Guidelines for the safe and

responsible handling of
bituminous products
Manual 8 May 2011
 Manual 8

Third edition
May 2011

Published by Sabita
Postnet Suite 56
Private Bag X21
Howard Place 7450

ISBN 978-1-874968-51-1

Considerable effort has been made to ensure the accuracy and

reliability of the information contained in this publication. However,
neither Sabita nor its members can accept liability for any loss, damage or
injury whatsoever resulting from the use of this information. The content of
this publication does not necessarily represent the views of any
member of Sabita.

2
Manuals published by Sabita

Manual 1 Construction of bitumen rubber seals

Manual 2 Bituminous binders for road construction and maintenance
Manual 3* Test methods for bitumen rubber
Manual 4* Specifications for rubber in binders
Manual 5 Manufacture and construction of hot mix asphalt
Manual 6* Interim specifications for bitumen rubber
Manual 7 SuperSurf: Economic warrants for surfacing unpaved roads
Manual 8 Safe and responsible handling of bituminous products
Manual 9 Bituminous surfacings for temporary deviations
Manual 10 Appropriate standards for bituminous surfacings
Manual 11 Labour enhanced construction for bituminous surfacings
Manual 12 Methods for labour intensive construction of bituminous surfacings
Manual 13 LAMBS - The design and use of large aggregate mixes for bases
Manual 14*** GEMS - The design and use of granular emulsion mixes
Manual 15* Technical guidelines for seals using homogeneous modified binders
Manual 16** REACT - Economic analysis of short-term rehabilitation actions
Manual 17 The design and use of porous asphalt mixes
Manual 18 Appropriate standards for the use of sand asphalt
Manual 19 Guidelines for the design, manufacture and construction of bitumen rubber
asphalt wearing courses
Manual 20 Sealing of active cracks in road pavements
Manual 21*** ETB: The design and use of emulsion treated bases
Manual 22 Hot mix paving in adverse weather
Manual 23 Code of Practice: Loading bitumen at refineries
Manual 24 User guide for the design of hot mix asphalt
Manual 25 Quality management in the handling and transport of bituminous binders
Manual 26 Interim guidelines for primes and stone precoating fluids
Manual 27 Guideline for thin layer hot mix asphalt wearing courses on residential
streets
Manual 28 Best practice for the design and construction of slurry seals
Manual 29 Guide to the safe handling of solvents in a bituminous products laboratory

* These manuals have been withdrawn and their contents have been incorporated in Technical
Guideline 1 (see below).
** This manual has been withdrawn and its software programme incorporated in TRH12: Flexible
pavement rehabilitation investigation and design.
*** These manuals have been withdrawn and their contents have been incorporated in Technical
Guideline 2 (see below).

Technical guidelines
TG1 The use of modified binders in road construction
TG2 Bitumen stabilised materials
TG3 Asphalt reinforcement for road construction

3
 Sabita DVD Series

DVD100 Testing of bituminous products

• Penetration bitumen tests
• Bitumen emulsion tests
• Hot mix asphalt tests
• Bitumen rubber tests

DVD200 Repair of blacktop roads

• Training guide for the construction and repair of
bituminous surfacings by hand

DVD300 Hot mix asphalt

• Manufacture, paving and compaction of HMA

DVD410 The safe handling of bitumen

DVD420 Treatment of bitumen burns

DVD430 Working safely with bitumen

DVD440 Firefighting in the bituminous products industry

4
Acknowledgements

Sabita gratefully acknowledges the valuable contribution of the members

of the Road Pavements Forum's Binder Distributor Task Team in
compiling the original version of this guideline document for the industry.

Some of the material incorporated in this document is based on

guidelines developed by the Petroleum Institute (now incorporated into
the Energy Institute), CONCAWE, the Refined Bitumen Association
(RBA), Eurobitume, Austroads, the New Zealand Pavement and
Bitumen Contractors Association (NZBCA) and the Australian Asphalt
Paving Association (AAPA). Their permission to do so is gratefully
acknowledged.

The comprehensive revision culminating in this third edition draws on the

most up-to-date information, knowledge and experience available from
various sources including specific techniques and methodology
developed by the oil industry. In particular, the Hazards and Effects
Management Process (HEMP) and BowTie methodology developed by
Royal Dutch Shell plc is today regarded as best practice for risk
assessment and the demonstration that risks are managed to As Low As
Reasonably Practicable (ALARP). The use of information and material
available from Shell and incorporated in the revision of this document is
also gratefully acknowledged.

5
CONTENTS
Preface 8
Glossary of terms 9
Sabita Health Safety and Environment Policy 12
1. Introduction 13
2. Product description 14
3. Types and grades of bitumen and bituminous binders 15
3.1 Penetration grade bitumen 15
3.2 Cutback bitumen 15
3.1 Bitumen emulsions 15
3.4 Modified bituminous binders 16
4. Hazards and potential adverse effects associated with 17
the handling and use of bitumen
4.1 General overview 17
4.2 Managing the health aspects of bitumen storage 18
and handling
4.3 Controlling the health hazards 19
4.4 Recovery measures for the consequences of bitumen 22
health hazards
4.5 Managing the safety aspects of bitumen storage and 24
handling
4.6 Recovery measures for fires involving bituminous 32
products
4.7 Managing the environmental aspects of bitumen
storage and handling 35

5. General guidance for specific bitumen storage, 39

handling and distribution activities
5.1 Vehicles, transport and transfer of bituminous 39
products
5.2 Blending 45
5.3 Storage and storage temperatures 46
6. Training 48

6
Annexures
Annexure A - Hazards and Effects management process 50
Annexure B - Example of a risk assessment matrix 53
Annexure C - Suggested structure and format for a hazard 55
register
Annexure D - Contents of a bitumen first aid kit 56
Annexure E - Emergency telephone numbers 57
Annexure F - Pre-trip aide mémoire for bitumen road tanker 58
driver
Annexure G - Typical contents of a Transport Emergency Card 59
(Tremcard)
Annexure H - Bitumen burns card 60

Figures
Figure 1 The fire triangle 26
Tables
Table 1 Typical physical properties of hydrocarbons 25
Table 2 Recommended storage and handling 28
temperatures for bituminous binders in general
use
Table 3 Time and temperature limits for binders 47

7
Preface
The standards of worker health, safety and environmental conservation
are constantly under review in the bituminous products industry as the
state of knowledge expands. This guideline reflects the state of
knowledge and HSE procedures at the time of publishing.

The scope of this manual has been revised to incorporate international

best practice in respect of the methodology used for hazards and effects
management. This document is however not intended to be a detailed or
exhaustive demonstration of HSE management of all activities
associated with the storage, handling and application of bituminous
products. Rather, it should be viewed and utilised as a generic "high
level" assessment of product specific hazards and should prompt further
site-specific detailed risk assessment of activities and associated
hazards.

Reference should be made to Sabita's publication Health, Safety and

Environment Manual for Sabita members (August 2010) for more
comprehensive information and guidance on health, safety and
environmental management processes and procedures that describe the
HSE control framework recommended for a typical Sabita member
organisation.

In general, the structure of the document is based on the concept of

HEMP associated with the handling of bituminous products and offers
precautionary (control) measures to minimise the risk of exposure to
such hazards. It should be read in conjunction with instructions issued
by site supervisors, and with those of plant specific operating manuals,
all of which should be observed by users of bituminous binders.

Note
In accordance with global nomenclature, the term “bituminous”
refers exclusively to binders and mixtures of binders and aggregate
containing bitumen. The term does not include tar products produced
by the pyrolysis of coal.

As it is now globally accepted that the use of coal tar products as

binders for road construction may introduce undue health and
environmental hazards; their use is no longer considered best practice.
Sabita therefore does not endorse the use of coal tar products as
binders and reference to this application is excluded from this document.

8
Glossary of terms

Additive Any substance which is added in small portions to

bitumen to impart some particular property, e.g.:
improved adhesion, lower viscosity.
Adhesion agent An additive which forms a water resistance
chemical bridge between binder and stone chip.
Anti-foaming liquid A substance which, when applied to the surface of
bitumen reduces the surface tension. This action
breaks foam as it forms on the treated surface.
Auto ignition When a material ignites on its own accord unaided
by an external source of ignition such as a flame.
Auto ignition The temperature at which a material will ignite on
temperature its own accord. (Not to be confused with flash
point which requires an external source of ignition
such as a flame).
Barrier cream A cream or ointment applied to the skin prior to
contact with irritant substances. Some work by
blocking the pores of the skin with soapy solids -
dry work - and others by spreading a water
resistant film - wet work. They may later be wiped
or washed off taking the irritant with them.
Bituminous binder A mixture of bitumen, additives, modifiers,
emulsifiers and cutters applied to road surfaces
as a spray in, e.g. chip seals or in an asphalt
mixture.
Bitumen A non-crystaline solid or viscous black or brown
substance derived from the distillation of crude
petroleum oil. Bitumen softens gradually when
heated and can be pumped at 120oC or higher
temperatures.
Bitumen emulsion Very fine particles of bitumen dispersed in water
with the aid of chemical emulsifiers. Acid
emulsifiers make cationic emulsions and alkaline
emulsifiers make anionic emulsions. Usually
emulsions contain 60-70% bitumen.
Boil over The rapid increase in volume caused by the
presence of water in hot bitumen and the
subsequent overflow of bitumen from a tank.
Bund wall An enclosed area around a tank, capable of
retaining a spillage from the tank or pipe-work.
Carcinogenic Capable of causing cancer.

9
Combustible Capable of burning with sufficient rapidity to
produce heat and flame.
Cutback bitumen A liquid bituminous product obtained by blending
bitumen with a volatile petroleum solvent. Bitumen
to which solvents such as illuminating paraffin or
kerosene have been added to make it more fluid.
Cutter An additive which is blended with bitumen to
temporarily reduce the viscosity of the bitumen to
assist handling e.g. illuminating paraffin or kerosene.
Extender oil An aromatic oil extracted during the manufacture
of petroleum lubricants, used in the manufacture
of bitumen rubber.
Flammable Synonymous with inflammable. Any substance,
solid, liquid, gas or vapour, which is easily ignited.
The term non-flammable refers to substances,
which are not readily ignited, but does not
necessarily indicate that they are not
non-combustible.
Flammable A flammable vapour mixed with air will only
limits/range ignite/explode if the mixture is in the flammable
range. The minimum and maximum percentage
gas concentrations, which can be ignited,
constitute the lower and upper limits respectively.
The flammable limits and the flammable range are
also known as the explosive limits and the
explosive range respectively.
Flash off The rapid evolution of vapour from volatile liquids.
Flash point The lowest temperature at which a flammable
liquid will give off vapour, which can be ignited.
Foam A collection of small bubbles of air or gas forming
in liquid, which rise and form a blanket on the
surface. For firefighting a foam produced from
water and chemicals is sprayed on the surface of
the burning material to exclude oxygen.
Gas free An enclosed space or area is considered to be
gas free when the concentration of flammable or
toxic gas in it is within prescribed safe limits, and
the oxygen content is sufficient to sustain the
respiration of workmen entering the enclosed
space or area.
Hazard The inherently dangerous properties of a substance.

10
HRA Health Risk Assessment as contemplated in the
Hazardous Chemical Substances regulations of
the Occupational Health and Safety Act.
Heating flues An oil or gas fired burner with a wide bore pipe
which is fitted to a binder tank for heating purposes.
Hot work Work involving flames or equipment, which can
cause ignition of flammable vapours.
Initial Boiling Point The temperature at which solvents like paraffin
(IBP) begins to boil.
Ignition temperature The temperature to which a solid, liquid or gas
must be heated to start burning.
Modifiers Substances added to bitumen to modify its
rheological characteristics for improved
performance over a range of operating conditions.
Modifiers broadly fall within the categories of
polymers, aliphatic synthetic waxes and natural
hydrocarbons.
Naked flame All uncontained flames, fires, exposed
incandescent materials and welding arcs.
Risk The probability of substances, operations or
circumstances causing harm to people or the
environment.
Source of ignition Naked light, fires, exposed incandescent
materials, electric welding arcs, lamps not of the
approved pattern, sparks and flames produced by
other means. They all provide temperatures in
excess of the ignition temperature.
Tremcard Transport emergency card that will assist in the
correct application of emergency measures in
vehicles carrying dangerous goods.
Ullage The amount by which the tank falls short of being full.
Viscosity A measure of the ease at which a liquid can flow.
A high viscosity liquid is one which does not flow
easily. Binder viscosities are usually measured in
pascal seconds or centistokes.
Volatile solvents A low boiling point hydrocarbon (typically of the
kerosene type) used in the manufacture of
cutback bitumen to produce a binder with a
temporarily low viscosity which will increase again
as the solvent evaporates.

11
Sabita Health, Safety and Environment policy
Sabita encourages its members to carry out their business in such a
way that the health and safety of their employees, and of other persons
both on and near their sites, is not endangered, and that the quality of
air, water and soil is protected for the continuing benefit of all
ecosystems.

Accordingly, in adopting a responsible integration of environmental and

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 other persons

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 of

employees, Sabita members are encouraged to strive for continuous
improvement in their performance under the health, safety, and
environmental requirements of the State and the industry, and
compliance with the relevant legislation. It is anticipated that every
employee of Sabita's membership, and those on their premises and
work sites, will comply willingly with this policy.

Sabita members not directly involved in the manufacture, storage and

transportation of bituminous binders should also note the wide-ranging
benefits resulting from the implementation of safe and healthy working
practices.

Conservation of life and the environment is an obligation.

12
1. Introduction
In South Africa bitumen is used primarily for road construction, but finds
uses in a variety of other applications where waterproofing and adhesion
are important requirements. Approximately 90% of all bitumen
consumed in South Africa is used to construct and maintain the
extensive road network. Waterproofing, roofing, flooring, anti-rust paints
and sealants for dams and reservoirs account for the other 10%
consumption.

Successful management of the hazards associated with the storage,

handling and transport of bituminous products requires a sound
understanding of the types, properties and characteristics of bitumen
and bituminous binders. This document summarises the health, safety
and environmental data currently available on bitumen and bituminous
binders, and the information covers the following:

• Product description, uses and typical properties;

• Hazards and effects of bituminous products; and
• General advice on handling, emergency treatment and disposal.

13
2. Product description
Composition

Bitumen is a complex combination of hydrocarbons with small amounts

of oxygen, nitrogen, sulphur and trace amounts of metals. A typical
analysis is 82-88% carbon, 8-11% hydrogen, 0-1,5% oxygen, 0-1%
nitrogen, 0-6% sulphur, and trace amounts of vanadium, nickel, iron,
magnesium and calcium.

Crude oils normally contain small quantities of polycyclic aromatic

hydrocarbons (PAHs) which are retained in bitumen. Some of these
PAHs are suspected of causing cancer in humans. However, the
concentrations of these suspected carcinogens are extremely low, and
no causal link between bitumen and cancer in humans has been
established.

To avoid confusion and misunderstanding that may arise from the use of
different terms such as bitumen, asphalt etc., it is essential to be clear
about terminology. In this document the following nomenclature is used:

Bitumen: A black or dark brown solid or semi-solid thermo-plastic

material derived from the distillation of crude petroleum oil and
possessing waterproofing and adhesive properties. Bitumen is defined in
this way in most parts of the world outside North America, where the
term used is "asphalt cement" or simply "asphalt".

Natural Bitumen: The term bitumen is also used for “natural bitumen”
which can occur as natural deposits or as a component of naturally
occurring asphalt, in which it is associated with mineral matter. Although
natural bitumen may be similar in physical properties to bitumen, it is
different in composition and is rarely, if ever, used in South Africa.

Asphalt: Refers to a mixture of bitumen (as defined above), or a

bituminous binder (as defined below) with mineral matter such as stone,
sand and a filler e.g. cement, lime or rock flour.

Bituminous binders: A mixture of bitumen, additives, modifiers,

emulsifiers and cutters used in applications for road surfaces or the
manufacture of asphalt mixes.

Note
Refer to the Glossary of Terms in the Preface (page 9) for a detailed
list of the terms used in this document.

14
3. Types and grades of bitumen and bituminous
binders

There are four main types of bitumen in general use in road construction
and maintenance in South Africa:

• Penetration grade bitumen;

• Cutback bitumen;
• Bitumen emulsion; and
• Modified bituminous binders.

3.1 Penetration grade bitumen

Penetration grade bitumen can be manufactured by straight-run

distillation or by blending two or more base bitumen components.
Penetration grade bitumen is used either as a primary binder or as base
bitumen for the manufacture of cutback bitumen, modified binders or
bitumen emulsions.

3.2 Cutback bitumen

These are mixtures of bitumen with volatile petroleum diluents such as

white spirit, kerosene or gas oil to render them more fluid for ease of
handling and application. Depending on the level and volatility of the
diluents used, the original properties of the bitumen may be partly or
completely recovered by evaporation after application of the cutback.
Cutbacks are sometimes heated for handling and application to
temperatures up to 175oC. Grades are designated by the solvent used
and the lower limit of kinematic viscosity at 60oC. Cutback grades are
mainly used in road prime coats and chip seals.

3.3 Bitumen emulsions

Two phased systems consisting of a dispersion of bitumen droplets in

water which contains an emulsifier. The emulsifiers are added to enable
the formation of the emulsion, to render it stable and to modify its
properties. The emulsions are available in two classes: cationic and
anionic, depending on the electrical charges on the bitumen globules. In
a cationic emulsion the bitumen particles are positively charged; in an
anionic emulsion they are negatively charged. Usually emulsions contain
60-70% bitumen.

15
3.4 Modified bituminous binders

The rheological properties of bituminous binders can be modified by the

introduction of polymers (including rubber crumbs) or hydrocarbons or
alopathic synthetic wax. Modification with rubber crumbs requires the
addition of oils and fluxes in some cases. Bitumen emulsions may also
contain modifiers, typically in latex form. Modified bituminous binders are
mainly used in road construction and maintenance in conditions where
enhanced performance is required.

Note
Oxidised and hard grades of bitumen used exclusively in industrial
applications such as roofing, flooring and pipe coatings are not
covered in this document.

16
4. Hazards and potential adverse effects associated
with the handling and use of bitumen
4.1 General overview

The hazards associated with bituminous products are invariably inherent

in the very nature of the product, and the handling and application
processes. When handling and using bitumens the potential adverse
effects (unwanted consequences) arise from:

• The elevated temperatures generally necessary for ease of

handling and application;
• Vapour and fume emissions associated with the product when
heated;
• The combustible and sometimes flammable nature of the product;
• Persistent skin contact, particularly when in solution;
• Contact of hot bitumen with water in piping, storage tanks or other
vessels, resulting in violent expansion of water to steam of more
than 1 600 times its volume. This can give rise to dangerous
froth-over and may cause boil-over and rupture of the tank roof;
• Use of compressed air to clear pipeline blockage or suspected
blockage in hot bitumen lines, or use of air in mixing in bitumen
tanks. As a general rule the potential adverse effects associated
with the manufacture, storage, distribution, product handling and
use of bitumen arise from one, or a combination of three initiating
(top) events:

o Loss of containment;
o Loss of control;
o Exposure to health effects.

In the sections that follow, generic guidance is provided on methods to

limit and control the hazards associated with the handling and use of
bitumen and bituminous binders. In Annexure A a generic table of
Hazards, consequences and recommended controls has been included
as an example of the output of a typical risk assessment process.

It is highly recommended that the Bitumen Safety Code, 4th edition,

September 2005, published by the Energy Institute, be read and used as
reference for the HSE aspects of bitumen manufacture, blending,
storage, distribution, product handling and use, and sampling associated
with the design, construction, operation, inspection and maintenance of
roads.

17
4.2 Managing the health aspects of bitumen storage and
handling

4.2.1 Physical hazards and effects

The most significant hazard in the use of bituminous binders is exposure

to elevated temperatures, with the associated personal effect being heat
burns. Bitumen is often handled at temperatures above 130oC. Modified
bituminous binders are handled at temperatures of up to 210oC. Skin
contact with liquid bitumen at these high temperatures will cause severe
burns and shock, and can be fatal. Contact with storage tanks and
pipelines containing hot bitumen will also cause severe skin burns.

4.2.2 Chemical hazards and effects

Exposure to toxic vapours and fumes

In confined spaces, vapours from bitumen products can be a health

hazard and may displace oxygen and cause suffocation. Potentially
hazardous concentrations of polycyclic aromatic hydrocarbons (PAHs)
and hydrogen sulphide (H2S) may be present in the vapour space of
bitumen storage tanks, or in bitumen fumes liberated when bitumen is
heated.

H2S is a chemical asphyxiant and inhalation can cause respiratory

paralysis. Prolonged or repeated skin contact with bitumen fumes may
lead to dermatitis and skin carcinomas.

Note
Because H2S inhibits (deadens) the sense of smell, the familiar bad
eggs odour cannot be relied on to warn of the presence of hazardous
concentrations.

4.2.3 Exposure to solvents contained in cold bitumen

Repairs to equipment used in conjunction with cutback bitumen and

emulsions may involve skin contact with solvents.

Prolonged or repeated skin contact with these solvents may lead to

dermatitis.

18
4.3 Controlling the health hazards

Legal responsibilities

Over and above the general requirements to "provide and maintain, as

far as is reasonably practicable, a working environment that is safe and
without risk to the health of employees", the Hazardous Chemical
Substances (HCS) Regulations, 1995, of the Occupational Health and
Safety Act, prescribe specific actions that "apply to an employer or a
self-employed person who carries out work at a workplace which may
expose any person to the intake of a hazardous chemical substance at
the workplace".

It is not practical to copy or discuss the detailed requirements of the

HCS Regulations in this guide. South African users of this manual must
however be aware that these regulations are the MINIMUM mandatory
requirements for control of HCS at the workplace. Therefore, cognisance
should be taken of the fact that the generic controls provided or
discussed in this document will not necessarily mean that full legal
compliance is achieved.

General control measures for health hazards of bitumen

The measures described below are also known as the "heirarchy of

control" because they should be considered in the order presented.

Administrative controls

A Health Risk Assessment (HRA) as required by the HCS regulations

should be performed. The HRA will also guide the implementation of
adequate control programmes to minimise the potential exposure to
hazards associated with bitumen, the identification of PPE that should
be worn and the development of training programmes for bitumen
workers.

Where indicated by the HRA, air monitoring and medical surveillance

programmes should be implemented. This should only be done by an
accredited occupational hygienist.

Engineering controls

Plant, equipment and processes should be planned and designed to

minimise the likelihood of personal contact with hot bitumen or
components of storage and distribution systems.

19
Storage tanks and pipelines containing hot bitumen and heated by
steam, hot thermal oil or petroleum fired burners must be shielded or
lagged with a suitable thermal insulation material.

Where hot bitumen is handled by persons working in places with

restricted ventilation, e.g. indoors, effective Local Exhaust Ventilation
(LEV) should be used to reduce exposure as far as possible.

Procedural controls

Always carry out bitumen operations at as low a temperature as possible

to minimise potential exposure to bitumen vapours or fumes.

Confined space entry and work must be strictly controlled by a Permit To

Work (PTW) system to eliminate exposure to oxygen-deficient
atmospheres and hazardous concentrations of harmful substances.

Internal tank cleaning and repair operations should only be entrusted to

competent specialist contractors with a proven track record.

Note
The development of vapours and fumes accelerates with increase in
temperature.

Personal hygiene precautions

Good personal hygiene in respect of hands and inner clothing must be

maintained in the course of work. Under no circumstances should a
person who has been handling bituminous products eat, drink, smoke or
go to the toilet before first washing their hands.

The application of suitable barrier creams to exposed parts of the skin,

prior to working with bitumen, assists in subsequent cleansing should
contact occur.

Petroleum products such as petrol, paraffin or diesel should never be

used for skin cleansing purposes because they damage the skin.

Note
Barrier creams are not adequate substitutes for gloves or other
impermeable clothing and should not be relied upon as the sole form
of protection.

20
Personal Protective Equipment (PPE)

Note

Legally, and in terms of heirarchical hazard control standards, the

prescription of PPE should not be the sole measure for controlling
hazards. In order to assure the effectiveness of PPE, personnel
should be trained in the correct use of PPE and arrangements must
be in place for routine inspection and maintenance. Adequate
facilities for storage should also be provided.

The objective of PPE is to prevent exposure and is also a recovery or

mitigating measure. If controlled adequately the correct use of PPE can
be an effective "last barrier" to prevent or minimise the potential
consequences (effects) of a hazard.

While the task-specific risk assessment will determine PPE requirements,

the typical PPE for a bitumen worker should be as follows:

Protective clothing for torso, arms and legs

Overalls appropriate to the hazard e.g. acid resistant or heat resistant

should be the standard choice. These should have close-fitting cuffs and
trouser legs capable of overlapping footwear. Added protection is
offered by wearing a leather apron when there is a high likelihood of
coming into contact with hot bitumen.

Face, neck and eye protection

21
As the minimum an approved face shield and suitable eye protection
(goggles) should be worn. A heat resistant (racing type) balaclava will
provide added protection for the exposed neck area and should be
considered for certain tasks as identified in the HRA.

Hand protection

Heat-resistant/chemical-
resistant gloves with
close-fitting cuffs.

Foot protection

Heat-resistant heavy duty safety boots, close

fitting at the top, such that trouser legs are
capable of overlapping them. Under no
circumstances should light shoes or sandals be
worn.

Respiratory protection

Besides the obvious respiratory protection

needed for confined space entry/work, there
may be other tasks (as identified in the HRA)
that require the use of respirators to protect
workers from toxic vapours or fumes. These
would typically be situations where it is not
practicable to eliminate the existence of
vapours or fumes entirely, i.e.when loading or offloading cutback
bitumen and emulsions containing cutters. A half face-piece respirator
with an approved P100/OV/AG filter is suitable for such applications.

4.4 Recovery measures for the consequences of bitumen

health hazards

Emergency response planning - bitumen burns

Bitumen burns require unique treatment. Each location where hot

bitumen is handled must have a bitumen specific medical emergency
response plan that should as a minimum cover the following:

22
 • Emergency water showers should be provided. It is recommended
that a minimum flow of 75 litres a minute at 2,1 bar should be
delivered for a minimum of 15 minutes. Eye bath facilities should
be available in close proximity to operational areas where the
likelihood of bitumen burns has been identified;
• First-aid workers that are likely to administer emergency treatment
MUST be specifically trained for this purpose and available on
each shift;
• An adequate number of approved bitumen burns first aid kits
should be provided, including a supply of the green BitSafe
bitumen burns tags;
• Arrangements should be in place to evacuate burn victims to an
approved burn/trauma unit as not all emergency medical treatment
centres are familiar with the correct methods for treating bitumen
burns.

Guidance for first aid and medical personnel

No attempt should be made to remove firmly adherent bitumen from the

skin of any victim at the work site!

Once the bitumen has cooled it is not harmful, and in fact provides a
sterile cover over the burned area. As healing takes place the bitumen
will detach itself, usually after a few days. If, because of the location of
contact, it becomes necessary to remove the bitumen, liberal amounts of
warm medicinal paraffin may be used. Alternatively, a blend of medicinal
paraffin and kerosene may be used. However, care should be exercised
as kerosene may cause skin irritation.

After any solvent treatment the skin should be washed carefully with
soap and water, followed by the application of a proprietary defatting
agent or skin cleansing cream. Only medically approved solvents should
be used to remove bitumen from burns as other solvents could cause
further skin damage.

Emergency treatment of bitumen burns

• Burns to the skin or eyes should be cooled immediately by

drenching the burned area of the body under clean cold,
preferably running, water. This treatment should continue until the
bitumen has cooled. (This should take no less than 15 minutes);
• DO NOT break blisters or remove solid bitumen from the skin or
area of the eye as it forms a sterile barrier to the affected part and
will protect against infection. A bitumen plaque will normally
detach itself within a few days;

23
 • DO NOT, under any circumstances, apply ointments, oils, butter,
solvents or other substances to a burn;

Note

When hot bitumen completely encircles a limb or other body part, a

tourniquet effect may result as the bitumen cools. In such cases the
bitumen should be softened as described above, and the patient
referred urgently for specialised medical attention.

• Apply a BURNSHIELDÒ dressing over the affected area and

secure the dressing lightly with a sterile bandage;
• DO NOT remove or cut away clothing over burnt areas;
• DO NOT pull away clothing which has stuck, this may cause
further injury;
• Keep the victim warm and provide plenty of fresh air;
• Attach a bitumen burns tag to the patient's clothing in a prominent
position before transport to doctor or hospital.

4.5 Managing the safety aspects of bitumen storage

and handling

Hazards arising from the combustible and flammable nature of

bituminous products

It is important to understand the various components that, potentially,

could combine to cause explosions and/or fires in the bitumen storage
and handling processes.

Combustion of liquids occurs when flammable vapours released from

the surface of the liquid ignite. Hydrocarbon vapour becomes flammable
when its percentage in air is generally at about 1% by volume. This is
known as the Lower Flammable Limit (LFL) and below this the mixture is
said to be "too lean to burn" or "below the lower flammable limit". The
flammable range extends to a higher level of about 8% by volume, when
it is said to be above the Upper Flammable Limit (UFL) or "too rich to
burn".
The amount of flammable vapour given off from a liquid, and therefore
the extent of the fire or explosion hazard, depends largely on the
temperature of the liquid, its volatility, the extent of the exposed surface
area, duration of exposure, and air movement over the surface.

24
Other physical properties of the liquid, such as flashpoint, auto-ignition
temperature and viscosity, give further information on the way in which
vapour/air mixtures may develop, and also on the potential hazards.

Some examples of the typical properties of the hydrocarbon substances that

may be present in bituminous products or used in bitumen operations are
illustrated in the following table:

Table 1. Typical physical properties of hydrocarbon substances

Product LFL/UFL (%/Vol) Flashpoint Auto ignition

temperature
Bitumen 300oC 500oC
o
Petrol 1,4% - 7,6% < -40 C 370oC
Diesel (AGO) 1,3% - 6% > 55oC 225oC
Kerosenes 0,6% - 6,5% > 43oC 205oC
o
LPG (n-Butane) 1,9% - 8,5% -60 C 287oC
LPG (Propane) 2,3% - 9,5% -104oC 460 - 580oC
o
Hydrogen Sulphide 4% - 45% -82 C 260oC
Toluene 1,3% - 7% 4oC 536oC

Mechanism of the ignition of bitumen

For effective blending and application in road construction and maintenance

operations, bituminous binders need to be in a liquid state. To achieve this the
viscosity of the product is lowered either by heating to produce a molten liquid
of very high temperature, or diluting with volatile solvents that release
flammable vapours, i.e. cutback bitumen and some bitumen emulsions, with
the following results:

• Product is at a high temperature - above its flashpoint - and contact with

an ignition source (flame) can ignite the flammable vapour released from
the surface of the bitumen;
• The elevated temperature also increases volatility, i.e. the ability of the
bitumen to release flammable vapours. Bitumen and its derivatives
contain hydrocarbons in various concentrations, depending on the
blend/mixture. Small quantities of the vapours of hydrocarbons in air can
form a flammable mixture that can be ignited by a flame, hot surface,
heating element, spark or other source of ignition, particularly in the
vapour space of storage tanks, road tankers and other confined spaces
where bitumen may be stored or handled;

25
 • Bitumen foams in the presence of water as the temperature of bitumen is
usually above the boiling point of water. Bitumen heated in the presence
of small quantities of water forms foam that can quickly expand and
cause the tank to overflow. The expanding foam can quickly reach hot
objects or burners, and cause the bitumen and/or flammable vapours to
ignite.

Control of flammable atmospheres

in bitumen operations

An understanding of the anatomy of a

fire is essential for establishing a
decision-making framework for the
development of controls for fire
hazards. The fire triangle illustrates the
necessary elements that must be
combined in order for a fire to start and
be sustained.

Controlling flammable atmospheres in bitumen operations will therefore be a

function of effectively excluding and/or removing one or more of the three
essential elements of fire. Fuel (bitumen) is obviously an essential ingredient of
the bituminous product and asphalt industry, and cannot be removed or
excluded.

Oxygen is ever present in the air that we breathe and in the atmospheres of the
containment systems of our bitumen storage and handling processes. Oxygen
can therefore also not be excluded or removed.

Note
A combination of the three elements fuel, oxygen and heat will, under ideal
conditions, result in ignition causing a fire or explosion. It therefore follows
that, by excluding any one of the three elements, a fire cannot start and, by
removing any one of the three elements from a fire, the fire cannot be
sustained and will be extinguished.

Heat (the source of ignition) is the only element that could possibly be excluded
or removed in order to control fire and explosion threats. Heating of most
bituminous products to temperatures of between 100oC - 230oC is also an
essential requirement for ease of handling and application and can therefore
also not be excluded or entirely removed. However we can control the heating
of bitumen and also effectively control other ignition (heat) sources in our
operations.

26
The relationship between the flashpoint/ignition temperature/flammable
range and the ultimate formation or existence of flammable atmospheres
in bitumen operations is very complex and is grade dependent. As can
be seen from Table 1, bitumen is invariably stored and handled at
temperatures above the flashpoints but, in most cases, below the auto-
ignition temperatures of the hydrocarbon components of bitumen blends.
In some cases the auto-ignition temperatures can actually be lower than
the flashpoint of a bitumen blend/mixture.

Furthermore, because of operational requirements to pump and apply

the bituminous binder, not much can be done about lowering heating
temperatures. However, in practice there are some fundamental rules
that can be applied to minimise the risk of ignition of potentially
flammable atmospheres in bitumen operations.

Maximum storage and handling temperatures

The first rule of temperature control should be to control the maximum

temperature at which bitumen is stored and handled. Bitumen should be
stored and handled at the lowest temperature commensurate with
efficient use, as recommended in Table 2.

27
Table 2. Recommended storage and handling temperatures for
bituminous binders in general use

Bitumen type Minimum Typical application Maximum

and grade pumping temperatures (oC) storage
temperature Mixing Spraying temperature
(oC) (oC)
Penetration grades <24hrs >24hrs
150/200 pen 105 - 155 - 165 160 115
80/100 pen 115 140 - 155 170 - 180 160 125
60/70 pen 120 150 - 160 - 160 125
40/50 pen 125 155 - 165 - 165 140
Cutback bitumen
MC30 15 - 55 60 Amb.
MC3000 85 - 130 - 145 130 90
Emulsions1
Cationic spray 60% 5 - 60 80 50
Cationic spray 65% 15 - 65 80 50
Cationic spray 70% 15 - 70 80 50-
Invert emulsion 5 - 60 80 50-
Modified binders
SBR modified 150 175 - 190 200 - 210 180 150
SBS modified 140 170 - 180 175 - 185 180 150
EVA modified 140 160 - 170 - 170 150
FT-Wax modified 120 135 - 145 - 150 120
Natural hydrocarbon
modified 130 165 - 175 - 175 150
Bitumen rubber 160 190 - 210 200 - 210 165 1402
SBR modified
emulsion 65% 15 - 65 70 Amb.
SBR modified
emulsion 70% 15 - 70 70 Amb.

1 Storage periods for emulsions may exceed 240 hours at the temperatures given in the 24 - 240 hour period.
2 Bitumen rubber should not be stored for more than 72 hours.

28
Temperature control measures in bitumen operations will include the
following:

• Engineering controls incorporated in the design of bitumen storage

tanks:

o heating element temperature controls;

o tank maximum working temperature controls;
o warning (alarms) for high temperatures in tanks.

Note
A planned inspection/maintenance programme should be in place to
assure the integrity of control instrumentation.

• Procedural controls:
o safe work practices to avoid excessive local heating (i.e.
spraying operations, clearing of pipeline blockages, bitumen
decanting, laboratory testing);
o Control of sources of ignition.

Control of ignition sources in the presence of potential flammable

atmospheres

• In terms of the Hazard Control Hierarchy, ignition sources in the

presence of potential flammable atmospheres can generally be
controlled in two ways:
o by complete elimination; or
o isolating the source (e.g. electrical sparks) by installing
approved electrical protection equipment in hazardous areas.
Although very important for total and effective control purposes, the
selection and installation of electrical protection equipment in hazardous
areas is not discussed in this document. Design personnel can obtain
detailed information on the subject by referring to various appropriate
national (SANS) and international codes of practice. The Bitumen Safety
Code, 4th edition, September 2005, published by the Energy Institute,
London UK, is an excellent general reference for this purpose.

Eliminating potential ignition source.

As the first step in this process a detailed risk assessment should be
done to identify the hazardous areas in which flammable atmospheres
could occur. A handy guideline to assist with identification of hazardous
areas is the IP publication Area classification code for installations

29
handling flammable fluids. The code subdivides hazardous areas into
the following zones:

• Zone 0: That part of a hazardous area in which a flammable

atmosphere is continuously present or present for long periods
(e.g. the vapour space of a cutback bitumen storage tank);
• Zone 1: That part of a hazardous area in which a flammable
atmosphere is likely to occur in normal operation (e.g. immediately
above/around/below the compartment hatch during bitumen road
tanker loading);
• Zone 2: That part of a hazardous area in which a flammable
atmosphere is not likely to occur in normal operation, and if it
occurs, will exist for a short period only (e.g. around the pump
seals and flanges of a bitumen pump manifold).

Note
Any area not classified under Zones 0,1 or 2 may, for ignition control
purposes, be classified as a non-hazardous area. However, caution
should be exercised in applying zone classification because
operational activities in close proximity to designated zones could,
under abnormal operating conditions, change the state of a safe zone
to hazardous.

Having identified the hazardous zones in which flammable atmospheres

in bitumen operations could occur, the following control measures
should be in place:

Engineering controls

• Design and construction of storage and handling facilities and

equipment in accordance with appropriate and approved
specifications.

Administrative controls

• The continued operational integrity of electrical protection

equipment in hazardous areas is assured by a planned inspection
and maintenance program;
• A Permit To Work (PTW) system to control all hot work in confined
spaces and other hazardous areas;
• A training programme to assure the competence of personnel
required to perform work in hazardous areas (including emergency
response training).

30
Procedural/process controls

Safe work practices, based on site-specific Job Hazard Analysis (JHA),

include the following:

• Clear definition of what is "routine" and "non-routine" hot work;

• All non-routine hot work is subject to a clearance
certificate/procedure and subsequent PTW control if the work will
be performed in a hazardous zone;
• Designated safe areas for performance of all routine hot work (i.e.
welding, cutting, etc.);
• General site safety instructions with regard to:
o Smoking and the carrying of matches, lighters, etc.;
o The use of spark or flame producing equipment on site;
• Clear procedures and instructions for loading and offloading of
bitumen to prevent loss of containment and contact with potential
ignition sources;
• To prevent frothing and/or boil over instructions must include
inspection to ensure all tanks are free of water before loading
bitumen. Additives and extender oils must also be checked for the
presence of water before adding to bitumen;
• The application of excess heat (e.g. welding torch) on bitumen can
cause thermal cracking and the development of flammable vapour.
Open flame heating should only be used to free plugged bitumen
valves as a last resort, and the vehicle must be in a safe zone
area. Spray bars should be heated with caution and under
supervision;
• The vapours in the closed space above a hot cutback are
invariably flammable, but almost always in too high a
concentration, above the Upper Explosive Limit (UEL) to be
explosive. However, where escaping vapour starts to mix with air,
extreme care must be exercised, since this is where the mixture
may become explosive. Consequently, whenever practical during
transfer operations, tank hatch covers should be kept closed, or at
least lowered, to preserve the vapour-rich atmosphere above the
binder;
• No surface of the heating flues should be exposed in the vapour
space as this could cause a dangerous explosion. Tanks should
always be dipped before lighting burners to ensure that the bitumen
level is at least 200mm above the burner flues or heating coils.

31
4.6 Recovery measures for fires involving bituminous products

Introduction

This section provides general guidance for bitumen fires in normal

day-to-day storage and handling activities, and does not cover the
protection of large fixed storage installations or bitumen loading facilities
at refineries. The scope is therefore limited to cover immediate response
to small fires and management must ensure that a comprehensive fire
risk assessment is performed to cover all potential fire scenarios on a
particular plant or site.

Note
Large bitumen fires can be difficult to extinguish and this task is best
left to competent professional fire fighting services.

Types of fires

For fire fighting purposes, fires are grouped in various classes as an aid
to identification of the most appropriate extinguishing medium. The fire
types most commonly encountered in the bituminous products industry
are class A, B and C.
Class A fires: The combustible materials involved in this class of fire
are usually organic materials such as grass, wood, paper, textiles etc.
This class of fire is usually extinguished by either quenching or cooling
with water.
Class B fires: Flammable liquids such as petroleum products, (e.g.
petrol, diesel oil, paraffin, lubricants and bitumen) and flammable and
combustible chemicals, are involved in this class of fire. When fighting
Class B 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 involves live electrical equipment. The reason for the separate
classification is that no extinguishing agent containing water can be used
to fight a fire involving electricity. Generally CO2 (carbon dioxide)
extinguishers are recommended as first choice to fight these fires.
However dry chemical extinguishers can also be applied effectively but
may damage sensitive electronic components.
Class D fires involve metals such as magnesium, aluminium, titanium
and potassium, and require special knowledge, skills and extinguishing
equipment. As it is not commonly encountered there will be no further
discussion of class D fires in this guide.

32
General principles to consider when fighting bitumen fires

• When bitumen burns it becomes a mobile liquid that can readily

flow, spreading the fire;
• Large bitumen fires are difficult to extinguish because of the high
heat content of the liquid;
• Direct application of water to the surface of a bitumen pool on fire
produces a froth of bitumen due to expansion of the water to
steam, which is likely to boil-over, spreading the fire and
endangering personnel. Straight water jets should never be used;
application of water should only be by fog or spray nozzle and only
performed by competent fire fighters;
• Un-burned liquid bitumen can be heated by the fire to a
temperature well above its ignition temperature, making it
necessary not only to extinguish the flames and cool the
surroundings but in order to prevent re-ignition, to cool the product
bulk before leaving it in contact with air;
• Bitumen fires produce a dense brown or black smoke, severely
reducing visibility downwind of the fire;
• As an initial measure to limit propagation of fire, (particularly for
large fires) the heating circuits of appliances to tanks and kettles
should be switched off as soon as is practicable.

Fighting small bitumen fires

Small bitumen fires from leaks or spills can be extinguished using dry
chemical (powder), foam, water spray, carbon dioxide or (where
available) steam lances. The use of foam, water spray and steam must
be avoided where it is not practicable to isolate the electrical supply from
equipment near the fire.

Provision and maintenance of first attack equipment

Note
It is a legal requirement that fire extinguishers should be serviced by
an accredited service provider at intervals of not less than once per
year. It is also good practice to have an inspection schedule in place
to perform in situ visual inspections of all fire equipment at least once
per month.

• Generally, portable (typically 9 kg) dry chemical extinguishers are

preferred for first attack on small bitumen fires. Alternatively

33
 semi-fixed portable (wheeled) installations (typically 50kg trolley
units) may also be considered;
• When planning the placement of first attack equipment, fire risk
assessments should assure that the correct extinguisher is placed
in the location where the fire potential has been identified. This
takes the guess work of selecting the appropriate extinguisher out
of the equation when an emergency arises;
• There should be a minimum of two extinguishers at each location
(including road tankers and spray vehicles) in case one fails;
• In addition road tankers and spray vehicles should carry at least
one shovel, and at each static loading/discharge point a shovel
and a supply of clean loose sand should be readily available for
emergency spill containment.

First attack training for personnel

• All personnel involved in work where the likelihood of bitumen fires
exist, must be trained in the correct use of fire extinguishers. It
should not be taken for granted that merely following the
instructions on the extinguisher body will ensure correct
application. Local authority fire services usually have fire training
programmes that can be customised to accommodate specific
needs;
• Regular fire drills should be planned and carried out to simulate
realistic fire scenarios. Although it is prudent to protect trainees
against injury during training exercises it must also be borne in
mind that in a real life fire emergency the fireman's PPE will not be
available and therefore training should be as realistic as is
practicable;
• A training programme for first attack fire fighting should include the
visual inspection requirements to ensure that fire extinguishers are
checked before the start of a shift or activity where the potential for
a fire exists (i.e. road tanker drivers, plant operators, laboratory
staff, etc.).

Fire Emergency Plans

A fire emergency plan should be in place at every site/workstation where
the potential of a bitumen fire has been identified. The plan should
include procedures for:

• Raising the alarm in case of fire;

• Evacuation of affected personnel and vehicles;
• Calling local authority emergency response teams (i.e. fire brigade
and if necessary an ambulance and the police);

34
 • First attack on the fire (i.e. availability and strategic placement of
suitable fire extinguishers, training of personnel in use of
extinguishers, maintenance of fire extinguishers, etc.);
• Handing over fire-fighting command to the local authority fire chief;
• Mitigating damage and in particular managing fire-fighting water in
order to prevent pollution;
• Signalling the end of the emergency.

Note
The best way to fight fires is to prevent them! Management must
insist on, and enforce, good housekeeping practices and adherence
to safe working procedures. Fire and explosions have devastating
destructive power, and the time and effort spent on fire prevention is
ALWAYS a good investment.

4.7 Managing the environmental aspects of bitumen storage

and handling
Introduction
The main environmental hazards related to bitumen are associated with
atmospheric discharges and the impact on the water environment
resulting from loss of containment during the manufacturing, storage,
transport, handling and use of bitumen, particularly cutback bitumen and
emulsions.
Air pollution
The key emissions from bitumen processes that warrant control are
bitumen fumes, odours, PAHs, H2S, volatile organic compounds, and
particulate matter.

Emissions could arise as result of the following activities or processes:

Activity/Process May give rise to

Delivering, storing, heating, mixing Bitumen fumes, odours and PAHs
and cooling of bitumen
Storage and delivery of solvents Volatile organic compounds and
and blending them with hot odours
materials
The oxidising of bitumen H2S, bitumen fumes, odours and
PAHs
Burning of coal tar fuel in boilers Coal tar fumes containing PAHs

35
Water pollution
Because of the viscous nature of penetration grade bitumen it is
extremely unlikely that these binders could cause water pollution as a
result of failure of storage systems. Cutback bitumen and bitumen
emulsions, however, have the potential to cause serious environmental
harm if they reach water courses or ground water.

In most cases hydrocarbons will form a layer at the surface of any water
body. However emulsions, by their nature, incorporate a range of
additional emulsification agents, acids and bases that are harmful in the
aquatic environment and will emulsify the bitumen, distributing it
throughout the water body and increasing the potential hazard.

Preventing air pollution and monitoring emissions

Environmental protection in South Africa is regulated under a myriad of

laws, regulations, codes of practice and standards. Full legal compliance
is not within the scope of this guideline and only a general discussion of
generic prevention measures is included. However, it is strongly
recommended that all parties involved in the planning, provision and
application of bituminous products ensure that the requirements of the
National Environmental Management: Air Quality Act, 2004 (Act no. 39
of 2004 effective from 1 April 2010) are taken into account when
assessing environmental risk and impact of their operations. In
particular, the schedule of listed activities and minimum emission
standards identified in terms of section 21 of the Act is of importance to
establish monitoring programmes and plans to manage emissions.

General pollution prevention measures in bitumen storage and

handling processes
Plant operations
• As processes which involve the use of bituminous binders at
elevated temperatures release fumes, a key method of reducing
emissions is to keep the bitumen temperature as low as possible;
• To prevent or limit the emission of vapours during storage,
manholes must be kept closed. Breather pipes must be open and
functional at all times;
• All site static tanks should be inspected on a daily basis for
possible subsidence or leaks. When not in use the valves should
preferably be locked;
• Regular tank gauging and stock reconciliation should be standard
practice as a measure to detect possible tank floor leaks;
• Contaminated materials should be removed from site and
disposed of in an environmentally acceptable manner;

36
 • Cleaning of contaminated equipment must be done under
controlled conditions to prevent seepage of washing and flushing
materials into water sources. Where possible make use of a
certified wash bay.

Transport, and spray operations (Refer to Sabita Manual 23: Code of

Practice: Loading bitumen at refineries, for safe loading procedures.)
• To minimise the risk of pollution of natural resources, i.e. rivers,
dams, groundwater or wildlife during transportation, a route with
the lowest possible pollution impact should be selected. This can
be done by researching information on the area, or consulting with
local authorities and emergency services. These bodies should be
informed of the operation and its nature;
• During long trips the driver should stop periodically to do
necessary in-transit vehicle inspections (at least every 2 hours if
practicable);
• Spray bars on spraying vehicles must be covered when lifted, and
the covers must have designated storage positions when the bars
are down and the vehicle is spraying;
• Transfer lines (flexible hoses) contribute toward leakages and
spillage. Where practicable, reverse the sprayer pump, leaving all
lines empty, prior to storage;
• Pressure and nozzle checks are usually conducted next to the
road to be sprayed. This must always be done using drip pans or
paper, which can be picked up for safe disposal;
• All flexible discharge hoses must be stowed in designated
positions. Hoses should be emptied before uncoupling. A
procedure should be in place for collection and disposal of all hose
drainings;
• All flanges, nozzles and pumps must be maintained in good
condition to prevent spillage. Where necessary drip trays must be
used to contain leakage;
• At the end of each day's spraying the spray bar system must be
flushed with cleaning solvent. All flushing fluids must be collected
in secure containers and returned to the base plant for recycling or
safe disposal.

Temporary storage of bituminous products on construction sites

To prevent pollution, the establishment of static tanks on sites must be
planned properly. Consideration must be given to:

• The hardness or firmness of the surface;

• The gradient;
• The drainage;

37
 • Position of adjacent water sources and sensitive environmental
areas;
• Accessibility;
• A bund wall around the tanks.

Disposal of bituminous waste

Although penetration grade bitumen has been declassified as a

hazardous substance for packaging and transport purposes, other
bituminous binders (i.e. cutbacks, emulsions, etc.) and waste contain
hazardous substances. Care should therefore be exercised when
bituminous waste is classified for disposal purposes.

Waste derived from bituminous binder applications may only be

disposed of at approved waste disposal sites. Under no circumstances
may waste be disposed of in any other manner or without the necessary
written authority. Bituminous binder waste includes spills, scrapings,
flushing residue, contaminated product and bituminous mixtures. Ensure
that a certificate of safe disposal is obtained from the disposal site.

Note
The National Environmental Management Act No. 107 of 1998 holds
the polluter accountable for any incident where environmental
degradation has occurred.

38
5. General guidance for specific bitumen storage,
handling and distribution activities
5.1 Vehicles, transport and transfer of bituminous products
General transportation requirements
Transportation of bituminous products must be conducted in accordance
with legislation on the transportation of dangerous goods. Some
bituminous products are classified as Dangerous Goods and all vehicles
carrying such products must display hazard warning placards, which are
used to provide the emergency services with information on how to
handle the cargo being carried in the event of an accident or other
emergency. These placards indicate the nature of the product, its UN
number and telephone numbers of the transporter and a specialist
response advisor, who should ideally be able to provide prompt physical
assistance in cleansing and rehabilitation of the area. Regulations based
on various codes of practice set out by the SABS govern the use of
these warning panels.
All relevant documents must be carried in the vehicle, including:

• MSDS, route plan, tremcards, licences and permits;

• Dangerous goods transportation documents, supplier's
commercial documentation;
• PrDP licence and any relevant medical documentation.

To assist emergency services, Tremcards must be available and stored

in the designated space i.e. orange coloured box.

The driver must ensure that emergency breakdown triangles, fire

extinguishers, flashing lights, first aid kit etc. are available. It is
recommended that a first aid kit containing the minimum items listed in
Annexure D is carried on each vehicle. Refer to Annexure F for a pro
forma aide mémoire that can be used by drivers to check on availability
of essential equipment before departure on a delivery trip. Legally,
drivers must undergo the prescribed annual medical examination.

Care of vehicles and equipment

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

39
Flexible hoses should be used under suction rather than under pressure.
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 ensure that no
residual binder is left in the line. When carried on items of plant or stored
at the depot, both hose ends should be fitted with dust caps to prevent
entry of foreign material (e.g. stones) that may jam or damage the
bitumen pump.

Operators should inspect all equipment required for the transport and
delivery of bitumen products before leaving the filling point. Faults
should be reported and rectified before any further deliveries are
permitted.

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

All vehicles, tanks and equipment should be maintained in accordance

with acceptable practices, maintenance schedules and procedures.

Equipment checks

Vehicle checks must be carried out on a scheduled basis. In addition

operational inspections should be done on a daily basis. Checklists must
be completed and maintained by the responsible personnel i.e. the
driver.

Regular checks on internal overflow and breather valves must be carried

out to ensure they are in proper working order.

All delivery hoses must be inspected regularly, be in good condition and

free of bitumen residue. All connections and hoses must be cleaned
thoroughly after each delivery. Residual bitumen in hoses must be
allowed to drain into suitable trays after use.

Spray nozzles must be inspected daily to ensure that they are

undamaged and correctly fitted. The bitumen pump must be turned off
before any attempt to inspect, replace or maintain spray nozzles, or any
part of the spray bar or its fittings.

Product sampling

Binder samples should preferably be taken from purpose-designed

sample cocks. Most tankers and sprayers are fitted with a sampling

40
device and this should be used at all times. If a sampling device is not
fitted, the sample may be taken, with great care and under supervision,
from a valve or single jet in the spray-bar.

During sampling or while handling the hot sample personnel should

stand clear and wear the recommended PPE to avoid being burned. The
binder pump should always be operated at the lowest speed when
taking a sample to minimise pressure in the system.

The recommended method is to have sample cocks fitted to sprayers,

tankers or storage tanks. In the event that the sample is drawn from the
manhole, a thief sampler should be used. Care should be taken to allow
the sample to cool in a safe place where it does not present a danger to
other people in the area. The sample should be allowed to cool before
the lid is put in place.

Heating

Note
Heating flues should be designed such that:

• the flues do not pass through the vapour space above the
product;
• the surface temperature will not exceed 350oC on any part of the
heating flue;
• the flame tube insert can be easily removed for service or
replacement;
• the inlet or exhaust flues will not be closer than 1,5m horizontally
from any manhole or vent pipe;
• the flues are not in direct contact with the tank.

The following requirements should be complied with during heating

operations:
• Bituminous material must be at least 200mm above heating flues.
Parking of vehicles on sloping ground may cause heating flues to
become uncovered and therefore pose a danger during heating;
• When discharging a tank, burners must be turned off. Fire
extinguishers must be removed and placed in a position ready for
use before heating commences. Manhole covers must be open;
• Appropriate PPE must be worn during heating operations;
• Under no circumstances should burners be used while travelling.
This is prescribed by legislation;

41
 • No source of ignition should be permitted within 3m of the vehicle
when loading or discharging. The operations must be supervised
constantly;
• Sufficient ullage must be left in a loaded vehicle or tank to allow for
expansion of the bitumen when heated;
• Gas cylinders must be stored and secured in an upright position.
When turning off gas supply after use, the valve on the cylinder
must be closed first, and thereafter the valve at the nozzle;
• Ensure that only required personnel are in the vicinity during the
heating operation;
• A product should never be heated above the recommended
temperature required for transporting, pumping and spraying.
Thermometers should be checked regularly and any
malfunctioning thermometer reported immediately;
• Cutback bitumen must only be heated in tankers with circulation
facilities.

Precautions during heating

• Do not leave the tanker unattended when burners are on;

• Position tankers so that the wind will carry vapours away 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 tubes are covered by at least 150mm;
• 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 phones during the heating operation.

Transfer (loading and offloading) of bitumen

The reader's attention is drawn to Sabita Manual 23: Code of Practice:
Loading bitumen at refineries, which offers guidelines for procedures
and safety requirements for hauliers collecting bitumen from refineries.

General considerations for transfer of hot bitumen are as follows:

• Tankers must not be offloaded during heating;
• It is recommended that two persons be in attendance during
loading and offloading of bulk bitumen carriers. When loading, one
person should be so positioned that he can clearly observe the
product level to prevent the likelihood of spill over;

42
• Fire extinguishers must be removed from storage and placed in a
suitable area ready for use;
• Flexible hoses and couplings must be inspected before use, and
unsafe hoses must not be used;
• The type and level of material in both the supply and receiving
tanks should always be checked. If the receiving tank contains
some material ensure that it is the same as, or compatible with,
the material being delivered and that there is sufficient space for
the quantity being delivered;
• Ensure that there is no water in the tank prior to loading as this
could cause a violent explosion, frothing or boiling over;
• Operators should be aware at all times of the potential dangers
when transferring hot bitumen, and remain at a safe distance from
the hose during transfer. All personnel not required for the
operation should keep well away and not stand near or over the
hose while it is in use. The equipment should never be left
unattended during the transfer operation;
• When loading is carried out using a discharge extension through
the manhole, the free end of the extension must be below the
opening of the manhole;
• Before loading commences a check must be carried out to ensure
that all discharge valves on the receiving tank are closed. Care
must be taken 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 to heat a steel bar to a temperature sufficient to melt the
bitumen and no more, and to insert the heated bar into the plug;
• The use of gas burners or other open flame methods to free
plugged valves must only be considered as a last resort. If this
method is to be used the vehicle must be moved to a clear safe
area with fire extinguishers on hand;
• During loading no source of ignition should be allowed in the
vicinity of the receiving tank;
• Earthing the vehicle to eliminate the accumulation of electrostatic
charge is necessary during the loading or offloading of cutback
bitumen. This is done by making sure that the metal of the loading
pipe is in electrical contact with the metal at the manhole by
means of an earth cable. The simple act of a material flowing
through a pipe or hose may generate sufficient static electricity to
cause a spark when connecting/disconnecting hoses unless there
is a continuous connection;
• Ullage of at least 10% should be left after loading to allow for
expansion resulting from any subsequent heating;

43
 • After completing the transfer of materials, a check should be
carried out to ensure that the valves on both the supply and
receiving units are closed and the bitumen pump is turned off;
• Carefully undo the hose. The bottom must first be loosened
slightly. A small amount of material may flow out of the hose
coupling into a drip tray, indicating that it is empty, that there is no
pressure, and that it is safe to remove. If there is a large amount of
material, or residual pressure in the hose, possibly due to a valve
not having been closed properly, this procedure will ensure that
the product squirts onto the ground rather than into the operator's
face or over his body;
• The free end of the hose must be kept clear of the ground to avoid
dirt, stones etc. lodging in the hose. There are special hose chairs
available to plug and hold the end clear off the ground. Common
practice is to turn the end of the hose up and over so that it will
remain in that position. This procedure will also prevent entry of
rainwater into the hose. Failure to do this could cause a dangerous
boil over of hot material loaded next into the tank;
• After loading, the pump lines must be emptied by sucking back
into the tank. On completion of discharge, pump, pipelines and
hoses must be flushed out with paraffin or diesel and cleared of
product. Hose couplings must also be thoroughly cleaned;
• Flushing fluids must be collected for re-use, and disposal must be
in accordance with statutory requirements and best practice
procedures;
• The manhole cover must be securely fastened before departure
after loading;
• In the event of any spillage of bitumen during delivery or transfer
(such as by hose failure or tank overflows), all valves should be
closed, hoses disconnected, all caps screwed down and the
customer or his representative informed of the spillage. The area
should be cleaned and authorities must be informed so that they
can certify that the site has been restored to its former condition.

Note
After the unloading of cutback bitumen that has been heated to
spraying temperatures the tank will contain a gas/air mixture that may
be in the explosive range. This is the time when the product is most
hazardous. All sources of ignition and heat must be prevented from
coming into contact with this explosive mixture.

44
Loading of different products

Change of product should be carried out only when approved and

supervised. When loading the next product, due consideration must be
given to the previous content of the vessel to avoid contamination or
boil-over. Generally this requires draining the tank lines and flushing the
system with appropriate fluid compatible with the new product being
loaded. All flushing and other residue must be collected and disposed of
in accordance with best practice procedures and the requirements of the
relevant legislation.

When bitumen emulsion is to be loaded into a tank that has contained

bitumen, it is necessary to drain out as much bitumen as possible. The
tank and pipeline should be flushed out with MC30 or similar material to
remove any remaining bitumen. All flushing solvents must be collected in
a manner that complies with both best practice and statutory regulations.

Centrifugal or low shear gear pumps are preferred for pumping

emulsions as some emulsions may be shear sensitive, especially latex
modified emulsions. Positive displacement pumps suitable for penetration
grade bitumen, cutbacks and modified binders have a tendency to shear
emulsions after excessive circulation unless the emulsion is hot, i.e.
above 50oC. When loading emulsion ensure that the emulsion is
discharged into the bottom of the tank and not allowed to free fall from
the top of the manhole.
There are two forms of emulsion - anionic (basic) and cationic (acid). If
these are mixed, almost instantaneous breaking of the emulsion will take
place in the tanker. The load will solidify and the tank will become
difficult to clean. If it is necessary to change tank contents from one to
the other product, the tank must be flushed out.

At the completion of discharge of emulsion, the pump, tank and lines

must be thoroughly cleaned with MC30 or similar material to ensure that
all emulsion is removed from the system. Any emulsion left in the unit
could result in a boil-over when hot bitumen is next loaded into the
vehicle.
5.2 Blending
Cutting back hot binders
On-site cutting back of hot binders with volatile solvents is undesirable
and is strongly discouraged from both quality and safety perspectives.
Best practice dictates that all blending operations using cutters be
carried out at fixed facilities under controlled conditions with the
recommended safety and quality measures in place.

45
Blending of modified binders
Blending of polymer modified binders and bitumen rubber must only be
conducted in tanks and blending units designed for this purpose and
must be carried out in accordance with the supplier's method
statements. Due to the limited shelf life of some modified binders such
as bitumen rubber, the blending of these materials must be done on site.
The digestion of rubber in hot bitumen could cause an increase of 10 to
25% in volume. Sufficient ullage must be allowed for this increase to
avoid boil over.

Polymers and rubber crumb must be stored in a dry place and away
from any source of heat. The addition of rubber crumb to a blending tank
should be done by mechanical means that is earthed to prevent the
build-up of static electricity.

Adhesion agents should only be added to binders shortly before

spraying unless they are temperature storage stable. The contents must
be circulated for 15 minutes before spraying. Gloves and eye protection
must be worn and care should be taken to avoid inhalation of fumes.

Compatibility with water should be established before dilution. When

mixing water with emulsions, always add water to the emulsion and not
emulsion to water.

5.3 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 cutback bitumen as considerable cutter can be lost. With modified
bitumen, degradation of the modifier will occur, resulting in the
subsequent loss of product quality. For safety reasons the maximum
storage and spraying temperatures given in Table 2 (page 28) should
not be exceeded.

Emulsions should only be heated prior to application. Heating should be

gradual to reduce the possibility of deposits forming on the burner flues.
Emulsions stored in bulk should be circulated for 30 minutes every
second day. Drums containing emulsions should be rolled before use.

46
Table 3 Time and temperature limits for binders

Typical temperature / time limits for binders

Binder class Short term handling Storage Maximum
spraying
temp.
(oC)
Max.temp. Max. Max. Max.
(oC) holding temp. holding
time (oC) time
(hrs) (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 80 24 50 240+ 80
(not modified)
S-E1; S-E2 180 24 150 240 200
C-E1 160 24 140 240 -
SC-E1; SC-E2 70 24 Ambient 240+ 80
CC-E1 Ambient 240+ Ambient 240+ -
S-R1 165 24 140 72 210

47
6. Training
All personnel involved in the handling, storage, blending or spraying of
bituminous binders must receive training in the safe handling of these
products and the relevant legal requirements. HSE critical positions and
tasks should be identified, documented and an appropriate training
programme should be developed to assure the competence of
personnel.

A typical training (competence assurance) programme could include the

following:

• Task risk assessment training;

• Managing of task specific hazards as identified in the site risk
assessments;
• Firefighting;
• Procedures to follow in case of emergencies;
• Treatment of bitumen burns;
• The use of protective clothing and safety equipment;
• Sampling procedures;
• Safe operation of bitumen handling equipment such as pumps,
hoses, burners and compressors;
• Advanced driver training for bulk vehicle operators;
• Incident investigation.

Sabita has developed a basic bitumen safety training programme called

BitSafe. The implementation of the BitSafe course is done through the
recruitment and training of selected employees of Sabita member
companies as trainers. After completing a "Train-the-trainer" course the
trainers conduct the training at their respective places of work.

The course has been designed in a modular format which allows for
short interventions of approximately two hours, thereby minimising the
impact on operations. The course consist of 12 training modules which
covers all the activities normally associated with the handling of
bituminous binders. These are:

Module 1 (a): Understanding the industry

Module 1 (b): The certification process
Module 2 (a): Hazards: General
Module 2 (b): Hazards: Fire prevention
Module 3: Health and safety awareness
Module 4: Reducing the risk
Module 5: Treatment of bitumen burns
Module 6: Our environment

48
Module 7: Loading of liquid bitumen
Module 8: Transport of bitumen
Module 9: Sampling and testing
Module 10: Storage
Module 11: Disposal of bitumen waste
Module 12: Application of bituminous binders

For more details contact Sabita on 021 531 2718 or email [email protected]

49
 Annexure A
Hazards and Effects Management Process (HEMP)
A.1 Brief introduction to the HEMP

The HEMP entails a detailed analysis and documentation procedure

using four basic steps:

1. Identify:
a. The hazards (what can cause harm):
b. The threats (under what circumstances can the hazard be
released); and
c. The potential consequences (injury, damage, etc) if the hazard
is released.
2. Assess:
a. Consider the likelihood of the occurrence of the potential
consequences and classify the risk using a risk assessment
matrix; and
b. Analyse the threats and determine the necessary controls
(barriers) to prevent the release of the hazards.
3. Control:
Document existing controls (barriers) and develop
new/additional controls that are necessary to manage the risk to
ALARP.
4. Recover:
Develop comprehensive reaction plans to mitigate the adverse
effects of potential consequences.

A.2 Suggested strategy for establishing a site HEMP programme

To assure full compliance with legal and HSE Management System

requirements the HEMP must be organisation and site-specific.

• Select, train and appoint a HEMP facilitator (ideally an HSE

practitioner);
• Establish a site HEMP team consisting of experienced personnel
from each department or business function i.e. administration,
engineering, production, laboratory, transport;
• Provide basic HEMP methodology training for team members;
• Prepare a project plan with scheduled HEMP workshops;
• Conduct HEMP workshops under guidance of the HEMP
facilitator;

50
 • Record/document the results of the HEMP in a hazard register
similar to the format suggested in Annexure C of this manual;
• Compile a register of HSE critical activities (processes) and
positions (jobs) for the site and assure competence of HSE critical
positions;
• Conduct further detailed analysis of HIGH RISK hazards and
demonstrate ALARP (using BowTie or similar methodology);
• Get management sign-off for hazard register;
• Communicate contents of hazard register as widely as necessary;
• Establish a procedure for maintenance of the hazard register
including:
o Management of change;
o Regular review to check barrier efficiency;
o Compliance auditing;
o Follow up on remedial action, etc.

Note
Sabita members are encouraged to establish their own site-specific
HEMP programmes to ensure that a detailed analysis of all HSE
critical operational activities and associated hazards is completed.

A.3 Table of hazards, potential consequences and

recommended controls

For purposes of this guideline a simple generic high level assessment

has been prepared to illustrate how the HEMP is applied. Annexure C
provides an example of a suggested structure and format for
documenting the HEMP results in a hazard register.

As an example, the table below provides an overview of the most

common hazards and effects associated with the types, properties and
characteristics of bitumen and bituminous binders, and also a brief
summary of the general precautionary measures that should be applied
to control these hazards.

Note
Threats are not included here and only product-related hazards are
discussed in this model.

51
Table A1. Hazards, potential consequences and recommended
controls

Hazard Consequence Recommended controls

and effect
Hazard group: People: • Thermal insulation: shielding,
cladding, lagging of plant
Thermal Severe burns and and equipment
shock, potentially fatal • Avoid contact of hot bitumen
Plant/Equipment/ with water to eliminate
Liquids at elevated Assets: Damage to potential of boil over
temperatures equipment, tools, • Proper design and
structures not maintenance of plant and
Hazard source: designed to resist equipment to prevent
high temperatures leaks/spillage
Bituminous binders stored, • Competent personnel follow
transported and handled at Environment: correct operating procedures
temperatures between Destruction of • Provide, maintain and use
100oC - 210oC sensitive flora appropriate PPE as
prescribed
Bitumen heating and • Medical, fire and spill
application equipment/tools emergency response plans
Hazard group: People: • Substitute cutback bitumen
with less hazardous binders
Chemical Fires and explosions • Proper design and
cause severe injury or maintenance of plant and
Flammable and toxic death equipment to prevent
vapours or fumes leaks/spillage
(kerosene, CO2 hydrogen Acute health effect: • All hot work and confined
sulphide, bitumen fumes, (asphyxiation) could be space work is strictly
nitrogen oxide, carbon fatal controlled by a Permit To
monoxide, polycyclic Work (PTW) system
aromatic hydrocarbons) Chronic health effects: • Where practicable provide
Long term regular and adequate local exhaust
Hazard source: repeated exposure ventilation at source of
(skin contact) may exposure
Cutback bitumen and other cause skin cancer • Provide, maintain and use
bituminous binders that appropriate PPE (respiratory
contain volatile organic Assets: Fire or protection) as prescribed
compounds explosion results in • Personal health monitoring
severe damage or programmes
destruction • Medical, fire and spill
emergency response plans
Environment: Air • Air quality monitoring
pollution; ground water • Engineering controls to limit
contamination; emission of noxious fumes
destruction of sensitive
habitat

52
 Annexure B
Example of a risk assessment matrix
An example of a Risk Assessment Matrix (RAM), used to determine the
risk potential in the hazard register example in Annexure C.

Consequences Increasing likelihood

A B C D E
Never Heard Has Has Has
heard of in happened happened happened
of in the in the at the more
the industry organi- location than
industry sation or more once per
Environment

Reputation or more than year at

than once the
Severity

People

once per year location

Assets

per year in the

in the organi-
industry sation
0 No No No No
injury damage effect impact
or health
effect
1 Slight Slight Slight Slight
injury damage effect impact
or health
effect
2 Minor Minor Minor Minor
injury or damage effect impact
health
effect
3 Major Moderate Moderate Moderate
injury or damage effect impact
health
effect
4 PTD or Major Major Major
up to 3 damage effect impact
fatalities
5 More Massive Massive Massive
than 3 damage effect impact
fatalities
For practical application the four areas (colours) of the RAM describe the level of control required to manage risk:

Manage for continuous improvement, although the organisation may set a higher priority for further
risk reduction.
Manage for continuous improvement through the effective implementation of the HSE
Management System.
Identify and implement controls and recovery measures to reduce risk to ALARP.
Identify and implement controls and recovery measures to reduce the risk to ALARP
and provide a documented demonstration of ALARP.

53
Note
The organisation defines the parameters and criteria in each of the
consequences and likelihood categories, as well as the processes
and methodology for determination of ALARP.

54
 Annexure C
Suggested format for a hazard register

Hazard Hazard Activity Location Threats Top event Consequence Risk potential ALARP
No. or incident documentation
considered for P A E R
RAM rating
H-01.12 Hydrocarbons: Bulk loading and Loading gantries, • Equipment Loss of Asset damage: 4B 4C 2C 1C BowTie hazard
Cutback bitumen deliveries; blending plants, failure containment. Fire in loading Comments: fire partially Control Sheet;
(flammable Bulk storage and laboratories. • The potential gantry. destroyed loading gantry at PTWS;
vapour). handling; of ignition not the XYZ refinery in April EIA;
Storage and recognised 2009. Design
handling of • Hot work in standards;
samples; hazardous Ops standards
Plant areas and procedures;
maintenance; • Static Site ERP.
Operation of electricity
bitumen heating • Lack of work
system; procedures
Binder spraying • Procedures
operations. not followed.
H-08.01 Moving transport Movement of Blending/storage • Operator error Loss of control. Injury/fatality: 4D 3D 1B 2B Hazard Control
on land. vehicles/mobile and distribution • Lack of site Vehicle collision Comments: Several fatal Sheet;
plant. sites: planning at road incidents have occurred on Site work
Road • Lack of construction SA roads during road instructions;
construction sites. journey traffic control construction projects Design
planning point. standards;
• Site work Site ERP.
instructions
not followed.

Note
The development of hazard registers should be done by a carefully selected team with relevant engineering, operational and HSE experience under the guidance of a
competent HEMP facilitator.

55
 Annexure D
Contents of first aid kit
The items below can be ordered from most pharmacists or safety
equipment suppliers. Sabita also provides complete bitumen first aid
kits. Order from [email protected].

The following items are in the bitumen burns first aid kit:

Antiseptic solution;
Antiseptic ointment;
Assorted packs of sterile burn dressing;
Cotton buds;
CPR mouthpiece;
Elastic bandages;
Eye pads;
Eye shields;
Gauze swabs;
Instant cold pack;
Latex gloves;
Micropore tape;
Non-adhesive burn dressing for open burns;
Rescue sheet;
Safety pins;
Scissors;
Sterile eye irrigation solution;
Triangular bandages;
Tweezers;
No. 3 wound dressing;
No. 5 wound dressing;
Burnshield dressings and burnshield liquid;
2 plastic interlocking straight splints

A 25l container of water should be kept with the kit for cooling down the
patient's burnt section.

56
 Annexure E
Emergency telephone numbers

Doctor
Ambulance
Fire Brigade
Police
Bitumen Supplier
Burns Unit/Medical Centre

57
 Annexure F
Pre-trip aide mémoire for bitumen road tanker driver
Company/operator: ...................................................
Driver: .......................................................................
Vehicle No: ...............................................................
Trailer No: ................................................................

Item Quantity
Equipment
Emergency triangle 2
Fire extinguisher (9kg dry chemical powder) 2
Shovel 1
Water in robust container 25 litre
The following PPE is worn or readily available:
• Heat resistant overall and leather apron; 1 of each
• Face shield, goggles and heat resistant balaclava; 1 of each
• Heat and chemical resistant gloves; 1 pair
• Heavy duty safety boots; 1 pair
• Half face-piece respitator with appropriate filter. 1
Hazchem decal 1
Elevated temperature warning decal 1
First aid kit (checklist for minimum contents inside) 1
Documentation
Operator registration card displayed
Orange document container mounted in the cab
Public Driving Permit for Dangerous Goods (PrDP-G)
Dangerous good declaration for product on board
(either separate or part of a waybill, consignment or
delivery note)
Tremcard
Material Safety Data Sheet relevant to product on
board
Roadworthy certificate
Medical certificate

58
 Annexure G
Typical content of a Transport Emergency Card
(Tremcard)
Cargo: MC30 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 storm-water drains and rivers;
• Vapour may create explosive atmosphere;
• Use sand, earth or spill control material to contain spill.
Fire:
• Extinguish with dry chemical 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 bitumen immediately flush skin (or
eyes) with large amounts of cold water. Do not remove bitumen
from skin!

59
 Annexure H
Bitumen burns card

H.1 Front page of the bitumen burns card

60
H.2 Back page of the bitumen burns card

61
Notes

62
Notes

63
Notes

64