20451 Operate Bitumen Gangbar Sprayer Transfer, Heating, and Blending Equipment

Explanatory notes

1The following legislation and requirements apply to this unit standard, and must be complied with:

Hazardous Substances and New Organisms Act 1996;

Health and Safety in Employment Act 1992;

Resource Management Act 1991;

Land Transport Act 1998;

Hazardous Substances and New Organisms (Personnel Qualifications) Regulations 2001;

Hazardous Substances (Classes 1 to 5 Controls) Regulations 2001;

Hazardous Substances (Classification) Regulations 2001;

Hazardous Substances (Tracking) Regulations 2001;

Land Transport Rule: Dangerous Goods 2005 (Rule 45001/1) and amendment 2010 45001/2;

Local authority requirements;

BCA E/2:97 Performance of Bitumen Distributors, Roading NewZealand,available on request at

The Safe Handling of Bituminous Materials Used in Roading – Code of Practice Code of Practice RNZ 9904:2006 , Roading New Zealand, available for purchase at

The Bitumen Safety Handbook; Roading NewZealand,available for purchase at

Chipsealing in New Zealand,New Zealand Transport Agency, available at

Manufacturer’s instructions;

Company procedures;

Gangbar sprayermanufacturer’s manual.

Any legislation or other requirements superseding any of the above will apply, pending the review of this unit standard.

2Personal protective equipment must be used throughout operations in accordance with company procedures.

3Assessment against this unit standard must be based on evidence from a workplace context.

4Assessment against this unit standard is limited to the operation of the gangbar sprayer’s equipment. The specialist skills of spraying bitumen on roads using a gangbar are covered in Unit20452, Spray bitumen for chipseal surfacing using a gangbar sprayer.

5Definitions

Blending operations refers to the blending of an adhesion agent or a minor modification of a cut. It does not include the blending of a major cut.

Company procedures refers to all documented policies, procedures, and methodologies of the candidate’s employer at the time of training including but not limited to those relating to health, safety, environment, quality, and operations.

Gangbarsprayer means tank wagon specifically built for automatically controlled spraying of bituminous materials on pavement surfaces. The equipment on a gangbar sprayer includes a handbar.

Walk round means to walk around a machine or equipment inspecting it, and its environment, for hazards and removing hazards that may impair operation.

Outcomes and evidence requirements

Outcome 1

Identify, assess, control, and monitor health and safety hazards and adverse effects on the environment associated with bitumen gangbar sprayer operations.

Rangeoperations – transferring, heating, blending, circulating, flushing, decontaminating, clearing blockages.

Evidence requirements

1.1Health hazards are identified, assessed, and controlled in accordance with company procedures and legislation.

1.2Safety hazards are identified, assessed, and controlled in accordance with company procedures, legislation, and The Bitumen Safety Handbook.

1.3Adverse effects on the environment are identified, assessed, and controlled in accordance with company procedures and legislation.

1.4Health and safety hazards are monitored in accordance with company procedures and legislation.

Rangeincludes but is not limited to – hazardous material, obstruction, people in the vicinity, personal injury.

1.5Adverse effects on the environment are monitored in accordance with company procedures and legislation.

Rangeincludes but is not limited to – noise, emission, spill.

1.6Procedures for preventing water contamination of hot bituminous liquids are demonstrated in accordance withCode of Practice RNZ 9904:2006 and company procedures.

Rangeincludes but is not limited to – process of adding additives.

1.7Compatibility of previous load and product to be loaded is determined from documentation.

1.8Tank and equipment are checked for possible water contamination and procedures for dealing with water contamination are demonstrated or simulated in accordance withCode of Practice RNZ 9904:2006 and company procedures.

Outcome 2

Perform operator servicing and maintenance on a bitumen gangbar sprayer and equipment.

Evidence requirements

2.1Machinery is checked in accordance with operator servicing requirements, and minor adjustments are made in accordance with gangbar sprayer manufacturer’s manual.

Rangeincludes but is not limited to – fuels, lubricants, tank, valves, bitumen pump, pipework, hoses, gangbar, gangbar valves, spray nozzles, bitumen filter, heating system, bitumen pump instrumentation, sensors, computer controls, hydraulic systems, air tanks, air control systems.

2.2Hoses and couplings are checked for current certification and for wear and tear, and are replaced, if necessary, in accordance with company procedures.

2.3Tyres and tyre pressures are checked and adjusted to ensure conformance with spray chart requirements and compliance with E/2 Specification.

2.4Procedures for clearing blockages are demonstrated in accordance withCode of Practice RNZ 9904:2006 gangbar sprayermanufacturer’s manual, and company procedures.

Rangeblockages – bitumen pump, gangbar, valves, pipework, hoses.

2.5Bitumen filters are cleaned and frequency of cleaning is maintained in accordance with gangbar sprayer manufacturer’s manual,and company procedures.

2.6Routine servicing and maintenance are documented in accordance with company procedures.

Outcome 3

Prepare for bitumen gangbar sprayer operation.

Evidence requirements

3.1Preoperational documentation is confirmed and/or completed in accordance with company procedures.

Rangedangerous goods, emergency procedures, tank contents.

3.2Prestart safety and operational checks are carried out in accordance withgangbar sprayer manufacturer’s manual, and company procedures.

Rangewalk round, first aid equipment, vehicle controls, vehicle gauges, tank, valves, bitumen pump, pipework, hoses, bitumen filter, heating systems, bitumen pump speed instrumentation, vehicle speed instrumentation, sensors, hydraulic system,air control systems;

gangbar – valves, spray nozzles, height.

Outcome 4

Prepare for bitumen transfer, heating, and blending operations with a gangbar sprayer.

Rangehot bitumen, emulsified bitumen;

transfer from – storage tank, road tank wagon;

transfer to – storage tank, road tank wagon, bitumen sprayer;

evidence is required of each of the above in any combination.

Evidence requirements

4.1Selection of site for heating and transferring of bulk bituminous liquids in the field is made with consideration for worker, public, and environmental safety and is in accordance with company procedures.

4.2Compatibility of previous load with product to be loaded is determined in accordance withcompany procedures andCode of Practice RNZ 9904:2006.

4.3Quantity and type of product or blend to be transferred are confirmed in accordance with company procedures, and job and/or client requirements.

Rangeincludes but is not limited to – allowance for modifying existing contents of tank.

4.4Delivery and receiving tanks, and placarding,are inspected in accordance with dangerous goods classification of the product to be transferred.

4.5Position and parking of bitumen gangbar sprayer is checked to facilitatesafe transfer and enable vehicle to be moved with minimal manoeuvring in the event of an emergency.

4.6Warning signage and cones are positioned and fire extinguishers are placed ready for use in accordance withCode of Practice RNZ 9904:2006 and company procedures.

4.7Certification, and safe condition, of hoses and couplings are checked and confirmedin accordance withCode of Practice RNZ 9904:2006and company procedures.

4.8Electrical bonding earth straps, if fitted, are connected and overhead filling equipment or filling hoses are positioned and securely clamped in preparation for loading/unloading in accordance withCode of Practice RNZ 9904:2006and company procedures.

4.9Delivery and receiving tanks are inspected, and pumping equipment, hatches, valves, inlets, and outlets are confirmed as ready for transfer in accordance with company procedures, The Bitumen Safety Handbook, gangbar sprayer manufacturer’s manual, and tank wagon manufacturer’s instructions.

Outcome 5

Undertake bitumen transfer operations with a gangbar sprayer.

Evidence requirements

5.1A check is made to ensure unauthorised persons are clear of the operational area.

5.2Bitumen is transferred in accordance with company procedures, TheBitumen Safety Handbook, and the gangbar sprayer manufacturer’s manual.

Rangehot bitumen, emulsified bitumen;

transfer from – storage tank, road tank wagon;

transfer to – storage tank, road tank wagon, bitumen sprayer;

evidence is required of each of the above in any combination.

5.3Gangbar sprayer pumping equipment is used to transfer bitumen between two tanks independent of the gangbar sprayer in accordance with company procedures, TheBitumen Safety Handbook, and the gangbar sprayer manufacturer’s manual.

5.4Total volume of load is confirmed as not exceeding the maximum load carrying capacity of vehicle.

5.5On completion of transfer, pipelines and/or hoses are purged, the transfer equipment, hoses, and earth strap, if fitted, are disconnected and secured, and valves and hatches on gangbar sprayer and receiving tank are secured, in accordance with company procedures andCode of Practice RNZ 9904:2006.

5.6Gangbar sprayer, ancillary equipment, and receiving tank are checked for leaks and the site is checked for spillage in accordance with company procedures, TheBitumen Safety Handbook, and the gangbar sprayer manufacturer’s manual.

5.7Warning signs and cones are removed and stored in accordance with company procedures.

5.8Dangerous goods documentation appropriate to the load is completed and is placed in the vehicle’s dangerous goods folder in accordance withCode of Practice RNZ 9904:2006.

Outcome 6

Heat, circulate, and blend bituminous liquids in a bitumen gangbar sprayer.

Evidence requirements

6.1Bulk bituminous liquid is heated in accordance with company procedures, The Bitumen Safety Handbook, and the gangbar sprayer manufacturer’s manual.

6.2Heating rates and maximum temperatures are monitored and controlled in accordance with the requirements of the product.

Rangetwo of – straight bitumen, cutback bitumen, polymer-modified bitumen, standard cationic emulsion, high binder content polymer-modified emulsion.

6.3Bitumen is circulated in accordance with the gangbar sprayer manufacturer’s manual, andcompany procedures

6.4On site blending of additives is carried out in accordance with The Bitumen Safety Handbook and the gangbar sprayer manufacturer’s manual, and contract requirements are met.

Rangeevidence is required of blending at least one additive.

Outcome 7

Clean bitumen gangbar sprayer equipment.

Evidence requirements

7.1Gangbar sprayer equipment is emptied, flushed, and decontaminated in accordance with The Bitumen Safety Handbook and the gangbar sprayer manufacturer’s manual.

Rangetank, hoses, pipes, gangbar, handbar.

7.2Gangbar sprayer equipment, hoses, and couplings are inspected and secured in accordance with the gangbar sprayer manufacturer’s manual.

7.3Waste materials are disposed of in accordance with company procedures and legislation.

Status information and last date for assessment for superseded versions

This CMR can be accessed at

Please note

Providers must be granted consent to assess against standards (accredited) by NZQA, before they can report credits from assessment against unit standards or deliver courses of study leading to that assessment.

Industry Training Organisations must be granted consent to assess against standards by NZQA before they can register credits from assessment against unit standards.

Providers and Industry Training Organisations, which have been granted consent and which are assessing against unit standards must engage with the moderation system that applies to those standards.

Requirements for consent to assess and an outline of the moderation system that applies to this standard are outlined in the Consent and Moderation Requirements (CMR). The CMR also includes useful information about special requirements for organisations wishing to develop education and training programmes, such as minimum qualifications for tutors and assessors, and special resource requirements.

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