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Home / Industries / Asphalt Handling Design, Loading, and Installation.Asphalt Handling Design, Loading, and Installation.
Hot Mix Asphalt Truck load-out Stations and Tank Car loading
Although no two Asphalt Loading solutions will be identical, the product itself determines much of the critical design criteria that will ensure that optimum safety and productivity can work together in harmony.
Asphalt, also known as bitumen, is a sticky, black, highly viscous liquid or semi-solid form of petroleum. It can be found in natural deposits or as a refined product, and is classified as a pitch or tar. Naturally occurring asphalt is sometimes specified by the term “crude bitumen” and the Canadian province of Alberta has most of the world’s reserves of natural asphalt in the Athabasca oil sands, which cover 142,000 square kilometres (55,000 sq mi), an area larger than England.
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Below are some of the loading and unloading solutions for illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs.
Asphalt Loading Arms
Asphalt is typically loaded into railcars or tank trucks via a 4” boom supported carbon steel, heat jacketed (steam or hot oil) loading arm, with a 3” stainless steel vapor hose. The arm is designed to self-drain after each use so excess product doesn’t harden or congeal inside the pipe. Due to the additional weight incurred by jacketing the arm, best practice includes adding pneumatics to a simple counterweighted arm, which substantially improves operator ergonomics. Other loading considerations may include: vapor line pressure switch to avoid over pressurization; Endress & Hauser Nivotester Liquifant high-level probe; parking latch and sensors, and bonding straps for electrical continuity. For unloading, typically asphalt is bottom unloaded via a rigid carbon steel, self-draining, jacketed (steam or oil) arm, or 20’ flex hose.
Loading Gangways and Safety Cages
A wider access gangway (36″-48″ is preferable) as it helps improve access and egress to and from the vessel. In addition, a wider gangway will reduce the risk of the operator’s PPE getting caught, torn or damaged, and will improve productivity and safety. Powered gangway solutions are also an option, with both hydraulic and pneumatic solutions being commonly used. Each gangway will be fitted with a two-rail safety cage for the railcar crash box. This will be a centered 6’x6’ safety cage to sit directly over the cashbox. This will provide a safe, secure work environment for your operator when connected to their breathing apparatus
GX FLAT RAMP ACCESS (FRT) GANGWAY
SafeRack’s NEW GX-FRT is a flat ramp model popular with railcars. It features a slip-resistant walk surface and, with the use of the telescoping extension, eliminates gaps on narrow railcars. Learn More
Asphalt Eye Wash/Drench Showers
ANSI guidelines state that an Eye Wash/Drench Showers need to be located 10 seconds or 55’ (16.8m) from contaminants or hazardous materials. Eyewash stations need to be on the same horizontal plane with no obstructions.
Therefore, we would propose the installation of a standard combination Drench Shower/Eyewash Unit, which will save limited space and fit easily into any work environment.
Asphalt Spill Containment
Spill containment pans will be provided at the point of loading operations and is an essential piece of equipment in overall site safety and environmental protection Asphalt Grounding
While asphalt is not flammable, industry best practice includes the grounding of all vessels before starting the (un)loading process. - Vehicle grounding and bonding — ensure true grounding before product flow is permitted
- Explosion-proof enclosures — meet or exceed UL, CSA, and Ex requirements
Asphalt Safety Gates
Safety Gates will be installed at the top of stairs and any other openings to ensure operator safety at all times. YellowGate Safety Gates
SafeRack’s line of industrial safety gates is the most flexible product on the market with the ability span openings between 16” and 36” and is field adjustable with nothing more than a wrench. Learn More
Asphalt Options
- Lighting – Lighting both over and under the platform will be provided. For overcast days or second shift, lighting is essential for improved safety and improved productivity.
- Platform & Canopies – Full platform canopies reduce exposure to the elements and improve the safe and productive loading operation from the operator’s perspective.
- Operator Shelter – Depending on your site requirements, consideration should be given to the requirement of an operator or guard building on the loading platform. This can be customized to meet specific site requirements
- Wheel Chocks – Railcar Wheel Chocks provide fast blocking of all types of railcars and meet OSHA regulations to safely prevent railroad cars from moving during loading or unloading operations. This is a requirement by the Department of Homeland Security
Personal Protective Equipment PPE Requirements
Eye/Face Protection: Wear chemical safety goggles. A face shield (with safety goggles) may also be necessary. Skin Protection: Wear chemical protective clothing e.g. gloves, aprons, boots. Coveralls or long sleeve shirts and pants in some operations. Wear a chemical protective, full-body encapsulating suit, and self-contained breathing apparatus (SCBA). Suitable materials include: butyl rubber, neoprene rubber, Viton®, Viton®/butyl rubber, Barrier® – PE/PA/PE, Silver Shield® – PE/EVAL/PE, Trellchem® HPS, Trellchem® VPS, Saranex®™, Tychem® BR/LV, Tychem® Responder® CSM, Tychem® TK. The following materials should NOT be used: natural rubber, polyvinyl chloride. Recommendations are NOT valid for very thin neoprene rubber gloves (0.3 mm or less).
Respiratory Protection: Up to 5 ppm:
(APF = 10) Any chemical cartridge respirator with cartridge(s) providing protection against asphalt*; or Any supplied-air respirator*.
*Reported to cause eye irritation or damage; may require eye protection.
APF = Assigned Protection Factor
Recommendations apply only to National Institute for Occupational Safety and Health (NIOSH) approved respirators. Refer to the NIOSH pocket guide to chemical hazards for more information.
Use a local exhaust ventilation and enclosure, if necessary, to control the amount in the air. Consider using a corrosion-resistant exhaust ventilation system separate from other ventilation systems. It may be necessary to use stringent control measures such as process enclosure to prevent product release into the workplace. Use backup controls (e.g. double mechanical pump seals) to prevent the release of this material due to equipment failure. * For illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs Asphalt 101
Things to know about Asphalt
Asphalt is regulated by the U.S. Department of Transportation (DOT) and is classified as a hazardous flammable and elevated temperature material, with the DOT identification number UN 3257.
Asphalt contains numerous compounds including nitrogen, sulfur, hydrogen, and trace amounts of metals such as iron, nickel, and vanadium. Asphalt is typically railed in between 300 and 325F and then trucked out to the end user, but the trucks are not heated.
Under proper work conditions, asphalt is not hazardous to work with; however it’s fumes can be very dangerous if inhaled. Being a petroleum product, asphalt can cause skin irritation and burns, as well as lung irritation. Known carcinogens have also been found in asphalt fumes at work sites, so due diligence should be taken to protect operators working around this product.
First aid measures for exposure include – removing operators from the source of exposure and into fresh air. Remove contaminated clothing immediately; wash skin thoroughly with soap and water; flush eyes with tepid water for 15 minutes. If ingested do not induce vomiting, but immediately call your local poison control center.
Is your plant or facility compliant with ANSI, OSHA, and local safety codes? We can help
North America’s largest loading terminal
World-leading designer, manufacturer, and installer of truck and railcar loading platforms
As one of the primary railcar loading points, Hardisty is one of the major crude oil hubs in North America and a major origination point of pipelines that export to the United States. SCS was asked to supply and construct a SafeRack crude oil loadout terminal spanning nearly half a mile. The USD Hardisty terminal can load up to two 120-railcar unit trains per day and consists of a fixed loading rack with 62 railcar loading positions enclosed, separate control, operator, and mechanical buildings, as well as a unit train staging area and loop tracks capable of holding multiple unit trains simultaneously. SCS also supplied and installed boom-supported loading arms with supply and vapor management systems.
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