.

Published by

SabitaPostnet Suite 56Private Bag X21Howard Place 7450

sabita

Manual 25November 2005ISBN 1-874968-10-1

Quality management in the handling and transport of

bituminous binders

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Manuals published by Sabita

Manual 1 Construction of bitumen rubber sealsManual 2 Bituminous products for road constructionManual 5 Manufacture and construction of hot-mix asphaltManual 7 SuperSurf: Economic warrants for surfacing

unpaved roadsManual 8 Guidelines for the safe and responsible handling

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

surfacingsManual 12 Methods and procedures - Labour enhanced

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

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

emulsion mixesManual 16 REACT - Economic analysis of short-term

rehabilitation actionsManual 17 The design and use of porous asphalt mixesManual 18 Appropriate standards for the use of sand

asphaltManual 19 Technical guidelines for bitumen-rubber asphaltManual 20 Sealing of active cracks in road pavementsManual 21 ETB - The design and use of emulsion treated

basesManual 22 Hot-mix paving in adverse weatherManual 23 Bitumen Hauliers’ Code: Guidelines for loading

bitumen at refineriesManual 24 User guide for the design of hot-mix asphalt

Training Guides

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

for bitumen and coal tar productsCEP Councillor Empowerment Programme

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Sabita Video Training AidsVideo series on testing of bituminous products

Bitumen

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

Bitumen Emulsion

AV-4 Saybold furol viscosity / Water content of emulsions

AV-5 Sedimentation value of emulsions / Residue on sieving

AV-6 Coagulation value with chippings / Coagulation value with Portland cement

AV-7 Binder content of slurry / Particle charge test

Hot-mix Asphalt

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

density and voids

Bitumen Rubber

AV-13 Ball penetration and resilience test / Dynamic viscosity

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

fibre test of crumb rubber

Video series on Blacktop Roads

AV-21 Blacktop roads for reconstruction and development

AV-22 Blacktop surfacing and repair (with Instructor Training Manual)

AV-23 Pavement surfacing and repairs for blacktop roads

Video series on Hot-mix Asphalt

AV-25 ManufactureAV-26 PavingAV-27 Compaction

Acknowledgments

The contribution made by Much Asphalt (Pty) Ltd inpreparing the initial draft document is gratefullyacknowledged.

Contributions made by members of the Road PavementsForum (RPF) Task Group on bitumen specifications and, inparticular, Unitrans, Tosas and BP, are also gratefullyacknowledged, as is the input from the Haulier Committeeconvened by John Lansdell.

Considerable effort has been made to ensure the accuracy andreliability of the information contained in this publication. However,

neither Sabita nor its members can accept liability for any loss,damage or injury whatsoever resulting from the use of this

information. The content of this publication does not necessarilyrepresent the views of any member of Sabita.

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Preface

This code of practice deals with all quality related issuesarising during the loading of bituminous binders into roadtankers, and the transportation and the offloading of thesebinders.

The document is intended as a guide to ensure that theprocedures associated with loading, transportation andoffloading of bituminous binders intended for use duringroad construction are conducted in such a manner as toensure that the quality of the binders is not adverselyaffected in any way.

The term “bituminous binder” as used in this documentincludes penetration bitumen, cutback bitumen, bitumenemulsion and modified binders used in road constructionand maintenance. Some health, safety and environmentalpractices are incorporated in the document as they form anintegral part of the entire process. It is however not theintention of this code of practice to address all health, safety and environmental issues in depth. This document shouldtherefore be used in conjunction with Sabita’s Manual 8 -Guidelines for the safe and responsible handling ofbituminous products and Sabita’s Training Guideline -Health, Safety and Environmental Guidelines for bitumenand coal tar products. The appendices of this document also contain information relating to health and safety.

Reference should, in addition, be made to Sabita’s Manual23 - Bitumen Hauliers Code: Guidelines for loading bitumenat refineries, as well as SABS 10228, 10229, 10230, 10231, 10232 and 10233, the Occupational Health and Safety Act,Road Traffic Act and other relevant legislation.

It is now a global convention that the application of coal tarproducts is no longer considered as best practice since theiruse in road construction may introduce undue health andenvironmental hazards. Sabita therefore does not endorsetheir application and reference to this material is excludedfrom this document.

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ContentsList of tables and diagrams

1. Introduction

2. Regulations 2.1 Driver requirements2.2 Driver declaration 2.3 Road transport 2.4 Documentation requirements

3. Procedures3.1 Pre-loading inspections3.2 Loading procedure

3.2.1 Overview3.2.2 General procedure3.2.3 Loading at the refinery

3.3 Heating3.4 Transportation3.5 Offloading procedure3.6 Sampling

3.6.1 Sampling methods 3.6.2 Refinery sampling procedure3.6.3 Sampling at offloading point3.6.4 Sampling at a secondary

manufacturer3.7 Test results3.8 Changing of product and flushing

procedure 3.8.1 Product compatibility3.8.2 Flushing procedure

4. Inspections of vehicles and equipment

5. Responsibility matrix

Appendix 1 Classification of bituminous bindersAppendix 2 Risk assessment/safe work proceduresAppendix 3 Hazards

3.1 Product related hazards3.2 Vehicle related hazards

Form 1 Driver’s declarationForm 2 2.1 Tanker/trailer inspection sheet

2.2 Vehicle pre-loading daily inspection checklist2.3 Tanker/trailer flushing certificate2.4 Tanker/trailer cleanliness certificate2.5 Tanker/trailer loading register 2.6 Auditing guide

Form 3 Dangerous goods declaration certificate

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7

9

1111111213

14141515171821222226262828

2930

323232

35

36

3839404040

List of tables and diagrams

Figure 1 Process flow of binders from source to point of use

Figure 2 Offloading at a site

Table 1 Recommended sampling and testingregime

Table 2 Flushing table

Table 3 Responsibility matrix

Table 4 Minimum driving and duty periods

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10

24

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1. Introduction

Incorrect practices during the handling of bituminousbinders can be detrimental to the quality of the binder.Contamination by small amounts of solvents or differentgrades of bituminous binders during the loading process can have serious adverse effects on the quality of the binder.Such adverse effects often only manifest themselves oncethe final product has been applied.

It is therefore of the utmost importance that the quality ismaintained by ensuring that bituminous binders are handled in a standardised way, and that possible sources ofcontamination or practices that could have an adverse effect on quality are identified and eliminated.

The code of practice includes all aspects involving thehandling of bituminous binders as a raw material, i.e. before use in the final product, and includes loading, transporta-tion, offloading, testing and sampling practices. Thesehandling activities generally occur when:

• penetration or cutback bitumen is transported from the refinery to a construction site or asphalt plant or depotor binder factory for further processing (e.g.emulsificaton or modification;

• modified binders or bitumen emulsions are transportedfrom the factory to the construction site, asphalt plantor depot.

Note:

For the convenience of users, essential declaration forms,checklists, inspection sheets and an auditing guide areincluded as fold-out forms at the back of this booklet. These may be photocopied for repeated use.

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Note:

For details on the classification of generic grades ofbituminous binders, refer to Appendix 1.

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Figure 1: Process flow of binders from source to point of use

2. Regulations

2.1 Driver requirements

All drivers must be in possession of a valid EC license and aprofessional driving permit for dangerous goods (PrDP(DG)license). Foreign drivers will be required to conform to theirhome country regulations. Drivers must undergo companyspecific training in the loading, transportation and offloading of penetration bitumen and other associated bituminousbinders, and have a complete knowledge of the appropriateregulations. Drivers will, in addition, be required to complete the required induction training in accordance with eachrefinery’s specific requirements.

All drivers must undergo an annual medical examination asrequired by the Hazardous Substances Act and Road TrafficAct.

Drivers must also be conversant with the relevant provisions and regulations of the Occupational Health and Safety Act,which must be adhered to at all times.

2.2 Driver declaration

To ensure compliance with relevant legislation, and toprotect the health and safety of the driver, the public andthose persons involved in loading, sampling, transportationand offloading operations, and to ensure that the quality ofthe product is not affected in any way, all bulk tankerdrivers transporting bituminous binders are expected to sign a declaration, detailing the regulations that must becomplied with. An example of such a declaration is includedin Form 1.

These regulations will be stringently enforced, anddisciplinary action may be taken against any driver whoinfringes.

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2.3 Road transport

Drivers must ensure that pre-departure vehicle inspectionsare always conducted, and that the relevant checklist(s) are completed prior to departure from the depot. In instanceswhere a rig is away from a depot for a long period andcompletes a number of loads, it is incumbent upon thedriver to ensure that a checklist, together with a list offaults (if any), is forwarded to the depot for action asappropriate. This must be done within a minimum period oftwo weeks of leaving the depot or the date of the lastchecklist. It is important at all times for the driver to stopthe rig if any fault is likely to endanger his safety or that ofany member of the public, and to immediately report anysuch fault to the supervisor. (Typical examples of atanker/trailer inspection sheet and a pre-loading dailyinspection checklist are included in Form 2).

Drivers must also ensure that the following are in place:

• Dangerous goods placards and the diamond-shapeddangerous goods warning placards with appropriatecode UN3257 should be used when penetration gradebitumens or hot modified bitumens are transported. UN1999 must be used when transporting cutbacks andemulsions. (Refer to note below);

• Orange coloured box containing transport emergencycards (tremcards) applicable to the material beingtransported, route plan, material safety data sheets(MSDS), licenses, permits, dangerous goods

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Note

In the past code UN1999 was applied to the

transport of all types and grades of bituminous

binders in accordance with SANS 10228.

Following a submission by Sabita, SABS has

formally advised that the appropriate code

for penetration grade bitumen is UN3257.

(SANS reference 5140/DG/1 dated

22 February 2005).

transportation documents and the supplier’sdocumentation; emergency breakdown triangles, fireextinguishers, personal protective equipment (PPE)flashing lights and first aid kit.

Dedicated tankers should be used for transporting specificbituminous binders, as far as is reasonably possible, inorder to minimise the likelihood of contamination betweendifferent products and grades of products.

2.4 Documentation requirements

Documentation during the loading, transportation andoffloading operations must include the following:

• Loading advice/order and loading register;• Customer’s order;• Driver’s instruction sheet, including temperature

specification;• Delivery note;• Route plan (if required by consignor);• Fire permit (if required);• Tremcard;• Vehicle inspection sheet/check list (refer Form 2.1

and 2.2);• Weighbridge, or meter ticket/certificate;• Cleanliness and flushing certificates (as applicable)

(refer Form 2.3 and 2.4);• Trip sheet;• Tanker/Trailer loading register (refer Form 2.5);• Laboratory certificate for the product;• Dangerous goods declaration from the consignor (refer

Form 3.

The driver must check that the required documents are inhis possession.

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3. Procedures

3.1 Pre-loading inspections

Before proceeding to the loading point the following vehicleinspections must be carried out:

• Ensure that a cleanliness certificate has been issued or, where appropriate, a back-haul certificate indicatingthe previous product transported;

• Make sure that the tanker has been flushed if adifferent type of product is to be loaded, and that aflushing certificate stating that the tanker is clean andwater-free has been issued;

• Ensure that all the personal protective equipment (PPE) needed for loading and unloading is available;

• Make sure the correct tremcard for the consignment isavailable, or obtain this from the consignor;

• Check that the correct placards are displayed on thetankers for the consignment as described in 2.3 above.

Upon proceeding to the loading point verify with theconsignor:

• What the product is;• What the quantity is; • The temperature requirements (refer Form 1);• If there are any compartment loading requirements;• The availability of the correct tremcard.

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Upon arrival at the loading facility, obey all

instructions regarding security, queuing, health,

safety, quality and environmental matters.

If there is any matter of concern, report it to the

control centre and note it on your trip report.

Before loading commences:

• Inform the loading point operator what product wasloaded previously, especially if it was bitumenemulsion;

• Produce the flushing certificate or loading register;• Put on PPE, including heat-resistant gloves.

3.2 Loading procedure

3.2.1 Overview

Although the loading procedures may differ from place toplace, the principles of loading remain the same at everyloading-point, site or refinery.

Even though loading a bitumen tanker may seem a verysimple procedure, there are many pitfalls that could result in serious consequences if the driver is not familiar with thecorrect loading procedure at a specific loading-point, site orrefinery.

While loading at a facility, the driver is responsible to theowners of the facility and must adhere to all theirregulations and instructions. The correct sequence of theloading operation must be adhered to.All health and safety precautions as detailed in SabitaManual 8- Guidelines for the safe and responsible handlingof bituminous products must be followed.

There are specific rules and regulations governing theloading of any hazardous product and the driver of thevehicle must be familiar with these.

Although the main product carried in the tanker ispenetration grade bitumen, other products which arebitumen-based — such as cutback bitumen, modifiedbitumen and bitumen emulsions — are also carried. It istherefore essential that the driver has the necessaryproduct knowledge and is able to distinguish between thevarious products.

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Bitumen and bitumen emulsion are not compatible. A violent reaction will be created if these two are mixed. Thepenetration grade bitumen or emulsion will also becontaminated and the contractor or customer will not beable to use it.

The rising level of product in the tanker should be observedfrom the top of the tanker or loading platform to preventthe possibility of a spill over.

All bitumen equipment must be kept in a sound and a cleancondition. This refers particularly to the burners and gaslines, and also to the gas regulators. The build-up ofbitumen residue on the equipment must be prevented ordifficulty will be experienced in handling the product.

Before leaving the yard a check should be made to ensurethat all discharge valves on the receiving tanker are closed.Care should be taken to ensure that no valves are pluggedwith solidified bitumen (which can give the impression thatthe valve is closed).

If the valves are plugged on an empty tanker, the safestmethod to remove the blockage is to move the tanker to aclear safe area in the yard, and open the manhole cover.With a fire extinguisher on hand heat the discharge valve,then open it completely until the bitumen has melted anddischarged into drip pans.

If the tanker had contained bitumen emulsion, or if there iswater in the tanker, it is likely to cause frothing (whichcould lead to “boiling”). Product contamination could occurand loading must not commence until the water or bitumenemulsion has been drained or removed from the tanker.

It is also important to allow sufficient ullage after loading toallow for expansion resulting from any subsequent heating,or when loading pipes need to be flushed after loading has

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Delivering a contaminated product to a customer

can have serious consequences.

been completed. After loading, ensure that the manholecover is secure.

To prevent injuries it is important that all persons involvedin the loading operations wear the required PPE and adhereto all the health and safety aspects. Reference must bemade to Sabita Manual 8 - Guidelines for the safe andresponsible handling of bituminous products.

The procedure detailed below is a general procedure to befollowed for loading a tanker. The procedure for loading atthe refinery is included thereafter.

3.2.2 General Procedure:

• Make sure that all valves are closed;• Open hatches and manholes;• If loading cutback bitumen, connect the static earth

cable to the earth point on the vehicle. Place theloading funnel in the manhole and align the loadinggantry and arm;

• If the previous load was emulsion, load the tanker toabout one-quarter (20% -25%) capacity and stoploading;

• Listen for a few minutes to detect any sound ofbitumen boiling (rumbling) which may cause boil-overand lead to injury if the tanker is full;

• If there is no boiling, load the remainder of theconsignment;

• Notify the loading point operator immediately if there is any indication of boiling. Take the necessaryprecautions to prevent injury;

• For heated loads and consignments, check that theload is at the right temperature as per therecommended loading temperature specified by thedriver’s instruction sheet and/or loading advice, and/or customer’s order;

• Close all hatches and manholes;• Check that valves are tightly closed and secure;• Check for cracks and/or leaks;• Ensure that all hoses and other equipment are

disconnected;

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• Check that all necessary hazchem documents areavailable, i.e. a Dangerous Goods DeclarationCertificate, Tremcard and MSDS, and that thedangerous goods warning diamonds are in place;

• Proceed to the unloading point, as per your driver’sinstruction sheet and the route plan;

• Report any problem, or incidents, at the loading pointfacilities to the control centre immediately.

3.2.3 Loading at the refinery

The following procedures refer specifically to the loading ofbitumen at a refinery and should be read in conjunction with Sabita Manual 23 - Bitumen Hauliers’ Code: Guidelines forloading bitumen at refineries.

Gates and weighbridge:

• Approach the security gates at the refinery and wait for permission to enter;

• The green light will flash on and the gates will openautomatically. If the gates are already open, wait forthe security guard to give permission to enter;

• When permission is obtained, proceed slowly onto theweighbridge, stop, and switch off engine;

• Alight from the cab and proceed to the weighbridgecontrol-room. Hand in all necessary documentation,produce cleanliness, back-haul and flushing certificates as applicable, and collect the weighbridge ticket afterthe tare mass has been taken;

• Return to the vehicle and accompany the securityguard as he inspects the vehicle inside and outside.The driver must always accompany the guard andadhere to all instructions;

• On completion of the inspection, proceed to the loading zone. Adhere to the speed limits at all times.

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Never leave the top of the tanker or platform

while loading is under way.

Loading zone:

• On arrival at the loading zone, park the tanker in theparking area if a tanker already occupies the loadingbay;

• Proceed to the loading office and hand order to theattendant;

• Attendant will advise which point to load from. Informthe attendant if the previous load in the tanker wasemulsion;

• Return to the cab and enter the necessary informationon the trip sheet;

• Put on PPE;• Once the loading area has been vacated, manoeuver

tanker so that the tanker hatch is directly under theloading arm;

• Before going onto the loading platform, ensure that the earth cable is attached to the “earth” point on thetanker if cutback bitumen is being loaded;

• Make sure all valves are closed;• Proceed to the top of the platform and onto the tanker,

and open the tanker hatch. Ensure that hatch coverseals have not been lifted. Reset seals if lifted. Placecover down gently as it may be an aluminium coverwhich can break if harshly handled;

• Remove the spill bucket from the loading arm andplace it out of the way on the platform or on thetanker;

• Lower the loading arm into the tanker. The arm shouldbe well below the rim of the hatch to avoid spillage;

• Secure the loading arm and open the loading valve;• Signal to the attendant by waving both arms to start

loading. The attendant may not start the loadingpumps until he gets the signal from the driver;

• If there are any signs of boiling, signal the attendant to stop the loading process immediately. Remove the

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Remember - bitumen emulsion and bitumen,

as well as water and bitumen, do not mix. The water

will boil, causing a violent reaction, and product

quality will be affected.

tanker from the loading zone, if safe to do so. Loadingmay only re-commence once the cause of the boilinghas been established, and authority has been obtainedfrom the authorised representatives of the refinery and hauling company;

• If there are no signs of boiling, continue the loadingprocess until the bitumen is at the required level;

• Once the bitumen is at the required level in the tanker, signal the attendant to stop the pumps. Close the valve on the loading arm;

• Raise the loading arm just above the level of thebitumen in the tanker to allow any bitumen in the pipeto run off into the tanker;

• Once the pipe is clear, raise it to its maximum heightand secure it with the locking chain. Hang the spillbucket on the hook attached to the loading arm;

• Grease the hatch cover seal, close and tighten thehatch cover to avoid spillage when the tanker is underway;

• Check that the valves are tightly closed and secure;• Disconnect the earth cable and hang it on the hook

provided for that purpose;• Drive the tanker away from the loading bay so that

other vehicles waiting to load are not obstructed ordelayed;

• Take off PPE and stow it away in an appropriate placein the cab;

• Park the vehicle, preferably facing the exit, and thenenter the office to sign and obtain the documents forthe load, including product laboratory certificate;

• Drive to the weighbridge where the tanker will beweighed to obtain the gross mass and the mass of theactual load;

• After obtaining the necessary weighbridge tickets forthe hauling company and the customer, return to thevehicle and again accompany the security guard for afinal inspection of the vehicle;

• Ensure that the driver is in possession of all necessaryhazchem documentation pertaining to the loadedproduct, i.e. Dangerous Goods Declaration, Tremcardand MSDS;

• Ensure that the correct dangerous goods placards andthe dangerous goods warning diamonds are in place;

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• Leave the refinery premises and drive to thedesignated site for offloading.

3.3 Heating

The following must be adhered to at all times when heatingbituminous binders:

• Always check the heating equipment before lighting the burners. Use only if it is safe to do so;

• Always wear the appropriate PPE;• Never heat bituminous products if the temperature is

at or above the recommended temperatures specifiedin Form 1;

• Heating must only take place where safe to do so andnever while travelling;

• Burners may not be left unattended once lit or whileheating is in progress;

• No unauthorised persons must be allowed in thevicinity while heating is under way. Only the driver orhis assistant is authorised to light the burners;

• Before igniting the burners, fire extinguishers must beremoved from storage and placed in a suitable areaready for use;

• The vehicle should be positioned so that wind will notcarry vapours from the hatches to the flues or sparksfrom flues to hatches;

• Ensure that the level of product is at least 200mmabove the flues before heating;

• All bitumen tankers are to be fitted with flue liners,extending at least 1,5 metres into the tanker;

• Heating may not take place during loading oroffloading;

• Bitumen is a poor conductor of heat. With LP gasheating, the temperature on the surface of the fluescan easily reach 5000C, and it is therefore important to circulate the binder while heating, especially in thecase of modified binders. Localised over-heating cancause carbon to form around the flues and/ordegradation of the polymer in the binder. This can lead to blocked nozzles when spraying and/or prematurehardening of the binder.

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3.4 Transportation

All road and traffic rules in relation to the transportation ofhazardous substances must be adhered to while travellingon public roads.

The specified route to the offloading point, as per instruction and route plan, must be followed. A route with the lowestpossible pollution impact should be selected.

Should spillage of any kind occur during transit, the drivermust stop immediately. The consignor and local authoritiesmust be notified without delay and the necessaryprecautions taken to prevent accidents and injuriesoccurring.

All details must be recorded on the trip report.

All incidents must be reported to the consignor andemergency services as soon as possible after the event.

While in transit, minimum heating must be applied in orderto maintain the temperature of the load above minimumoffloading temperature. This must take place in a safe areaand never while travelling.

It is important that the driver has regular stops to rest, andcarries out the required in-transit vehicle inspections.

3.5 Offloading procedure

General:

• The driver must obtain permission before entering thesite, after which the customer’s representative shouldexamine the consignor’s and haulier’s documentationto ensure that the correct product has been loaded.

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Only light gas burners when it is safe to do so.

Never drive with gas burners ignited.

If the product is incorrect, the required correctiveaction must be taken immediately;

• The gross mass of the tanker should, where possible,be determined and recorded on a weighbridgecertificate, together with the temperature of thebitumen;

• The correct receiving tank must be established and the driver advised to proceed accordingly;

• It is recommended that the vehicle be parked with therear wheels of the truck tractor on elevated ground toincrease the angle of slope of the tanker, so that afterdischarging the tanker will drain completely;

• Discharge cannot begin until permission has beenobtained from the customer’s representative and bothhe and the driver are in attendance. It must also beconfirmed that discharge is into the correct storagetank, and that the tank can take the full load (asdetermined by dipstick measure). This is particularlyapplicable to construction sites;

• Put on personal PPE, including heat-resistant gloves;• If the product requires heating, check the fuel lines for

damage before lighting the burner. Also ensure thatfire extinguishers are on hand in case of emergency;

• Switch on the bitumen pump to ensure that theimpeller is running freely. Switch pump off and applyfurther heat if the impeller does not run smoothly when switched on. Place drip trays in position to preventspillages;

• Before coupling up the discharge pipe to the tanker,check that the discharge valve is not plugged withsolidified bitumen. Carefully heat the valve to clear it ifrequired;

• Connect the discharge pipe from tanker to thedischarge pump. Ensure that the seals are fixed inposition in the pipe’s female coupling; keep dischargevalve in closed position;

• Connect the discharge pipe from the pump to thestorage tank. Ensure that the seals are fixed in position in the pipe’s female coupling;

• The discharge hoses must have industrial couplings onboth sides. Should an open-ended hose be used it isessential that the free end be secured on the receivingtank;

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• Open the manhole cover without lifting or disturbingthe seals. Keep in mind that if the tanker is on anincline overflow through the manhole could cause aspillage;

• Switch off the burners on the road tanker and receiving tank before commencing with transfer of product.

Top loading tank:

• After heating the discharge pump, valves and pipesadequately, open the storage tank intake valve.

• Open the tanker discharge valve slowly, activate thedischarge pump and, when the bitumen begins to flowfreely through the pump, open the tanker dischargevalve to its maximum open position.

• Turn off the hand burner and close off the gas flow;• Secure the burner in its correct storage position.

Bottom loading tank:

• In view of the potential for unsafe practice associatedwith discharging into bottom loading tanks, the drivershould act strictly in accordance with instructions froma suitably qualified employee of the consignee, as a

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Figure 2: Offloading at a site

good understanding of the equipment employed isnecessary for safe discharge when this method is used;

• Discharge the load under constant control andobservation. Two persons must always be presentduring the offloading process and the required safetyregulations must be adhered to;

• Ensure that the whole load is completely dischargedinto the customer’s tanks by visual inspection;

• If the load is a heated one, allow the load to stand forfifteen to thirty minutes after initial discharge to allowmaterial to drain from sides of tanker;

• When the load is completely discharged, switch thepump off, remove the hoses and close valves andhatches. Flexible pipes should be drained and stored on an incline to facilitate slow drainage into a quarterdrum. This ensures empty serviceable pipes ready forthe next operation. Replace and secure fireextinguishers and remove drip trays;

• Return to the weighbridge if applicable, and obtain atare mass. Obtain the customer’s signature on thedelivery notes. Check all documents and visuallyinspect the vehicle and trailers for leaks beforeproceeding;

• Return to the depot or to the nearest wash-bay, asinstructed.

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Tankers must not be left unattended during

the offloading exercise.

Note 1

Offloading is the consignee’s responsibility

and the driver must act only under the consignee’s

direction and instruction. Upon arrival at the

consignee’s premises, their instructions regarding

security, queuing, weighing/metering and

unloading, as well as safety, health,

environmental and quality matters, must be

adhered to. If there is any matter of concern, report

it to the control centre and record it on the trip

report.

Loading emulsions:

• Impeller, centrifugal or low-shear pumps are best forpumping emulsions;

• Positive displacement pumps cause shearing of thebitumen droplets, and thus damage the emulsion if not hot — i.e. above 500C;

• Only heat the emulsion prior to pumping. The emulsion must be circulated for a short period daily to preventsettlement;

• Continued heating and/or circulation (especially with agear pump) will cause the bitumen droplets toagglomerate and the polymer (if any) to separate;

• Emulsions must be loaded through a sieve to removeany lumps which may have formed;

• When filling a tank the emulsion must not be allowedto fall from a height as this will damage the emulsion.

3.6 Sampling

3.6.1 Sampling methods

Sampling must be carried out by a competent, trainedperson in accordance with the sampling process based onthe requirements of ASTM D140 and any additional aspectsspecified in TMH 5. The following shall apply:

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Note 2

Extreme care must be taken in all instances to

ensure that product is only discharged into the

allocated tank. It is the consignee’s

responsibility to ensure that product is only

discharged into a tank dedicated to that

particular type and grade of product and

that the tank can accommodate the load.

If dedicated tanks cannot be

used, the necessary cleaning must be done

beforehand.

• The required safety precautions must be taken. Faceshield, heat resistant gloves and protective clothingmust be worn;

• Easy and safe access must be provided to samplingvalves. Sampling valves should be situated so thatmaterial can be drawn as close as possible from themiddle of the tank, tanker or trailer. Sampling valvesshould be locked to prevent accidental orunauthorised tampering;

• The contents of the tank, tanker or trailer must bethoroughly circulated before sampling;

• All persons involved in sampling should be qualified in sampling techniques;

• Samples may be taken from an in-line sampling valve during the loading process at the refinery or factory;

• Samples taken from tankers must be taken throughsampling valves. Samples must be taken in clean twolitre or five litre tins, free from solvent or otherbituminous binders. Glass or plastic containers maybe used for emulsions;

• At least 5 litres of material must be drawn fromsampling valves to clean them before samplingbegins;

• Sample size must be at least 1,5 litres unlessspecified otherwise;

• Filled sample containers must not be submerged insolvent or wiped with a solvent saturated cloth. Aclean dry cloth must be used if cleaning is necessary;

• Samples must be allowed to cool before sealing.Ensure that lids are airtight and cannot becomedislodged during transit. All samples must be labelledas indicated under 3.6.2 and 3.6.3 below. Labellingmust be on the container, not on the lid;

• Heat must not be applied to samples, except whenrequired for testing. Samples should be stored atmoderate ambient temperatures. This is particularlyimportant in respect of emulsions and cutbacks, asextreme temperatures could change the properties ofthese products.

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3.6.2 Refinery sampling procedure

A representative from the refinery, trained in the samplingof bituminous binders, is responsible for taking samples.Samples must be taken of each batch of bitumen from thedesignated sampling valves. The refinery must ensure thatbatch samples are retained for a minimum of two years.

Samples should also be taken from the designated in-linesampling valves during the loading of tankers. Such samples should be taken while loading the second third of the load.These samples will be deemed representative of the product in the tanker and should be retained at the refinery for atleast six months.

Samples, marked with an indelible marker, must contain the following information:

• Grade of bitumen; • Date;• Batch number; • Registration numbers of tanker and pup trailer (in case

of samples taken at loading point); • Time of sampling;• Tank number.

3.6.3 Sampling at offloading point

The responsibility for product quality passes from thehaulier to the consignee at this stage. The consignee shouldtherefore sample all loads delivered, but the driver must beconversant with the method of sampling so as to verifyconformity to standard.

The sample must be taken after at least a third or beforethe last third of the total volume of product has beenoffloaded into the consignee’s plant or site tank.

Samples should only be taken from the sampling valve,which will be positioned between the discharge pump andthe consignee’s tank. If such a sampling valve is notavailable then the sample should be taken from the

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sampling valve situated on the tanker. Samples must not be taken from the top of the tank or from delivery hoses. Samples, marked with an indelible marker, must contain the following information:

• Grade of bituminous binder;• Date and time when sample was taken;• Refinery or supplier;• Batch number of product;• Transporter;• Registration numbers of tanker and/or pup trailer;• Delivery note number;• Temperature of product;• Name of person taking the sample.

Sample volumes must be large enough to ensure that atleast one litre can be retained, after testing, in caseadditional testing is required to resolve a dispute. Retainedsamples should be kept for a minimum of six months,unless a longer period is specified. It is the responsibility ofthe customer to ensure that samples are clearly marked and stored for the agreed period of time in a manner that wouldenable easy and rapid retrieval.

3.6.4 Sampling at a secondary manufacturer

When penetration grade bitumen is emulsified or modifiedat a binder factory, samples of the base bitumen and theprocessed binder product must be taken to check forcompliance. The sampling of the base bitumen must bedone during offloading of the tanker in accordance with theprocedures described in 3.6.3.

The secondary manufacturer must keep retained samples of the processed product, after testing, in case additionaltesting is required to resolve a dispute. Retained samplesshould be kept for a minimum of six months, unlessotherwise specified. These samples must be clearly markedand readily available if required for testing.

Labelling of the retained samples must contain the following information:

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• Sample number;• Type and grade of product;• Date and time when sample was taken;• Batch number of product;• Tank number;• Base bitumen details;• Temperature of product;• Name of person taking the sample.

3.7 Test results

A laboratory certificate must be provided with each load ofbitumen supplied by the refinery. The laboratory certificateshould be attached to the weighbridge certificate andhanded to the consignee by the driver.

The same will apply to the supply of bitumen emulsions ormodified binders from a secondary manufacturer, the latteralso to supply a copy of the laboratory certificate for thebase bitumen together with the modified binder laboratorycertificate. It is the consignee’s responsibility to ensure thatproducts delivered are sampled and tested to ascertaincompliance with the relevant specification. Minimum testingrequirements for the different binders are:

Penetration birumen Penetration and softening pointCutback bitumen Viscosity at 600CBitumen emulsion Binder contentPolymer modified binder Softening pointBitumen rubber Haake viscosity at 1900C

The customer must immediately (preferably within one dayof delivery) notify the haulier in writing should results befound to be out of specification or differ significantly fromthe results supplied by the refinery or supplier. Instantaction should include the immediate isolation andsuspension of the use of the tank containing the suspectproduct, joint independent re-testing and correlationtesting.

The haulier must, by all means possible, investigate thepossibility of contamination.

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Table 1: Recommended sampling and testing regime

Source Sample taken from: Type ofbinder

Testsrequired

Suppliertank

Haulier

RefineryYes Penetration Full batch

Yes Cutback Full batch

Secondarymanufacturer

Yes Penetration Penetration,Softening

point

Yes Cutback Viscosity

@ 600C

Yes Emulsion Full batch

Yes Modified Full batch

Asphalt plantor site

Yes

Penetration Penetration,Softening

point

Yes Cutback Viscosity

@ 600C

Yes Emulsion Bindercontent

Yes Polymermodified

Softeningpoint

Yes Bitumenrubber

Haakeviscosity

@ 1900C

Notes:

1. Full batch infers the full spectrum of tests required in terms of themanufacturer’s quality management system, although in somecases some tests may only be required on a frequency basis.Compliance of these test results to the product specification andthe reporting thereof constitutes the laboratory certificate which isa prerequisite for the release of the product.

2. In the case of the haulier these are the minimum tests requiredbut do not prohibit the consignee from doing additional qualitycontrol testing on the product sample.

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3.8 Changing of product and flushing procedure

3.8.1 Product compatibility

Tankers should, as far as possible, be dedicated to thetransportation of a particular product and grade of product.However, the need to change from one product to anotherwill arise from time to time. In such cases specifiedprecautions must be taken and flushing procedures adhered to if any possibility of contamination between incompatibleproducts and the resulting effect on product quality, as wellas possible boil-over, is to be avoided.

3.8.2 Flushing procedure

Penetration and hard grade bitumens may be switch loaded. However, if bitumen emulsion is to be loaded into a tankthat has contained bitumen, it is necessary to drain as much bitumen as possible from the tank, after which the tank and pipeline should be flushed out with MC30, paraffin or dieselto remove any remaining residue. Surplus MC30, paraffin or diesel fuel should be flushed out with water.

Care must be taken when switching between penetration orhard grade bitumen and cutback bitumen, as productproperties could be adversely effected if the previous loadhas not been drained properly. Flushing is however notrequired, providing the tanker was totally empty afterdischarging.

If it is intended to load cationic emulsion after anionicemulsions have been carried (or vice versa) then the tankmust first be flushed out with water, followed by MC30 ordiesel. Anionic and cationic emulsions must not be allowedto come into contact with each other, as immediatechemical breaking will take place.

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Flushing is always necessary when

changing from anionic to cationic

emulsion or vice versa

Change of product may be carried out only when approvedand supervised in accordance with the following procedure and flushing table:

• Park the tanker at the flushing point at the depot;• Make sure that the valves and pipelines are clear before

coupling up to the flushing plant. If the valves and pipeshave to be heated, do this gently with the burner;

• Drain the tanker into the flushing plant tanks. It isrecommended that the rear wheels of the truck tractor be parked on elevated ground to ensure more effectivedrainage;

• Pump about 6000 litres of flushing product into thetanker;

• Agitate the tanker contents by driving around for at least15 minutes;

• Drain the mixture into the flushing plant;• If further flushing is required, proceed with the process

as indicated in the table;• Check that the tanker is clean and free of previous

product, water and residue;• Check that the valves and pipes are clean;• The tanker is now deemed clean and fit to proceed to the

loading point;• To prevent contamination of product, ensure that all

flushing material is drained out of the tanker.

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Productlast loaded

Product next loaded

Penetration and

modifiedbitumen

Cutback bitumen

Anionicbitumenemulsion

Cationicbitumen

emulsion

Fueloil

Penetrationand

modifiedbitumen

_ A* A A A*

Cutbackbitumen

C _ A A C

Anionicbitumenemulsion

A A _ B A

Cationicbitumenemulsion

A A B _ A

Fuel oil A A A A -

Suspectedpresence of

moistureA A _ _

Procedures:

A Drain vehicle of product and flush with MC30, paraffin or diesel* Provided the tank has been drained, this operation is not required.

B Flush out surplus product from the tank with water until it is not discoloured, and drain tank and lines; drain vehicle of productand flush with MC30, paraffin or diesel; flush out surplus MC30,paraffin or diesel with water (about 450 litres) and drain tank and lines.

C Drain out tank and drain valves.

Note: Earth tanker to paraffin or diesel fuel supply line beforeflushing. The tanker must also be earthed before flushing.

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Table 2: Flushing table

4. Inspections of vehicles and equipment

Inspections of vehicles and equipment must never beneglected or compromised. Besides ensuring the health andsafety of everyone concerned, regular inspections alsoreduce the likelihood of product quality deterioration and/ordamage to the environment. Form 2 contains examples ofthe following:

1. Tanker/trailer inspection sheet; 2. Vehicle pre-loading daily inspection checklist;3. Tanker/trailer flushing certificate;4. Tanker/trailer cleanliness certificate;5. Tanker/trailer loading register;6. Auditing guide.

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5. Responsibility matrix

Table 3: Responsibility matrix

Activity/ Record

Refinery Consignor/Supplier

Haulier/

Driver

Consignee/Custome

r

Vehicleinspections X

Pre-loadinginspections

X

Transportemergency

cards(Tremcards)

X X X

Materialsafety data

sheets(MSDS)

X

Route plan X

Roadworthycertificate

X

Loadingadvice/

registerX

Customer’sorders

X X X

Driver’sinstruction

sheetX

Fire permit X

Weighbridgeor meterticket/

certificate

X X

Tripsheet/report

X

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Activity/ Record

Refinery Consignor/Supplier

Haulier/

Driver

Consignee/Custome

r

Sampling ofeach batch of

bitumenX

Storage ofbitumen

batchsamples

X

Samplingwhile loading

tankerX

Storage ofsample taken

duringloading

X

Acceptanceof load at

customer’ssite

X

Sampling atcustomer’s

siteX

Storage ofcustomer’s

sampleX

Cleanlinesscertificate

X

Flushingcertificate

X

Laboratorycertificate

X

Trainingrecords

X X X

DangerousGoods

DeclarationX

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Appendix 1

Classification of bituminous binder

38

[ 40/50[ 60/70[ 80/100[ 150/200

[ MC30[ MC3000

[ Stablemix [ Stablemix[ Premix[ Spray

[ SBR[ SBS[ Rubber Crumb

[ EVA

Anionic Cationic Elastomer Plastomer

CutbackBitumen

BitumenEmulsions

ModifiedBinders

PenetrationBitumen

Bituminous Binders

Appendix 2

Risk assessments and safe work procedures

In addition to the information contained in this code ofpractice the necessary risk assessments, in terms of theoccupational health and safety act, must be conducted by all organisations involved in the handling, storage,transportation and delivery of bituminous binders. Safework procedures must be compiled from the informationobtained from these risk assessments. It must be ensuredthat personnel receive the required training relevant tothese procedures. Risk assessments and safe workprocedures must be reviewed on an ongoing basis.

Risk assessments and safe work procedures not only set out to ensure safe work practices, but have the additionaladvantage that the quality of work is affected in a positiveway.

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Appendix 3: Hazards

3.1 Product related hazards

It is of utmost importance that the driver of the vehicle beaware of all the possible hazards involved in the variousloading, transporting and offloading procedures ofbituminous binders. Should an emergency arise, the drivermust also be able to take the initiative and handle thesituation competently.

The possibility of bitumen burns remains a significanthazard. It is therefore essential to ensure that the requiredpreventative measures are enforced at all times to reducerisk, and that personnel are trained in the treatment ofbitumen burns.

As the temperature of penetration and modified bitumen isnormally above the boiling point of water, the necessaryprecautions must be taken to prevent water from cominginto contact with these binders. Water will cause boil-overs,with the possibility of injuries and/or fires, and deterioration of product quality.

Cutback bitumens are handled above the flashpoint of thecutter used, and the vapour space above the product istherefore flammable. There is also the possibility ofexplosions. Extreme care must be exercised when heating is required. The ignition of vapours must be prevented, during the loading and offloading operations by keeping all sourcesof ignition away. This includes naked flames and cellphones.

3.2 Vehicle related hazards

The driver must obey all rules and regulations during theloading, transportation and offloading phases, includingon-site regulations. The driver must be able to manoeuvrethe vehicle in confined spaces. This is especially relevantduring loading and offloading operations. The need toreverse the vehicle should, however, be kept to a minimum. Misjudging manoeuvres while positioning the tanker under

40

the loading arm could, for example, result in a collisioncausing serious damage to the tanker.

Spillages must be reported to management and the relevant authorities.

It is vitally important that drivers be alert and attentive atall times when driving. Under no circumstances should adriver be in control of a moving vehicle when feeling tired,and must avoid this by ensuring adequate rest. In the event of feeling tired a driver must stop the vehicle in a safe place as soon as possible and get ample rest.

Table 4: Minimum driving and duty periods

Maximum driving and duty periods

Maximum driving hours per day 14 hours

Maximum duty hours per day 17 hours

Maximum driving hours without a break 6 hours

Minimum breaks per day 40 mins (4 X 10 mins)

Maximum driving hours per week 85 hours (7 days)

Minimum rest periods per day 8 hours

Minimum rest periods per week 70 hours

Minimum days off per month 3 days+

Note:

The consignor may impose more stringent times oncontractual work

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Notes

42

Notes

43

Notes

44

46

47

48

49

50

51

52