Page 1 of 8 Title Operate bitumen gangbar sprayer transfer, heating, and blending equipment Level 4 Credits 15 Purpose People credited with this unit standard are able to: identify, assess, control, and monitor health and safety hazards and adverse effects on the environment associated with bitumen gangbar sprayer operations; perform operator servicing and maintenance on a bitumen gangbar sprayer and equipment; prepare for bitumen gangbar sprayer operation; prepare for bitumen transfer, heating, and blending operations with a gangbar sprayer; undertake bitumen transfer operations with a gangbar sprayer; heat, circulate, and blend bituminous liquids in a bitumen gangbar sprayer; and clean bitumen gangbar sprayer equipment. Classification Pavement Surfacing > Chipseal Surfacing Available grade Achieved Entry information Critical health and safety prerequisites Unit 20459, Transport bulk bituminous liquids by road and assist with loading and unloading; and Unit 20461, Demonstrate knowledge of bitumen gangbar sprayers and operations; or demonstrate equivalent knowledge and skills. Explanatory notes 1 The 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;
Page 2 of 8 BCA E/2:97 Performance of Bitumen Distributors, Roading New Zealand, available on request at http://www.roadingnz.org.nz/; 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 http://www.roadingnz.org.nz/; The Bitumen Safety Handbook; Roading New Zealand, available for purchase at http://www.roadingnz.org.nz/; Chipsealing in New Zealand, New Zealand Transport Agency, available at http://www.nzta.govt.nz/resources/chipsealing-new-zealand-manual/; Manufacturer s instructions; Company procedures; Gangbar sprayer manufacturer s manual. Any legislation or other requirements superseding any of the above will apply, pending the review of this unit standard. 2 Personal protective equipment must be used throughout operations in accordance with 3 Assessment against this unit standard must be based on evidence from a workplace context. 4 Assessment 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 Unit 20452, Spray bitumen for chipseal surfacing using a gangbar sprayer. 5 Definitions 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. Gangbar sprayer 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.
Page 3 of 8 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. operations transferring, heating, blending, circulating, flushing, decontaminating, clearing blockages. 1.1 Health hazards are identified, assessed, and controlled in accordance with company procedures and legislation. 1.2 Safety hazards are identified, assessed, and controlled in accordance with company procedures, legislation, and The Bitumen Safety Handbook. 1.3 Adverse effects on the environment are identified, assessed, and controlled in accordance with company procedures and legislation. 1.4 Health and safety hazards are monitored in accordance with company procedures and legislation. includes but is not limited to hazardous material, obstruction, people in the vicinity, personal injury. 1.5 Adverse effects on the environment are monitored in accordance with company procedures and legislation. includes but is not limited to noise, emission, spill. 1.6 Procedures for preventing water contamination of hot bituminous liquids are demonstrated in accordance with Code of Practice RNZ 9904:2006 and includes but is not limited to process of adding additives. 1.7 Compatibility of previous load and product to be loaded is determined from documentation. 1.8 Tank and equipment are checked for possible water contamination and procedures for dealing with water contamination are demonstrated or simulated in accordance with Code of Practice RNZ 9904:2006 and
Page 4 of 8 Outcome 2 Perform operator servicing and maintenance on a bitumen gangbar sprayer and equipment. 2.1 Machinery is checked in accordance with operator servicing requirements, and minor adjustments are made in accordance with gangbar sprayer manufacturer s manual. includes 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. 2.2 Hoses and couplings are checked for current certification and for wear and tear, and are replaced, if necessary, in accordance with 2.3 Tyres and tyre pressures are checked and adjusted to ensure conformance with spray chart requirements and compliance with E/2 Specification. 2.4 Procedures for clearing blockages are demonstrated in accordance with Code of Practice RNZ 9904:2006 gangbar sprayer manufacturer s manual, and blockages bitumen pump, gangbar, valves, pipework, hoses. 2.5 Bitumen filters are cleaned and frequency of cleaning is maintained in accordance with gangbar sprayer manufacturer s manual, and company procedures. 2.6 Routine servicing and maintenance are documented in accordance with Outcome 3 Prepare for bitumen gangbar sprayer operation. 3.1 Preoperational documentation is confirmed and/or completed in accordance with dangerous goods, emergency procedures, tank contents.
Page 5 of 8 3.2 Prestart safety and operational checks are carried out in accordance with gangbar sprayer manufacturer s manual, and walk 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. hot 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. 4.1 Selection 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 4.2 Compatibility of previous load with product to be loaded is determined in accordance with company procedures and Code of Practice RNZ 9904:2006. 4.3 Quantity and type of product or blend to be transferred are confirmed in accordance with company procedures, and job and/or client requirements. includes but is not limited to allowance for modifying existing contents of tank. 4.4 Delivery and receiving tanks, and placarding, are inspected in accordance with dangerous goods classification of the product to be transferred. 4.5 Position and parking of bitumen gangbar sprayer is checked to facilitate safe transfer and enable vehicle to be moved with minimal manoeuvring in the event of an emergency. 4.6 Warning signage and cones are positioned and fire extinguishers are placed ready for use in accordance with Code of Practice RNZ 9904:2006 and 4.7 Certification, and safe condition, of hoses and couplings are checked and confirmed in accordance with Code of Practice RNZ 9904:2006 and company procedures.
Page 6 of 8 4.8 Electrical 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 with Code of Practice RNZ 9904:2006 and 4.9 Delivery 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. 5.1 A check is made to ensure unauthorised persons are clear of the operational area. 5.2 Bitumen is transferred in accordance with company procedures, The Bitumen Safety Handbook, and the gangbar sprayer manufacturer s manual. hot 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. 5.3 Gangbar sprayer pumping equipment is used to transfer bitumen between two tanks independent of the gangbar sprayer in accordance with company procedures, The Bitumen Safety Handbook, and the gangbar sprayer manufacturer s manual. 5.4 Total volume of load is confirmed as not exceeding the maximum load carrying capacity of vehicle. 5.5 On 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 and Code of Practice RNZ 9904:2006. 5.6 Gangbar sprayer, ancillary equipment, and receiving tank are checked for leaks and the site is checked for spillage in accordance with company procedures, The Bitumen Safety Handbook, and the gangbar sprayer manufacturer s manual. 5.7 Warning signs and cones are removed and stored in accordance with company procedures. 5.8 Dangerous goods documentation appropriate to the load is completed and is placed in the vehicle s dangerous goods folder in accordance with Code of Practice RNZ 9904:2006.
Page 7 of 8 Outcome 6 Heat, circulate, and blend bituminous liquids in a bitumen gangbar sprayer. 6.1 Bulk bituminous liquid is heated in accordance with company procedures, The Bitumen Safety Handbook, and the gangbar sprayer manufacturer s manual. 6.2 Heating rates and maximum temperatures are monitored and controlled in accordance with the requirements of the product. two of straight bitumen, cutback bitumen, polymer-modified bitumen, standard cationic emulsion, high binder content polymermodified emulsion. 6.3 Bitumen is circulated in accordance with the gangbar sprayer manufacturer s manual, and company procedures 6.4 On 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. evidence is required of blending at least one additive. Outcome 7 Clean bitumen gangbar sprayer equipment. 7.1 Gangbar sprayer equipment is emptied, flushed, and decontaminated in accordance with The Bitumen Safety Handbook and the gangbar sprayer manufacturer s manual. tank, hoses, pipes, gangbar, handbar. 7.2 Gangbar sprayer equipment, hoses, and couplings are inspected and secured in accordance with the gangbar sprayer manufacturer s manual. 7.3 Waste materials are disposed of in accordance with company procedures and legislation. Replacement information This unit standard and unit standard 20461 replaced unit standard 1497.
Page 8 of 8 Planned review date 31 December 2016 Status information and last date for assessment for superseded versions Process Version Date Last Date for Assessment Registration 1 27 October 2005 31 December 2013 Revision 2 25 May 2007 31 December 2013 Review 3 15 March 2012 N/A Consent and Moderation Requirements (CMR) reference 0101 This CMR can be accessed at http://www.nzqa.govt.nz/framework/search/index.do. 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. Comments on this unit standard Please contact askus@infratrain.co.nz if you wish to suggest changes to the content of this unit standard.