Guidelines for the safeand responsible handlingof bituminous products

SABITA MANUAL 82nd Edition

December 2003

Published bySabitaPostnet Suite 56Private Bag X21Howard Place 7450

2Manuals published by Sabita

Manual 1 Construction of bitumen rubber sealsManual 2 Bituminous products for road constructionManual 5 Manufacture and construction of hot-mix asphaltManual 7 SURF+ Economic warrants for surfacing roadsManual 8 Guidelines for the safe and responsible handling of

bituminous productsManual 9 Bituminous surfacings for temporary deviationsManual 10 Appropriate standards for bituminous surfacingsManual 11 Labour enhanced construction for bituminous

surfacingsManual 12 Methods and procedures - Labour enhanced

construction for bituminous surfacingsManual 13 LAMBS - The design and use of large aggregate

mixes for basesManual 14 GEMS - The design and use of granular emulsion

mixesManual 16 REACT - Economic analysis of short-term

rehabilitation actionsManual 17 The design and use of porous asphalt mixesManual 18 Appropriate standards for the use of sand asphaltManual 19 Technical guidelines for bitumen-rubber asphaltManual 20 Sealing of active cracks in road pavementsManual 21 ETB: The design and use of emulsion treated basesManual 22 Hot-mix paving in adverse weatherManual 23 Bitumen Hauliers Code: Guidelines for loading

bitumen at refineries

Training Guides

TRIP Technical Recommendations in PracticeHMA Hot-mix Asphalt Training SeriesHSE Health, Safety and Environmental Guidelines for

bitumen and coal tar productsCEP Councillor Empowerment Programme workshop notes

and CD

Technical Guideslines

TG1 Technical guidelines: The use of modified bindersin road construction

TG2 Interim technical guidelines: The design and useof foamed bitumen treated materials

3Sabita Video Training Aids

Video series on testing of bituminous products

Bitumen

AV-1 Penetration test / Softening point (ring and ball)AV-2 Spot test / Rolling thin film oven testAV-3 Brookfield viscosity / Ductility

Bitumen Emulsion

AV-4 Saybold furol viscosity / Water content of emulsionsAV-5 Sedimentation value of emulsions / Residue on

sievingAV-6 Coagulation value with chippings / Coagulation

value with Portland cementAV-7 Binder content of slurry / Particle charge test

Hot-mix Asphalt

AV-8 Optimum binder content for asphaltAV-9 Marshall testAV-I0 Binder content / Moisture contentAV-11 Static creep test / Immersion indexAV-12 Rices density and binder absorption/Bulk relative

density and voids

Bitumen Rubber

AV-13 Ball penetration and resilience test / Dynamicviscosity

AV-14 Compression recovery / Flow testAV-15 Bulk density of crumb rubber / Grading and loose

fibre test of crumb rubber

Video series on Blacktop Roads

AV-21 Blacktop roads for reconstruction anddevelopment

AV-22 Blacktop surfacing and repair (with InstructorTraining Manual)

AV-23 Pavement surfacing and repairs for blacktop roads

Video series on Hot-mix Asphalt

AV-25 ManufactureAV-26 PavingAV-27 Compaction

ACKNOWLEDGMENTS

Sabita gratefully acknowledges the valuable contribution of themembers of the Road Pavements Forum (RPF) Binder DistributorTask Team in compiling this guideline document for the industry.The Task Team consists of:

Trevor Distin (Chairman) Colas SA

Wally Bennett KZN DoTDouglas Judd WSP SA Civil and Structural

EngineersSimon Kotze Vela VKE Consulting EngineersPhilip Khn Power Construction RoadsTheuns Lewis GautransKobus Louw Colas SAGerry Reitsma Black Top SurfacesDennis Rossmann SANRALDenzil Sadler TosasSteven Single Spray Pave

Some of the material incorporated in this document is based onguidelines developed by CONCAWE, the Refined BitumenAssociation (RBA), Eurobitume, Austroads, the New ZealandPavement and Bitumen Contractors Association (NZBCA) and theAustralian Asphalt Pavement Association (AAPA). Their permissionto do so is gratefully acknowledged.

Considerable effort has been made to ensure the accuracy andreliability of the information contained in this publication.However, neither Sabita nor its members can accept liability forany loss, damage or injury whatsoever resulting from the use ofthis information. The content of this publication does notnecessarily represent the views of any member of Sabita.

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Preface

The scope of this manual on health, safety and environmentalaspects, which replaces Sabitas Manual 8: Bitumen SafetyHandbook, has been updated in accordance with current legislationand extended to incorporate international best practice in respect ofworker safety and health, as well as environmental conservation.

As it is now globally accepted that the use of coal tar products asbinders for road construction may introduce undue health andenvironmental hazards, their use is no longer considered bestpractice. Sabita therefore does not endorse their application, andreference to this material is excluded from this document.

Note that, in accordance with global nomenclature, the termbituminous refers exclusively to binders and mixtures of bindersand aggregate containing bitumen. The term does not include tarproducts produced by the pyrolysis of coal.

This new edition has been further expanded to include all aspectsinvolving the Safety, Health, Environmental, Risk and Quality(SHERQ) requirements related to the manufacture and application ofbituminous binders.

In general, the structure of the document is based on the concept oflisting hazards associated with various operations in the handling ofbituminous products, and offers precautionary procedures tominimise the risk of exposure to such hazards.

The document is intended as a reference and training manual for allpersons involved in the handling, storage and transportation ofbituminous binders used in road construction. It should be read inconjunction with instructions issued by site supervisors, and withthose of plant operating manuals, all of which should be observedby users of bituminous binders. The standards of worker health,safety and environmental conservation are constantly under reviewin the bituminous products industry as the state of knowledgeincreases. This guideline reflects the state of knowledge andSHERQ procedures applicable at the time of publishing.

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This manual is published under the auspices of Sabitas Centre forOccupational Safety and Health and Environmental Conservation(COSHEC) and incorporates the findings of the RPF Task Team onBinder Distributors.

Reference should be made to Sabitas publication Health, Safetyand Environmental Guidelines for bitumen and coal tar products(revised edition July 1998) for more comprehensive information onhealth, safety and environmental conservation proceduresassociated with the use of bitumen and bituminous products.

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Health, safety and environment policy

Sabita encourages its members to carry out their business in such away that the health and safety of their employees, and of otherpersons both on and near their sites, is not endangered, and thatthe quality of air, water and soil is protected for the continuingbenefit of all ecosystems.

Accordingly, in adopting a responsible integration of environmentaland economic considerations, members are urged to design,operate and maintain their facilities in such a manner as to:

avoid harm or injury to the health of employees or otherpersons on their premises, or those living in the vicinity;

avoid damage or loss to the environment; ensure the manufacture of quality products, and promote the

safe and efficient delivery of those products; and implement the best available technology to limit emissions,

noise and the production of waste.

Through visible management, commitment and the contributions ofemployees, these members strive for continuous improvement intheir performance under the health, safety, and environmentalrequirements of the State and the industry, and compliance with therelevant legislation. It is anticipated that every employee of Sabitasmembership, and those on their premises and work sites, willcomply willingly with this policy.

Sabita members not directly involved in the manufacture, storageand transportation of bituminous binders should also note thewide-ranging benefits resulting from the implementation of safe andhealthy working practices.

PROTECTING THE ENVIRONMENT IS AN OBLIGATION,

NOT A CHOICE

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Contents

1. INTRODUCTION

2. HAZARDS2.1 Material Safety Data Sheets (MSDS)2.2 Hazards from high temperatures2.3 Hazards from the flammable nature of the product2.4 Hazards from noxious vapours

3. PERSONAL PROTECTION3.1 Prevention of contact3.2 Personal Protection Equipment (PPE)3.3 Personal hazards3.4 Personal hygiene

4. FIRST AID4.1 Treatment of burns4.2 Eye burns4.3 Circumferential burns4.4 Mouth-to-mouth resuscitation4.5 Basic steps for mouth-to-mouth resuscitation4.6 First Aid Kit4.7 Cardio-pulmonary resuscitation

5. HEALTH ASPECTS5.1 Bitumen5.2 Cutback bitumen5.3 Modified bitumen5.4 Aromatic oils5.5 Bitumen additives

6. PRECAUTIONS6.1 Fire prevention6.2 Fire protection preparation6.3 Types of fires6.4 Fire-fighting6.5 Fire-fighting equipment

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1212121315

1717171919

2121222222232425

262626272727

282828283032

7. ENVIRONMENTAL ASPECTS7.1 Transporting and storage of bituminous binders7.2 Application of bituminous products on site7.3 Spillages7.4 Flushing procedures7.5 Disposal procedures

8. LEGAL RESPONSIBILITIES8.1 Duties and responsibilities8.2 Vehicles and transportation8.3 Accidents/Incidents8.4 Product handling8.5 Environment8.6 Risk Management

9. PROCEDURES9.1 Care of equipment9.2 Equipment checks9.3 Product handling and sampling9.4 Heating9.5 Loading and offloading9.6 Transportation9.7 Blending9.8 Loading of different products9.9 Storage and storage temperatures

10. TRAINING

11. GLOSSARY

APPENDICES

1. Contents of First Aid Kit2. Treatment of bitumen burns3. Emergency telephone numbers4. Risk assessment form and risk assessment matrix5. Vehicle check list for safety equipment and

documentation6. Tremcard7. Flammability of cutbacks

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1. INTRODUCTION

Worker health and safety, from both physical and chemical hazards,should be assured at all times. This manual considers the hazards towhich workers handling bituminous binders may be exposed, andthe risks associated with these hazards including various aspectsof personal safety, precautions to be taken when working withbituminous binders, health aspects and environmentalconsiderations.

The European Inventory of Existing Commercial ChemicalSubstances (EINECS) makes specific reference to the concepts ofhazard and risk:

Hazard : the inherently dangerous properties of asubstance

Risk : the probability of the hazardous propertiesof a substance causing harm to people orthe environment

Besides compliance with environmental legislation and theimplementation of preventative measures, it must be understoodthat the cradle to grave concept applies should environmentaldamage take place. Emergency procedures for bitumen burns arelisted in Appendix 2, and are duplicated on the Bitumen Burnstags inside the back cover of this manual. These tags are intendedto accompany a burns victim to a formal medical facility.

Appendix 3 should be used for recording emergency telephonenumbers relevant to your area.

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2. HAZARDS

2.1 Material Safety Data Sheets (MSDS)

The suppliers remain responsible for drawing up material safetydata sheets (MSDS) for each product according to theregulations for hazardous chemical substances.

However, the following environmental compatibilityguidelines should be observed:

The suppliers MSDS is the primary source of safe handlingadvice for the specific product;

The MSDS should address the safety of both personnel andthe physical environment;

The MSDS should provide an indication of each class of fumesthat may be generated at application temperatures;

The supplier will be liable for the consequences of negligentlyincorrect information or deliberate omission of known facts;

The user is liable for the consequences of the incorrect use ofapplication techniques;

The user has an overriding responsibility to ensure that workpractices minimise exposure to fumes and contact withproduct.

2.2 Hazards from high temperatures

The most significant hazard associated with bitumen is heat burns.Bitumen is normally handled at temperatures above 1500C. Modifiedbitumens are handled at temperatures of up to 2100C.

Skin contact with bitumen at these high temperatures will causesevere burns and shock, which can be fatal.

Storage tanks and pipelines containing hot bitumen and heated bysteam, hot thermal oil or petroleum fired burners must be shieldedor lagged.

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Note

Always wear the required Personal Protection Equipment(PPE), including overalls, heat resistant gloves, face shield

and safety boots when working with bitumen.

Bitumen foams in the presence of water as the temperature ofbitumen is usually above the boiling point of water. Bitumen heatedin the presence of small quantities of water forms foam that canquickly expand and cause the tank to overflow. The expanding foamcan quickly reach hot objects or burners, and cause the bitumenand equipment to catch fire.

Ensure all tanks are free of water before loading bitumen. Additivesand extender oils must also be checked for the presence of waterbefore adding to bitumen.

2.3 Hazards from the flammable nature of theproduct

At or below the maximum fuming temperature, penetration gradebitumen will remain below its flashpoint and only some solventevaporation will take place. However, bitumen cutbacks are usuallyhandled at temperatures above the flashpoint of the cutter orsolvent. Some cutters have a flash point as low as 380C, and are afire and explosion hazard, particularly on warm days or duringheating.

The vapours in the closed space above a hot cutback are invariablyflammable, but almost always in too high a concentration to beexplosive. It is much safer to aim for an over-rich vapourconcentration than to risk lowering it into the explosive range byopening a hatch.

Consequently, wherever practicable during transfer operations, tankhatch covers should be kept closed, or at least lowered, to preservea vapour-rich atmosphere above the binder. As a precaution againstany sudden pressure build-up (from, say, a trace of water), thesehatches must be latched shut.

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Note

The temperature of bitumen in storage is normally above theboiling point of water. Water should not be allowed tocontact hot bitumen as this will cause boil-over and

possible fire or explosion.

Note also that in the region where escaping vapour starts to mix withair, extreme care should be exercised, since this is where themixture may become explosive. Further away from an exit, thevapour will be too dilute to ignite.

It is important that the precautions and instructions contained in thismanual be strictly observed to prevent vapours igniting.

It is necessary to isolate any source of ignition in areas where thereis likely to be a concentration of flammable vapours, e.g. in theproximity of loose or open manhole covers, and at the ends ofhoses.

Smoking, naked lights or the use of cell phones is not permittedwithin 15 m of any vehicle when filling or circulating bitumen orchanging LPG bottles. Gas burners must be fitted with safetynozzles.

Cutback bitumen will readily ignite or explode in the presence of aflame, spark or hot object. Fire or explosion can occur if LPGburners are used to heat pipelines or pumps when handling cutbackbitumen.

The application of excess heat (e.g. welding torch) to bitumen cancause thermal cracking and the evolution of flammable vapour.Open flame heating may only be used to free plugged bitumenvalves as a last resort, and the vehicle must be in a clear area.

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Figure 1: Keep any source of ignition away from potential fire sources.

Suitable foam, dry powder or CO2 fire extinguishers must be onhand.

Always dip tanks before lighting burners to make sure there is aminimum of 200mm of bitumen above the burner flues or heatingcoils.

See also Appendix 7 Flammability of Cutbacks

2.4 Hazards from noxious vapours

In confined spaces, vapours from bitumen products can be a healthhazard and may displace oxygen and cause suffocation. Potentiallyhazardous concentrations of hydrogen sulphide may be present in

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Figure 2: No surface of the heating flues should be exposed in the vapourspace as this could cause a dangerous explosion

Note

Safety precautions must be followed to prevent fumes fromflammable products coming into contact with sources ofignition!

Avoid use of open flames or sparks near flammableproduct;

Do not smoke or use cell phones within 15m offlammable product;

Do not heat products above the recommended temperatures; Fumes must blow downwind from gas burners.

the vapour space of bitumen storage tanks. Because hydrogensulphide deadens the sense of smell, the familiar bad eggs odourcannot be relied on to warn of the presence of hazardousconcentrations. Persons entering spaces where bitumen has beenstored should wear full protective clothing and fresh air breathingmasks.

Persons are not permitted to enter any tank without ensuring that ithas been degassed and ventilated. Confined space entry permitconditions must be enforced at all times.

In open areas, vapour given off from bitumen can have anunpleasant odour. Exposure needs to be minimised.

The higher the temperature the higher the concentration of fumes.The use of modified binders at high temperatures, and the fumesgiven off by the modifiers and oils in use, needs to be carefullymonitored. The manufacturers recommendations as set out in theMaterial Safety Data Sheets (MSDS) must be followed.

Vapours given off by cutback bitumen cutters and additives are toxicand exposure must be controlled. Adhesion agents used in bitumenalso presents possible hazards as they irritate the skin, and whenheated produce an irritant vapour. The necessary care must betaken and the manufacturers recommendations must be observed.

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Note

Fumes may be toxic:

Locate equipment and plant operations so that odoursand other irritations to workers and the public areminimised;

Wear appropriate respiratory protection equipment whenworking in poorly ventilated spaces;

Provide first aid to workers affected by fumes; Follow procedures given in Material Safety Data Sheets

(MSDS); Dont breathe fumes from open hatches, vents, etc.

3. PERSONAL PROTECTION

3.1 Prevention of contact

Operations for the movement or transfer of bitumen should be inclosed and controlled systems.

Repairs to cold bitumen equipment may involve skin contact withcold bitumen, emulsions or cutbacks. In these instances, oilinsoluble barrier creams may be applied to exposed parts of the skinprior to working with the bitumen. The skin should be thoroughlywashed after being exposed to contact with bitumen or aftercompletion of the work. Petrol or solvents must not be used to cleanexposed parts of the skin as this can cause dermatitis.

3.2 Personal ProtectionEquipment (PPE)

Because of the danger of serious burns,and for protection against inhalation offumes, the following safety equipment andclothing must be available. All personneland site visitors are required to use thenecessary safety equipment.

Eye wash kits; Container of clean, fresh water

(approximately 25 litres); First aid kit; Overalls or long trousers and long

sleeved shirts appropriate to thehazard e.g. acid resistant or heatresistant. (The wearing of shorts andsandals could result in serious injuryand is NOT recommended). Thesleeves of overalls must be worn

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Note

It is stressed that barrier creams are not a substitute forprotective clothing and gloves.

Figure 3: Personal ProtectionEquipment (PPE)

secured at the wrists and the legs of overalls must be wornoutside the boots;

Gloves. Thick soft leather or heavy-duty PVC gloves must beworn when handling hoses, valves, hatches and dips.Impervious gloves must be used when handling oils, solventsand additives;

Eye and Face Shields. Full-face type eye protection i.e. heatresistant racing balaclava, must be worn when:- disconnecting hoses;- loading / offloading;- lighting burners;- dipping tanks;- handling additives;- blending; or- sampling.

SABS approved respirator must be used when handlingcutbacks or modified binders;

Leather apron. Added protection is offered by wearing aleather apron when there is a possibility of coming into contactwith hot bitumen;

Protective footwear with toe protection. Heavy working bootsor sturdy shoes are necessary. Under no circumstancesshould sandals, thongs or moccasins of any kind be worn;

Reflective safety vests when working on construction sites.

When spraying, asprayer operatormust also wearprotective gloves,overalls andappropriate safetyvests for visibility. Arespirator is alsorequired whenspraying cutbacksor modified binders.

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Note

Polyester and other combustible materials, which can meltand stick to the skin, must not be used for protective

Figure 4: Wear full protective clothing

3.3 Personal hazards

Splashes and burns

All bitumen burns should be treated with immediate firstaid as set out in Section 4.

Fumes

Fumes from hot bitumen and additives may be toxic.Exposure and inhalation should always be minimised. Referto Section 2.3.

When working in poorly ventilated or confined spaces, e.g.tanks, special procedures must be followed. Cleaning of theinterior of tanks and tankers must be carried out in accordancewith legislation. Only personnel trained accordingly andwearing the appropriate breathing apparatus are permitted towork inside tanks.

Skin exposure

Avoid direct and prolonged skin contact with bitumen, itsfumes and/or additives.

Impervious gloves must be used when working with cutters,stone precoating fluid, adhesion agents and extender oils.

Materials Safety Data Sheets (MSDS) must be checked forspecific working procedures.

3.4 Personal hygiene

A high level of personal hygiene should always be observed tominimise skin exposure and risk of ingestion of bituminous materialsand additives.

In addition to the required Personal Protection Equipment,bituminous binder workers should be provided with appropriatebarrier creams and washing facilities.

The application of barrier creams to exposed skin, before workingwith bitumen, assists with subsequent cleaning should accidentalcontact occur. However, barrier creams are not a substitute forprotective clothing.

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Bitumen contamination should be removed from the skin bythoroughly washing with hand cleaner and thereafter with soap andwater. Paraffin is an irritant to the skin and should be used with careand preferably under supervision. Degreasing fluids should not beused.

Wash hands before eating and drinking and before going to thetoilet. Overalls must be changed regularly; heavily soiled clothingmust not be worn.

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4 First Aid

First Aid can be defined as the initial preservation of life and thepreliminary management of pain and injury until formal medicalattention or treatment can be obtained. First Aid is not a substitutefor prompt and appropriate medical attention or treatment. Adequatenumbers of people trained in First Aid must be on site duringhazardous operations. It is recommended that each driver/operatorbe trained to at least Level 1.

Suitable contents of a first aid kit are listen in Appendix 1.

Appendix 2 covers guidance notes for first aid and medicalpersonnel. The content of this guideline is also contained in aBitumen Burns tag, five copies of which are packed in the sleeveinside the back cover of this manual. The tag should be tied orpinned onto the clothing of the patient before transport to a medicalfacility.

4.1 Treatment of burns

Immediately cool the affected area by drenching in or flushingwith cold, preferably running water;

Keep the victim comfortable and reassured to prevent furthercomplications;

Keep the victim warm and provide plenty of fresh air; Seek medical attention and attempt to advise the doctor or

hospital in advance:- When the injured person will arrive;- The extent or seriousness of the injury (including

assessment of burn damage where possible);- When hot bitumen completely encircles a limb or other

body part;- When an eye burn has occurred.

Attach a Bitumen Burns tag (inside back cover) to thepatients clothing in a prominent position before transport todoctor or hospital;

Do not remove or cut away clothing over burnt areas; Do not pull away clothing which has stuck; this may cause

further injury; Do not break blisters or remove solid bitumen from the skin;

they both protect and aid rapid healing;

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Do not, under any circumstances, apply ointments, oils, butter,solvents or other substances to a burn.

4.2 Eye burns

If hot bitumen has entered an eye, it should be flushed with sterilewater for 20 minutes. Thereafter the eye is to be padded and thepatient immediately hospitalised. Again no attempt should be madeby unqualified personnel to remove the bitumen.

4.3 Circumferential burns

When hot bitumen completely encircles a limb or other body part,swelling of the burned tissue may have a tourniquet effect. Thebitumen should be softened as described in Appendix 2, and thepatient referred urgently for medical attention.

4.4 Mouth-to mouth resuscitation

What to do if breathing stops (the following instructions areprovided as a refresher for those trained in First Aid.):

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Basic steps for mouth-to-mouth resuscitation

1. Gently tilt the head well back, open the mouth and ensure theairway is open;

2. Use thumb and index finger to pinch the nose tightly closed;3. Take a full breath, place

your lips over thepatients lips and make agood seal. Blow into themouth until the chestrises. Give two effectivebreaths;

4. Look to see if the patientschest rises. Check thecarotid pulse in the neck;

5. If there is no pulse startcardio-pulmonaryresuscitation (CPR) (seepage 25);

6. If there is a pulse thenbegin the detailedprocedure listed below.

Give one breath every 3seconds until breathingrecommences or formalmedical assistance arrives.

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1

2

3

4

Figure 5. Mouth-to-mouth resuscitation.(Graphics by courtesy of St. John

Ambulance)

Detailed procedure

Place the patient on his back. Open the mouth and check for anyobstructions.

If obstructed, turn the patient onto his side and clear the airwayusing your fingers (wearing disposable gloves), then place thepatient on his back.

Tilt the patients head backwards by placing the hand high on theforehead. At the same time, support the chin with the thumb andindex finger of the other hand. Lift the jaw forward and support whilstopening the patients mouth slightly. Keep the tongue clear of theairway, and check for breathing. If the patient is not breathingproceed as follows:

1. Pinch the patients nostrils closed between your thumb andforefinger, keeping the head tilted back. Open your mouth andtake a deep breath;

2. Cover the patients mouth with your mouth (if possible, insert adevice to prevent direct skin contact) making an airtight seal.Blow into the mouth to inflate the lungs;

3. Look to see whether the patients chest rises. The rise of thechest should be similar to that of normal breathing. Listen for theair to be expelled;

4. Place your mouth back over the patients mouth and give fourfull breaths quickly, checking the chest between inflations;

5. Check whether the carotid pulse is present. If it is, this meansthe heart is beating and circulation is functioning. Continue withmouth-to-mouth resuscitation one breath every threeseconds. Check the carotid pulse and breathing after oneminute and every two minutes thereafter.

4.5 First aid kit

It is recommended that a first aid kit containing the minimum itemslisted in Appendix 1 be part of the Personal Protection Equipment(PPE) for every site/vehicle.

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4.6 Cardio-pulmonary resuscitation

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Figure 6. CPR (Graphics by courtesy of St. John Ambulance.)

The CPR procedure described below should only beconducted by suitably qualified personnel who have

received first aid training up to Level 2

ASSESS CASUALTYFOR CIRCULATION

Look, listen and feel for breathing,coughing, movement, normal colouror other signs of life for no morethan ten seconds.

POSITION HANDS FORCHEST COMPRESSIONS

Place the middle finger of yourlower hand over the point where thelowermost ribs meet thebreastbone.

1

2

Place your index fingerabove it on the breastbone;

Place the heel of your other handon the breastbone; slide it downto meet your index finger;

Place the heel of your of your firsthand on top of the other hand andinterlock your fingers.

GIVE CHEST COMPRESSIONS ANDMOUTH-TO-MOUTH

Lean well over the casualty with your armsstraight;

Press down vertically on the breastbone anddepress the chest by about one-third of its depth;

Complete 15 chest compressions, aiming forabout 100 per minute;

Give two breaths of mouth-to-mouthventilation (see Page 23);

Continue alternating 15 chest compressionswith two breaths of mouth-to-mouthventilation until formal medical assistance arrives.

If there are no signs ofcirculation, begin CPRimmediately.

3

Slide heel of hand down

Interlock fingers

5. HEALTH ASPECTS

5.1 Bitumen

The question of the potential adverse effects of the use of bitumenon health and the environment is the subject of ongoing research inEurope and the United States.

Generally, it may be stated that the health risk from working withbitumen increases with the temperature of the product, the principalhazards being burns or inhalation of fumes. The greatest risk, by far,is burning of the skin.

Some agencies, particularly in the US, have raised the issue of thepotentially harmful effects of very low concentrations of PolycyclicAromatic Hydrocarbons (PAHs) in fumes. PAHs occur in crude oilsbut are present in lesser quantities in bitumens. These PAHs areconsidered carcinogenic. The concentration of PAHs in bitumenfumes at normal road application temperatures is extremely low andno studies to date have demonstrated any significant health risk toworkers exposed to these fumes.

At very high temperatures (2300C) not normally associated with roadbuilding, or with the addition of solvents, cutters or aromatic oils, theexposure to volatiles is increased. The specific exposure conditionswould relate to the type of additive being used, its composition andthe conditions of the working area itself. Information on the handlingconditions for these additive products must be obtained from thesuppliers.

The principal routes of worker exposure are through inhalation andskin contact. Worker exposure depends on: PAH emission rate,operator behaviour, protective measures taken, working conditionsand influences from outside, such as weather.

5.2 Cutback bitumen

As this group of binders consists of bitumen and hydrocarbonsolvents, they differ significantly in their behaviour and compositionfrom road grade or oxidised bitumen. The effects of exposuredepend largely on the types of solvents or cutters used in theirmanufacture.

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Studies have shown that the application of cutbacks may increasethe risk of skin cancer. Eliminating skin contact and working inwell-ventilated conditions will reduce the risk significantly.

5.3 Modified bitumen

Modified bitumens contain special additives such as elastomers(including crumbed rubber) and plastomers. Although thesesubstances are not normally considered health hazards, the additionof extender oils and additives, coupled with higher temperaturesthan those associated with conventional binders, could producetoxic fumes. The manufacturers recommendations must be adheredto.

5.4 Aromatic oils

Aromatic oils are used in small quantities in the manufacture ofcertain modified bitumen products, and may contain highconcentrations of harmful PAHs. Extra precautions should be takento reduce the exposure of workers to fumes and skin contact.

Information on the composition and handling conditions for theseproducts must be obtained from the suppliers.

For further information on health, safety and environmental issues,contact Sabita.

5.5 Bitumen additives

Certain additives used as adhesion agents are toxic. Skin contactand inhalation must be limited and the manufacturersrecommendations, as set out in the MSDS, must be followed.

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6 PRECAUTIONS

6.1 Fire prevention

A disorderly or dirty workplace can introduce its own hazards inaddition to those associated with bituminous products and theirhandling. Good housekeeping is the first principle of fire prevention:

Keep all areas clear of non-essential equipment and materials; Store and handle flammable liquids carefully, in accordance

with regulations; Install an adequate number of the right type of fire

extinguishers; Keep fire extinguishers in good working order; Keep all equipment clean; Ensure that all equipment is in its assigned place and that no

loose or unnecessary tools are left lying about in theworkplace.

6.2 Fire Protection Preparation

Layouts of plant should provide access for mobile fire appliances. Itis wise to co-operate and pre-plan with the local fire brigade whenplanning and preparing for the possibility of fire. Sufficient fireextinguishers must be available at all times.

At least two dry chemical and/or foam fire extinguishers must beavailable on sprayers.

Procedures in the event of a fire and fire-fighting equipment drillshould be established and known to all persons. It should bepractised at regular intervals and include night-time drills.

6.3 Types of fires

Fires are divided into different classes, the more commonlyencountered being classified as:

Class A Fires

The combustible materials involved in this class of fire are usuallyorganic materials such as grass, wood, paper, textiles, etc.: This

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class of fire is usually easy to extinguish by either quenching orcooling with water.

Class B Fires

Combustible liquids such as petroleum products (petrol, diesel oil,paraffin, grease, oils, bitumen etc.), and flammable and combustiblechemicals, make up the fuel of this class of fire. When fighting ClassB fires the exclusion of oxygen by smothering is usually employed.

Class C Fires

This class of fire is essentially either a Class A or B fire that involveslive electrical equipment. The reason for the separate classificationis that no extinguishing agent containing water can be used to fighta fire involving electricity.

Class D Fires

This class of fire involves metals such as magnesium, aluminium,titanium and potassium, and is relatively difficult to extinguish.Standard equipment such as a gas-charged dry chemicalextinguisher cannot be used as the force of the discharge powderdisturbs the surface of the burning metal and may intensify theblaze.

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Figure 7. Anatomy of a fire (From Asphalt Institute)

6.4 Fire-fighting

What to do when a fire starts:

Keep calm and think rationally; Know how to select and use your fire extinguisher; Attack the fire cautiously and sensibly; Call the fire brigade.

If the fire gets too large or fierce, and the extinguishers becomeineffective, leave the area.

Once the methods used to extinguish the fire have succeeded,immediately cover the burnt area with sand and if practical, hosedown with water. This will help to keep out the oxygen and cool itdown, preventing re-ignition.

6.4.1 Fire Extinguishers

There are four main classes of fire extinguishers in general use.

1. Water extinguisher;2. Carbon dioxide extinguisher;3. Dry chemical powder extinguisher;4. Vaporising liquid extinguisher.

Three basic ways of extinguishing a fire:

6.4.2 Quenching

Water is used to cool the surface of the fuels to a temperaturebelow the flash point of the particular fuel. Fuels with a lowflashpoint (petrol) cannot be cooled sufficiently with water to stopthe formation of vapours.

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Precautions

Water must not be used when fighting a fire in a bitumentank. However, a water spray may be used to cool adjacent,

intact tanks.

6.4.3 Smothering

The fire is deprived of the oxygen needed to burn. CO2 or foamcuts off the air supply.

6.4.4 Starving

This is achieved by shutting off the supply of fuel to the fire.

Bitumen fires

Foam for extinguishing a bitumen tank fire should be graduallyspread as a blanket over the surface of the burning liquid. This maybe done by directing it against part of the tank or other obstruction.Indiscriminate application of foam will not extinguish the fire.

The fire may re-ignite when dry powder or CO2 extinguishers havebeen used. It is recommended that this treatment be followed by afoam application.

Tyre Fires

With moving vehicles, there is always a danger of tyre fires. Thesefires often re-ignite and need application of foam or water to cool therubber as dry powder and CO2 extinguishers will not be effective.

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Remember

Once the fire is out, re-ignition can be prevented if thefollowing procedures are carried out.

Class A fires Use water to cool burn areas or smotherwith sand.

Class B fires Smother burn area with sand or gravel toexclude oxygen and then cool down theequipment with water, if necessary.

Class C fires Cut off power.

Note

When high-pressure water is available, such as in a refinery,water may be used, provided it is applied in the form of afine spray through fog or diffuser nozzles.

Figure 8. Whenever possible, a fire should be fought from upwind.

6.5 Fire-fighting equipment

First aid and fire-fighting equipment should be provided andmaintained as required in the Plant Manual for the particular unitconcerned.

Typical fire fighting equipment and deployment

1. Fire extinguishers

Of the many types of fire extinguishers available, the dry chemicalstored pressure type is recommended for use on all items of plantand equipment, including camp accommodation units. If theextinguisher is discarded for any reason whatsoever or the seal isbroken, it must be replaced with a serviced and sealed unit as soonas possible after returning to base.

2. On sprayer:

Dry chemical and/or foam, stored pressure fire extinguishers,preferably 2 X 9kg, one mounted on either end of the truck;

One dry chemical stored pressure fire extinguisher (2 kg) inthe cabin;

A shovel for spreading sand is desirable.

3. Around Bitumen Tanker Site

4 X 9kg dry chemical, stored pressure fire extinguishers; Heap of loose sand or gravel and shovels (preferable).

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Wind direction

7. ENVIRONMENTAL ASPECTS

Legislation has become stricter regarding the protection andpreservation of the environment. Preventative measures must be inplace where bituminous binders and vehicles carrying suchproducts can cause damage to the environment.

The viscous nature of most penetration grade binders ensures thatdirect contact with the environment results in minimal contamination.Volatile materials are released in very small amounts on heatingand, under normal use and storage, pose negligible threat to theenvironment. Cutback bitumens and bitumen emulsions have thepotential to cause significant pollution to the environment.

There is at present no evidence to suggest that long-term emissionsinto the atmosphere have any significant detrimental effect.

7.1 Transporting and storage of bituminous binders

Legislation defines how the product is to be transported, andspecifies requirements such as labelling, packaging, transportation,storage and disposal (SABS Codes 0228 & 0229).

Drivers of vehicles transporting hazardous goods in bulk arerequired by law to have a Public Driving Permit for DangerousGoods (referred to as the PDPDG license).

The supplier ultimately remains responsible for any adverseconditions caused by bituminous products to the environment.

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Precautions

Prevent spillage of bituminous materials and oils; Prevent seepage of washing and flushing materials into

water sources; and Remove all surplus and/or contaminated materials from

site and dispose of them in an environmentallyacceptable manner. This includes products used forflushing purposes.

Transport and application vehicles often operate far from base, thuspre-departure vehicle inspections are essential to minimise incidentson site, and to ensure that the driver is adequately equipped andtrained to deal with any incident.

Over and above the checklist, specific focus can also be directed tothe following:

1. In the cab

In terms of current legislation all relevant documents related tothe delivery must be stored in an orange coloured box, affixedin a conspicuous position. The contents must include MSDS,route plan, tremcards, licenses and permits, dangerous goodstransportation documents, suppliers commercial documen-tation, PDPDG license and any relevant medical documen-tation;

No loose items of any nature may be left lying around. Allitems must be secured, e.g. bedding, items of clothing,refreshments, etc.;

All windscreens and windows to be clean with no unnecessarystickers obscuring the drivers view;

First aid kit to be readily accessible.

2. Spray vehicle

All equipment must be stored in designated secured places; Fire extinguishers, emergency water (25 litre) and toolboxes

must be secured in such a way that easy access is possible; Spray bars must be covered when lifted, and the covers must

have designated storage positions when the bars are downand the vehicle is spraying;

All flexible discharge hoses must be affixed in designatedpositions. Ensure the hoses have been emptied beforeuncoupling;

All working platforms must be kept clean and clear oftoolboxes, solvents, cleaning material, tins and rags;

Hand rails and steps of all ladders must be clean and dry; All gauges must be clean and readable; All flanges, nozzles and pumps must be maintained to prevent

spillage. However, where circumstances prevent this, driptrays must be used;

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Flushing fluid that has been used to clean plant must bereturned to the depot in secure containers for recycling or safedisposal;

The duration on the site will define whether it is necessary toprovide multiple containers for the various classes of wastegenerated.

To prevent the pollution of natural resources, i.e. rivers, dams,groundwater or wildlife during transportation, select a route with thelowest possible pollution impact. This can be done by researchinglocal knowledge of the area, or by consulting with local authoritiesand emergency services. Inform them of your presence and thenature of your operation.

During the loading operation the driver must do a pre-trip inspectionto ensure that all valves and manholes are properly sealed andclosed, and that there are no leakages. At no time should the driverleave his vehicle during the loading exercise.

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Spillage procedure

Should spillage occur during transit, the driver must stopand call for help. The driver must then put on his PPE,

assess the situation, and if safe, use a shovel to contain anddivert the product from any nearby sensitive environmental

areas until support arrives.

Note

Any form of malfunction of valves is to be reported tomaintenance for immediate repair or replacement;

During long trips the driver should stop periodically todo necessary in-transit vehicle inspections (every twohours).

Arrival on site

On arrival, the driver must request permission to stop in adesignated area where he may carry out his pre-spray checks. Thisarea is to be left in the same condition of cleanliness as it was priorto his arrival.

Temporary storage of bituminous products on construction sites

To prevent pollution, the establishment of static tanks on sites mustbe planned properly.

Consideration must be given to:

The hardness or firmness of the surface; The gradient; The drainage; Position of adjacent water sources and sensitive environmental

areas; Accessibility; Vegetation fire risk.

Depending on the length of visit a bund wall around the tanks mayat times be necessary.

Static tanks are to be transported empty unless compliant with theNational Road Traffic Act.

To prevent air pollution and the evaporation of vapours duringstorage, manholes must be kept closed. Breather pipes must beopen and functional at all times.

After erection and filling, all site static tanks must be inspected on adaily basis for possible subsidence or spillage. When not in use thevalves should preferably be locked.

7.2 Application of bituminous products on site

Prior to spraying, the product is usually heated and circulated.Pressure and nozzle checks are usually conducted next to the roadto be sprayed. This must always be done using drip pans or paper,which can be picked up for safe disposal.

36

When a pan test has to be done on site, no person must be allowednear the spray bar without the necessary Personal ProtectionEquipment. On completion of the test, the product used for the testmust be sucked back into the sprayer.

Transfer lines (flexible hoses) contribute toward leakages andspillage. Where possible, reverse the sprayer pump, leaving all linesempty, prior to safe storage.

Sprayer with product waiting to spray must have the necessary drippans to prevent contaminating the soil.

Dirty tankers are difficult to clean on site without polluting theenvironment. It is recommended that sprayers or sprayingequipment never be washed on site using hazardous chemicals orsolvents. It is more effective to return the vehicle to the nearestcertified wash bay to be cleaned under controlled conditions.

7.3 Spillages

Spillages must be avoided wherever possible. However, should theyoccur, they must be cleaned up immediately and the waste productstored for safe transport to the depot, after which it may be disposedof at a classified waste dump for hazardous chemical substances.

Where spillage occurs, appropriate containment measures must betaken depending upon the quantity involved. Small spillages willcool rapidly, and should not spread to any significant distance.Spills can be impounded with sand, earth, sawdust or specificallydesigned impounding and absorbing agents. Sources of ignitionshould be eliminated. Spilled binder may be reclaimed forreprocessing or removed for disposal at an approved landfill site(refer local government authority).

Bund walls must be erected around permanent storage installations.On-site arrangements must be in place to limit the risk of spillages,and to limit the extent of such spillages where they do occur.

If bituminous binders or petroleum solvents enter stormwaterchannels or sewers, the authorities must be notified immediately.

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7.4 Flushing procedures

At the end of each days spraying the spray bar system must beflushed with cleaning solvent, which must be returned to the depotfor safe disposal.

7.5 Disposal procedures

Waste derived from bituminous binder applications can only bedisposed of at classified waste disposal sites. Under nocircumstances must waste be disposed of in any other manner orwithout the necessary written authority. Bituminous waste includesspills, scrapings, flushings, contaminated product and bituminousmixtures.

On the completion of the days spraying activities, all bars are to beflushed with a flushing solvent and then drained. The flushingsolvent used must then be stored in closed containers prior to beingdumped at a classified waste dump site in accordance with therequirements of the Environmental Conservation Act (Act 73 of 1989Section 20). A certificate of safe disposal must also be obtainedfrom the dumpsite.

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Note

The National Environmental Management Act 107 of 1998will hold the polluter accountable for any incident where

environmental degradation has occurred.

Note

Waste must be handled as detailed in 7.5 below.

8. LEGAL RESPONSIBILITIES

The following are some of the important requirements of currentlegislation:

8.1 Duties and responsibilities

The Occupational Health and Safety Act focuses on the health andsafety aspects of employees in the workplace, and of those likely tobe affected by their activities.

In terms of this Act the employer and employee have distinctresponsibilities and duties to ensure health and safety in the workingenvironment:

Employers shall provide and maintain, as far as is reasonablypracticable, a working environment that is safe and without riskto the health and safety of employees. Employers must ensurethat employees are fully conversant with hazards in theirworkplace, and precautionary measures to minimise oreliminate these hazards must be in place. The Chief ExecutiveOfficer is the official with overall responsibility andaccountability for health and safety;

Employees shall adhere to health and safety regulations andtake reasonable care for the health and safety of themselvesand of other persons affected by their activities.

8.2 Vehicles and transportation

Bituminous products are classified as Dangerous Goods and allvehicles carrying bituminous products must display hazard warningplacards, which are used to provide the emergency services withinformation on how to handle the cargo being carried in the event ofan accident or other emergency. These placards indicate the natureof the product, its UN number and telephone numbers of thetransporter and a specialist response advisor, who should ideally beable to provide prompt physical assistance with the cleansing andrehabilitation of the area. Regulations based on various codes ofpractice set out by the SABS govern the use of these warningpanels.

To assist emergency services, Transport Emergency Cards(Tremcards) must be available and stored in the designated spacei.e. orange coloured box (refer to section 7.1).

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All relevant documents must be carried in the vehicle, includingMSDS, route plan, tremcards, licenses and permits, dangerousgoods transportation documents, suppliers commercial documen-tation, PDPDG license and any relevant medical documentation.

The driver must ensure that emergency breakdown triangles, fireextinguishers, flashing lights, first aid kit etc. are available.

Drivers must undergo an annual medical examination.

8.3 Accidents/Incidents

All accidents and incidents must be reported to the employer andrelevant authorities as soon as possible after the event. All accidentsmust be properly investigated and findings documented.

8.4 Product handling

All procedures involving the handling of bituminous binders mustcomply with legal requirements and the suppliersrecommendations. These include:

Appropriate safety equipment and protective clothing,including the wearing of high visibility clothing on site;

Health and safety officers; Health and safety audits and surveys; Health evaluations; First aid facilities; Fire protection; Control of hazardous substances.

8.5 Environment

Everybody has the right to a clean, healthy, harmless and safeenvironment which requires that the environment be kept asclean as is reasonably practical in terms of current best practice.

This requires that everybody concerned take care to preventpollution of any kind. Spills must be stopped at source as soon aspossible. In the case of major spills the authorities concerned mustbe notified at once. Disposal of waste must take place only atapproved dumping sites.

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8.6 Risk management

It is essential to assess and manage the risk to employees and anyothers whose health and safety may be affected by their work oractivities.

It is therefore necessary that all organisations dealing with thehandling of bituminous binders carry out systematic assessments toidentify and assess the risks associated with these products, tomanage these risks effectively, and to ensure that subsequentdecisions are informed, rational and structured.

A typical risk assessment matrix and suitable procedures areincluded in Appendix 4. This procedure must be carried out, and anaction plan agreed, with time scales set for rectification of anyunacceptable conditions. This should be repeated at regularintervals.

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9. PROCEDURES

9.1 Care of equipment

All bitumen equipment must be kept in good condition at all times.Hoses, fittings and threads in particular should be thoroughlycleaned after each delivery or transfer. Product lines, hand sprays,pumps, valves and hoses should be flushed after use to avoidbitumen slugs. Bitumen slugs blocking partially closed valves orleaking hoses may remain undetected until the bitumen is too hot toapproach with safety.

Flexible hoses should be used under suction rather than underpressure.

Hose assemblies should be inspected regularly for defects or holes.Defective hoses and fittings must be withdrawn and destroyed.

Hose assemblies should be stored flat in such a way as to ensurethat no residual binder is left in the line.

Figure 9. Faulty delivery equipment should not be used.

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When carried on items of plant or stored at the depot, both hoseends should be fitted with dust caps to prevent entry of foreignmaterial (e.g. stones) that may jam or damage the bitumen pump.

Operators should inspect all equipment required for the cartage anddelivery of bitumen products before leaving the filling point. Faultsshould be reported and rectified before any further deliveries arepermitted.

9.2 Equipment checks

All vehicles, tanks and equipment should be maintained inaccordance with the schedules and procedures set out in theCompanys Procedure Manual.

All ladders, catwalks, safety rails and grab points must bemaintained in a good and clean condition. Accumulation of bitumenmust not be allowed.

Vehicle checks must be carried out on a scheduled basis. Refer toAppendix 5 for an example of a vehicle checklist. In additionoperational inspections should be done on a daily basis. Checklistsmust be completed and maintained by the responsible personneli.e. the driver. Regular checks on internal overflow and breathervalves must be carried out to ensure they are in proper workingorder.

All delivery hoses must be inspected regularly, be in good conditionand free of bitumen residue. All connections and hoses must becleaned thoroughly after each delivery. Residual bitumen in hosesmust be allowed to drain into suitable trays after use.

Spray nozzles must be inspected daily to ensure that they areundamaged and correctly fitted. The bitumen pump must be turnedoff before any attempt to inspect, replace or maintain spray nozzles,or any part of the spray bar or its fittings.

Temperature gauges on tanks must be calibrated annually, andmust be positioned where they will accurately indicate thetemperature of the contents.

Manhole covers must be fastened securely after loading.

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9.3 Product handling and sampling

Transportation of bituminous products must be conducted inaccordance with legislation on the transportation of dangerousgoods. Emergency information systems on the transportation ofbituminous products must be adhered to.

Dangerous goods placards, including the UN number, flammableliquid warning and emergency contact numbers, must be displayedat all times.

Tremcards must contain the relevant information and must be storedin the designated space (orange coloured box, refer to section 7.1).See Appendix 6 for an example of a Tremcard.

Personal Protection Equipment (PPE) must be worn at all timesaccording to requirements.

Binder samples should preferably be taken from purpose-designedsample cocks. Most tankers and sprayers are fitted with a samplingdevice, and this should be used at all times. If a sampling device isnot fitted, the sample may be taken, with great care and undersupervision, from a valve or single jet in the spraybar. Stand clearand wear the recommended PPE to avoid being burnt duringsampling or while handling the hot sample. Always operate thebinder pump at the lowest speed when taking a sample to minimisepressure in the system. The recommended method is to havesample cocks fitted to sprayers or storage tanks.

Take care to allow the sample to cool in a safe place where it will notpresent a danger to other people in the area. Cool the samplebefore putting the lid in place.

In the event that the sample is drawn from the manhole, a samplethief should be used.

Always use gloves and safety shoes with toe protection whenhandling drums.

Use any additional safety equipment required for the job. Keephands and feet in a safe position when handling drums.

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When handling product in drums the same safety precautions as forbulk binders applies. Specific care must be taken when handlingdrums containing hot product. Full drums should be loaded andunloaded by mechanical means, such as a forklift. Full drums arealways transported in an upright position.

Procedures for heating product, loading/offloading, filling, blending,changing product and reheating are set out below, and must beadhered to.

9.4 Heating

Bituminous material must be at least 200mm above heating flues.Parking of vehicles on sloping ground may cause heating flues tobecome uncovered and therefore dangerous during heating. Whendischarging a tank, burners must be turned off.

Fire extinguishers must be removed from storage and placed in aposition ready for use before heating commences. Manhole coversmust be open.

PPE must be worn during heating operations.

Under no circumstances should burners be used whilst travelling.This is prescribed by legislation.

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Important notice

Heating flues should be designed such that:

The flues do not pass through the vapour space abovethe product;

The surface temperature will not exceed 350 C on anypart of the heating flue;

The flame tube insert can be easily removed for serviceor replacement;

The inlet or exhaust flues will not be closer than 1.5mhorizontally from any manhole or vent pipe;

The flues are not in direct contact with the tank.

No source of ignition should be permitted within 3m of the vehiclewhen loading or discharging. The operations must be supervisedconstantly.

Sufficient ullage must be left in a loaded vehicle or tank to allow forexpansion of the bitumen when heated.

Gas cylinders must be stored and secured in an upright position.When turning off gas supply after use, close the valve on thecylinder first, and thereafter the valve at the nozzle.

Ensure that only required personnel are in the vicinity during theheating operation.

A product should never be heated above the recommendedtemperature required for transporting, pumping and spraying.Thermometers should be checked regularly and any malfunctioningthermometer reported immediately.

Cutbacks must only be heated in tankers with circulation facilities.

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Precautions

Do not leave the tanker unattended when burners areon;

Position the tanker so that the wind will carry vapoursaway from the burners;

Do not stand on top of the tank during heating; Discharge product from the tanker only when the

burners have been turned off; Only heat product if heating flues are covered by at

least 200mm; Do not use burners if any heating equipment has fuel

leaks; Do not stand directly behind burners when lighting or

adjusting; Do not store open solvent or fuel containers near

heating operation. Do not smoke or use cell phonesduring the heating operation.

9.5 Loading and offloading

The readers attention is drawn to the Sabita publication BitumenHauliers Code which offers guidelines for procedures and safetyrequirements for hauliers collecting bitumen from refineries.Hauliers should also note that there may be particular regulationsissued by a specific refinery that are not covered in the publicationmentioned above.

It is recommended that two persons be in the vicinity during loadingand offloading of haulers, distributors and trailers.

At permanent installations an emergency shower must be availablewithin twenty metres of the discharge point.

When loading, one person should be so positioned that he canclearly observe the product level to prevent the likelihood of spill-over.

Fire extinguishers must be removed from storage and placed in asuitable area ready for use.

Tanks must not be offloaded during heating!

Flexible hoses and couplings must be inspected before use, andunsafe hoses must not be used.

Always check the type and level of material in both the supply andreceiving tanks. If the receiving tank contains some material, ensurethat it is the same as, or compatible with, the material beingdelivered, and that there is sufficient space for the quantity beingdelivered.

Operators should be aware at all times of the potential danger whentransferring hot bitumen, and remain at a safe distance from thehose during transfer. All personnel not required for the operationshould keep well away and not stand near or over the hose while itis in use. Do not leave the equipment unattended at any time duringthe transfer operation.

When loading is carried out using a discharge extension through themanhole, the free end of the extension must be below the openingof the manhole.

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Before loading commences a check must be made to ensure that alldischarge valves on the receiving tank are closed. Care must betaken to ensure that no valves are plugged with solidified bitumen,giving the impression of being in the closed position.

The safest method of clearing plugged valves on an empty tank is toheat a steel bar to a temperature sufficient to melt the bitumen andno more, and to insert the heated bar into the plug.

The use of gas burners or other open flame methods to freeplugged valves must only be considered as a last resort. If thismethod is to be used the vehicle must be moved to a clear safe areawith fire extinguishers on hand.

Before loading heated bitumen a check must be carried out toensure that the receiving tank is free of water or volatile liquid.

During loading no source of ignition should be allowed in the vicinityof the receiving tank.

Earthing the vehicle to eliminate the accumulation of electrostaticcharge is necessary during the loading or offloading of cutbackbitumen e.g. MC30. This is done by making sure that the metal ofthe loading pipe is in electrical contact with the metal at the manholeby means of an earth cable. The simple act of a material flowingthrough a pipe or hose may generate sufficient static electricity tocause a spark when connecting/disconnecting hoses unless there isa continuous connection.

Ullage of at least 10% should be left after loading to allow forexpansion resulting from any subsequent heating.

After completing the transfer of materials check that the valves onboth the supply and receiving units are closed and the bitumenpump is turned off.

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Note

Ensure that there is no water in the tank prior to loading asthis will cause a violent explosion, frothing and boiling over.

Carefully undo the hose. The bottom must first be loosened slightly.A small amount of material may run out of the hose coupling into adrip tray, indicating that it is empty, that there is no pressure, andthat it is safe to remove. If there is a large amount of material, orresidual pressure in the hose, possibly due to a valve not havingclosed properly, this procedure will ensure that the product squirtsonto the ground rather than into the operators face or over hisbody.

Keep the free end of the hose clear of the ground to avoid dirt,stones etc. lodging in the hose. There are special hose chairsavailable to plug and hold the end clear off the ground. Commonpractice is to turn the end of the hose up and over so that it willremain in that position. This procedure will also prevent entry ofrainwater into the hose. Failure to do this could cause a dangerousboil-over of hot material loaded next into the tank.

After loading, empty the pump lines by sucking back into the tank.On completion of discharge, pump, pipelines and hoses must beflushed out with paraffin or diesel and cleared of product. Hosecouplings must also be thoroughly cleaned. Flushings must becollected for re-use or disposal in accordance with statutoryrequirements and best practice procedures (refer to section 7.5).

The manhole cover must be securely fastened.

In the event of any spillage of bitumen during delivery or transfer(such as by hose failure or tank overflows), all valves should beclosed, hoses disconnected, all caps screwed down and thecustomer or his representative informed of the spillage. The areashould be cleaned and authorities must be informed so that theycan certify that the site has been restored to its former condition.

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Note

After the unloading of cutback bitumen that has been heatedto spraying temperatures, the tank will contain a gas/air

mixture that may be in the explosive range. This is the timewhen the product is most dangerous. All sources of ignitionand heat must be prevented from coming into contact with

this explosive mixture.

9.6 Transportation

In addition to compliance with legislation in terms of thetransportation of bituminous binders, road rules and theroadworthiness of the vehicle, the following requirements must beconsidered during the transportation phase:

Cleanliness of the vehicle and visibility of hazard identificationsigns;

Equipment checks before and after loading and unloading; Proper closing of valves and covers, including gas supply

valves and manhole covers; Fire extinguishers fitted and a stocked first aid kit to be on

hand; Condition of tyres in compliance with the legal requirements

and tyre pressures to meet the manufacturers specification; Adequate supply of PPE, including high visibility clothing and

a flashing light on the vehicle.

9.7 Blending

Cutting back hot binders

On-site cutting back of hot binders with volatile solvents isundesirable and is not recommended, either from quality or safetyperspectives. Best practice dictates that all blending operationsusing cutters be carried out at fixed facilities under controlledconditions with the recommended safety and quality measures inplace.

Blending of modified binders

Blending of polymer modified binders and bitumen rubber must onlybe conducted in tanks and blending units designed for this purposeand must be carried out in accordance with suppliers methodstatements. Due to the limited shelf life of some modified binderssuch as bitumen rubber, the blending of these materials must bedone on site. The digestion of rubber in hot bitumen could cause anincrease of 1025% in volume. Sufficient ullage must be allowed forthis increase to avoid boil over.

The addition of rubber crumb to a blending tank should be done bymechanical means that is earthed to prevent the build-up of staticelectricity.

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Polymers and rubber crumb must be stored in a dry place and away fromany source of heat.

Adhesion agents should only be added to binders shortly before sprayingunless they are temperature storage stable. The contents must becirculated for 15 minutes before spraying. Gloves and eye protection mustbe worn and care should be taken to avoid inhalation of fumes.

When mixing water with emulsions, always add water to the emulsion andnot emulsion to water. Compatibility with water should be establishedbefore dilution.

9.8 Loading of different products

Change of product should be carried out only when approved andsupervised. When loading the next product, due consideration must begiven to the previous content of the vessel to avoid contamination orboil-over. Generally this requires draining the tank lines and flushing thesystem with appropriate fluid compatible with the new product beingloaded. All flushing and other residue must be collected and disposed of inaccordance with best practice procedures and the requirements of therelevant legislation (refer to section 7.5).

When bitumen emulsion is to be loaded into a tank that has containedbitumen, it is necessary to drain out as much bitumen as possible. Thetank and pipeline should be flushed out with MC30 or similar material toremove any remaining bitumen. All flushing solvent must be collected in amanner which complies with both best practice and statutory regulations(refer to section 7.5).

Centrifugal or low shear gear pumps are preferred for pumping emulsionsas some emulsions may be shear sensitive, especially latex modifiedemulsions. Positive displacement pumps suitable for penetration gradebitumen, cutbacks and modified binders have a tendency to shearemulsions after excessive circulation unless the emulsion is hot, i.e. above500C. When loading emulsion ensure that the emulsion is discharged intothe bottom of the tank and not allowed to free fall from the top of themanhole.

There are two forms of emulsion ANIONIC (basic) and CATIONIC (acid).If these are mixed, almost instantaneous breaking of the emulsion willtake place in the tanker. The load will solidify and the tank will become

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difficult to clean. If it is necessary to change tank contents from one to theother product, the tank must be flushed out.

At the completion of discharge of emulsion, the pump, tank and lines mustbe thoroughly cleaned with MC30 or similar material to ensure that allemulsion is removed from the system. Any emulsion left in the unit couldresult in a boil-over when hot bitumen is next loaded into the vehicle.

9.9 Storage and storage temperatures

If binders are stored for long periods above their application temperatures,a loss in quality may occur. This is more likely in the case of cutbackbitumen as considerable cutter can be lost. With modified bitumendegradation of the modifier will occur, resulting in the subsequent loss ofproduct quality. For safety reasons the listed maximum storage andspraying temperatures should not be exceeded.

Emulsions should only be heated prior to application. Heating should begradual to reduce the possibility of deposits forming on the burner flues.

Emulsions stored in bulk should be circulated for 30 minutes every secondday. Drums containing emulsions should be rolled before use.

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Table 1. Time and temperature limits for binders

Typical Temperature/Time Limits for Binders

BinderClass

Short TermHandling

Storage Max.Spraying

Temp(0C)

Max.Temp(0C)

Max.Holding

time(hrs)

Max.Temp(0C)

Max.Holding

Time (hrs)

80/100 180 24 130 240 190

150/200 170 24 120 240 180

MC30 65 24 30 240 65

MC70 80 24 50 240 80

MC800 110 24 60 240 130

MC3000 130 24 90 240 155

Emulsions(not mod)

80 24 50 240+ 80

S-E1; S-E2 180 24 150 24- 200

C-E1 160 23 140 240 -

SC-E1;SC-E2

70 24 Ambient 240+ 80

CC-E1 Ambient 240+ Ambient 240+ -

S-R1 165 24 140 72 210

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10. TRAINING

All personnel involved in the handling, storage, blending or sprayingof bituminous binders must receive training in the safe handling ofthese products and the relevant legal requirements.

Drivers and operators involved with the handling, storage ortransportation of hot binders must be fully trained in the treatment ofbitumen burns caused by contact with hot bitumen.

Personnel shall receive training in the correct procedures for:

The hazards involved; Fire fighting; The use of protective clothing and safety equipment; Sampling procedures; Safe use of bitumen handling equipment such as pumps,

burners and compressors; Procedures to follow in case of emergencies; Treatment of bitumen burns.

The personnel required to operate equipment must receiveappropriate training in the operation of such equipment.

Training records of all individuals must be kept on file.

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11. GLOSSARY

Additive: Any substance which is added in smallportions to bitumen to impart someparticular property, e.g.: improvedadhesion, lower viscosity.

Adhesion agent: An additive which forms a waterresistance chemical bridge betweenbinder and stone chip.

Anti-foaming liquid: A substance which, when applied to thesurface of bitumen, reduces the surfacetension. This action breaks foam as itforms on the treated surface.

Barrier cream: A cream or ointment applied to the skinprior to contact with irritant substances.Some work by blocking the pores of theskin with soapy solids dry work others by spreading a water resistant film wet work. They may later be wiped orwashed off taking the irritant with them.

Bitumen: A viscous or semi-solid black or brownsubstance derived from the distillation ofcrude petroleum oil. Bitumen softenswhen heated and is pumpable at 1200C ormore.

Bitumen emulsion: Very fine particles of bitumen dispersed inwater with the aid of chemical emulsifiers.Acid emulsifiers make cationic emulsionsand alkaline emulsifiers make anionicemulsions. Usually emulsions contain60-73% bitumen.

Bituminous binder: A mixture of bitumen, modifiers,emulsifiers and cutters used for roadsealing or the manufacture of asphaltmixes.

Boil over: The rapid increase in volume caused bythe presence of water in hot bitumen andthe subsequent overflow of bitumen froma tank.

Bund wall: An enclosed area around a tank, capableof retaining a spillage from the tank orpipework.

Carcinogenic: Capable of causing cancer.

55

Combustible: A substance capable of burning withsufficient rapidity to produce heat andflame.

Cutback bitumen: Bitumen to which solvents such asparaffin have been added to make it morefluid.

Cutter: An additive which is blended with bitumento temporarily reduce the viscosity of thebitumen to assist spraying e.g. paraffin.

Extender oil: Aromatic oil extracted during themanufacture of petroleum lubricants.Used during the blending of bitumenrubber.

Flammable: (Synonymous with inflammable). Anysubstance, solid, liquid or vapour,which is easily ignited. The termnon-flammable refers to substances,which are not readily ignited, but does notnecessarily indicate that they are notcombustible.

Flammable limits/ A flammable vapour mixed with air willrange: only ignite/explode if the mixture is in the

flammable range. The minimum andmaximum percentage gas concentrations,which can be ignited, constitute the lowerand upper limits respectively. Theflammable limits and the flammable rangeare also known as the Explosive Limitsand the Explosive Range respectively.

Flash Off: The rapid evolution of vapour from volatileliquids.

Flash Point: The lowest temperature at which aflammable liquid will give off vapour,which can be ignited.

Foam: A collection of small bubbles of air or gasforming in liquid, which rise and form ablanket on the surface. For fire fighting afoam produced from water and chemicalsis sprayed on the surface of the burningmaterial to exclude oxygen.

56

Gas Free: An enclosed space or area is consideredto be gas free when the concentration offlammable gas or toxic gas in it is withinprescribed safe limits, and the oxygencontent is sufficient to sustain therespiration of workmen entering theenclosed space or area.

Hazard: The inherently dangerous properties of asubstance.

Heating flues: An oil or gas fired burner with a wide borepipe which is fitted to a binder tank forheating purposes.

Hot Work: Work involving flames or equipment,which can cause ignition of flammablevapours.

IBP: The Initial Boiling Point or temperature atwhich solvents like paraffin begin to boil.

Ignition temperature: The temperature to which a solid, liquid orgas must be heated to start burning.

Naked flame: All uncontained flames, fires, exposedincandescent materials and welding arcs.

Risk: The probability of a substance, operationsor circumstances causing harm to peopleor to the environment.

Self ignition: When a material ignites on its own accordunaided by an external source of ignitionsuch as a flame.

Self ignition temp.: The temperature at which a material willcatch fire on its own accord. (Not to beconfused with flash point which requiresan external source of ignition such as aflame).

Source of ignition: Naked light, fires, exposed incandescentmaterials, electric welding arcs, lamps notof the approved pattern, sparks andflames produced by other means. They allprovide temperatures in excess of theignition temperature.

Tremcard: Transport emergency card. To be used forvehicles carrying dangerous goods.

Ullage: The amount by which the tank falls shortof being full.

57

Viscosity: A measure of the ease at which a liquidcan flow. A high viscosity liquid is onewhich does not flow easily. Binderviscosities are usually measured incentistokes.

Volatile solvents: (e.g. a solvent that evaporates easily). Alow boiling point hydrocarbon used in themanufacture of cutback bitumen toproduce a binder with a temporarily lowviscosity which will increase again as thesolvent evaporates, e.g. paraffin.

58

APPENDIX 1

CONTENTS OF FIRST AID KIT

The items below can be ordered from most pharmacists orsuppliers.

Antiseptic solutionAntiseptic ointmentAssorted packs of sterile burn dressingCotton budsCPR mouthpieceElastic bandagesEye padsEye shieldsGauze swabsInstant cold packLatex glovesMicropore tapeNon-adhesive burn dressing for open burnsRescue sheetSafety pinsScissorsSterile eye irrigation solutionTriangular bandagesTweezersNo. 3 wound dressingNo. 5 wound dressingBurnshield & burnshield liquid

A 25 litre container of water (minimum) should be kept with thesafety box for cooling down the patients burnt section.

59

APPENDIX 2

TREATMENT OF BITUMEN BURNS

Notes for the guidance of first aid and medical personnel

All persons working with hot bitumen should be familiar with theserecommendations in order to administer first aid to burn victims. Aburns tag (in the pocket at the back of this manual) shouldaccompany the patient and be placed in a prominent position beforethe patient is transported to a doctor or hospital.

NO ATTEMPT SHOULD BE MADE TO REMOVE THE BITUMENFROM THE BURNED AREA AT THE WORKSITE!

FIRST AID

If hot bitumen contacts the skin, the affected area should becooled immediately by drenching in cold preferably running water for at least five minutes;

The cooling treatment should be continued until the bitumenhas cooled and hardened;

No attempt should be made to remove the bitumen fromthe burned area.

Further treatment - first aid and medical care

The bitumen layer will be firmly attached to the skin, andremoval should NOT be attempted except at a medical facilityunder the supervision of a doctor. The cold bitumen will form awaterproof, sterile layer over the burn which will prevent theburn from drying out. If the bitumen is removed from thewound there is a possibility of complications.

The bitumen should be left in place and covered with tulledressing containing, or soaked in, liquid paraffin.Petrolatum-based antibiotic ointments or petroleum jelly maybe used. The dressing should be changed daily, at which timeany emulsified bitumen can be gently removed.

The degree and extent of burns, and the general condition ofthe patient, will dictate when transfer to a specialised burnsunit is indicated.

60

Circumferential burns

When hot bitumen completely encircles a limb or other bodypart, the cooled and hardened bitumen may have a tourniqueteffect. The bitumen should be softened as described aboveand the patient referred urgently for specialised medicalattention.

Eye burns

If hot bitumen enters an eye, it should be flushed with wateruntil the bitumen has cooled. No attempt should be made byunqualified personnel to remove the bitumen. The patientshould be referred urgently for specialised medicalassessment and treatment.

61

APPENDIX 3

EMERGENCY TELEPHONE NUMBERS

Doctor

Ambulance

Fire Brigade

Police

Bitumen Supplier

Burns Unit/Medical Centre

Others

Doctor

Ambulance

Fire Brigade

Police

Bitumen Supplier

Burns Unit/Medical Centre

Others

Doctor

Ambulance

Fire Brigade

Police

Bitumen Supplier

Burns Unit/Medical Centre

Others

62

AP

PE

ND

IX4

RIS

KA

SS

ES

SM

EN

TF

OR

MA

ND

RIS

KA

SS

ES

SM

EN

TM

AT

RIX

Ris

kasse

ssm

en

tfo

rm:

Acti

vit

y

(a)

Po

ten

tial

hazard

s

(b)

Pe

rso

ns

at

risk

(c)

Cu

rre

nt

co

ntr

ols

(d)

Ris

kra

tin

g

(e)

Fu

rth

er

co

ntr

ols

tom

inim

ise

risk

(if

req

d.)

(f)

Re

sid

ual

risk

(g)

Re

vie

wd

ate

(h)

Th

et

ask

or

acti

vit

y

be

ing

pe

rfo

rm

ed

Lis

tall

the

po

ten

tial

hazard

s.

(Wh

at

are

the

mo

st

like

lyin

juri

es

that

co

uld

resu

ltfr

om

the

acti

vit

y?)

Lis

tth

ose

pe

rso

ns

wh

oco

uld

be

at

risk

fro

mth

isacti

vit

y.

Wh

at

co

ntr

ol

me

asu

res

are

alr

ead

yin

pla

ce

tore

du

ce

the

risk?

Th

eri

sk

rati

ng

fro

mth

eR

isk

Asse

ss-

me

nt

Matr

ix(i

.e.

H,M

or

L).

Ifth

eri

sk

rati

ng

inth

ep

revio

us

co

lum

n(e

)is

Ho

rM

,th

en

list

ad

dit

ion

al

co

ntr

ols

req

uir

ed

tofu

rth

er

red

uce

the

risk.

Th

isis

the

risk

rem

ain

ing

aft

er

the

furt

he

rco

ntr

ols

liste

din

co

lum

n(f

).

On

lyL

isacce

pta

ble

.

Iffu

rth

er

co

ntr

ols

are

req

uir

ed

the

na

revie

wd

ate

mu

st

be

ag

ree

d.

63

Ris

kA

sse

ssm

en

tM

atr

ix:

Co

nse

qu

en

ce

or

Se

ve

rity

PR

OB

AB

ILIT

Y

Extr

em

ely

un

like

lyN

ot

like

lyto

occu

rP

ossib

ilit

yo

fo

ccu

rrin

gat

so

me

tim

e

Po

ssib

ilit

yo

fis

ola

ted

incid

en

ts

Po

ssib

ilit

yo

fre

pe

ate

din

cid

en

ts

Slig

ht

inju

ryo

rle

ss

LL

LL

M

Min

or

inju

ryL

LM

MM

Se

rio

us

inju

ryM

MM

HH

Fata

lity

MM

HH

H

RIS

KR

AT

ING

S:

H=

UN

AC

CE

PT

AB

LE

M=

FU

RT

HE

RC

ON

TR

OL

SR

EQ

UIR

ED

L=

AC

CE

PT

AB

LE

64

APPENDIX 5

65

Item Quantity

Equipment

Emergency triangle 2

Fire extinguisher 2

Water 25 litre

Personal protection equipment

Hazchem decal 1

First aid kit 1

Documentation

Public Driving Permit for Dangerous Goods

Tremcard

Material Safety Data Sheet

Roadworthy certificate

Medical certificate

Drivers Workmans Compensation Act number

APPENDIX 6

TRANSPORT EMERGENCY CARD (TREMCARD)

CARGO: MC 30 CUTBACK BITUMEN UN NO: 1999 BLACK BITUMINOUS PRODUCT

NATURE OF HAZARD:

Highly flammable; Product may adhere to the skin and cause burns; Fumes may cause eye and skin irritation, respiratory irritation,

dizziness and nausea.

BASIC PERSONAL PROTECTION:

Face and eye protection; Protective overalls; Safety shoes; Heat resistant gloves.

IMMEDIATE ACTION BY DRIVER:

Stop the engine; No naked lights, no smoking; Mark roads with self-standing warning signs and warn other road

users or passers by. Keep public away;

Keep upwind; Notify emergency services.

SPILLAGE:

Stop leaks if without risk; Prevent material from entering stormwater drains and rivers; Vapour may create explosive atmosphere; Use sand, earth or spill control material to contain spill.

FIRE:

Extinguish with dry foam, powder or fine water spray; Sand or earth may be used for small fires.

FIRST AID:

Remove to fresh air; In case of contact with hot material immediately flush skin (or eyes)

with large amounts of cold water. Do not remove material from skin.

66

67

APPENDIX 7

FLAMMABILITY OF CUTBACKS

To understand why the hazards arising from the flammable nature ofbitumen cutbacks and their components are variable, parametersused to define some of the properties relating to combustion areprovided below.

7.1 Flash Point:

7.1.1 Definition:

The temperature at which a flammable liquid gives off sufficientvapour to flash momentarily on the application of a small flame.

7.1.2 Typical flash points:

Flash Point (()C)

Petrol < 40

Illumination paraffin 38 40

Diesel 63 90

Bitumen* 290 310

* Flash point temperatures can be as low as 2500C.

7.1.3 Hazard from low flash point:

As a penetration grade bitumen is progressively cut