduce capacity). For non-bunded units, an external double-skin tank or kit-based drip tray to capture any release.
   Acceptable whenBund holds 110% of largest tank. Sealed and dry (no leaks out). External drip tray under any external connection. Spill kit accessible.
   StandardControl of Pollution (Oil Storage) (England) Regulations 2001 (where stored quantity triggers). EA PPG2 (above-ground oil storage). CIRIA C736.
   Common defectsBund full of rainwater — capacity goneDrain valve in the bund left open — bund leaks dryDrip tray cracked through forklift contactRefuelling done outside the bund — drips straight onto groundSpill kit removed for another job, not replaced
8. 8.

   PAT test current (electrical equipment)
   What to look forWhere the unit has electrical components or connections (generator output sockets, controls, charging) — PAT label in date. Visual condition of plugs, sockets, leads. Earth bonding visible (e.g. on generator chassis to earth spike).
   Acceptable whenPAT (in-service inspection) in date per the IET Code of Practice intervals. Class I bonding intact. Earth electrode (TT generator) installed where required.
   StandardElectricity at Work Regs 1989. BS 7671. IET Code of Practice for In-service Inspection and Testing (5th ed.). HSG107.
   Common defectsPAT label missing — assume out of testGenerator earth spike not installed — TT system unprotectedOutput socket cracked at the casing — IP rating lostCable repaired with insulation tape rather than a glanded jointTest sticker covering damage — done as a paperwork exercise

Questions people ask