Product Overview

Summary: This Bitumen Handling Safe Operating Procedure sets out clear, practical steps for safely storing, heating, transporting and applying bitumen on Australian worksites. It helps control the significant burn, fire, fume and traffic interface risks associated with hot bituminous products while supporting compliance with WHS laws and environmental obligations.

Bitumen handling presents a unique mix of high-temperature, chemical and traffic-related hazards that can quickly escalate into serious incidents if not tightly controlled. From heating and transferring bitumen in tanks and sprayers to working around live traffic and ignition sources, every stage of the process requires clear, consistent procedures. This Bitumen Handling Safe Operating Procedure provides a structured, step-by-step framework that integrates WHS best practice with the realities of Australian road construction and maintenance work.

The SOP guides workers and supervisors through safe preparation, plant start-up, temperature control, transfer operations, on-site application, and shutdown, with a strong focus on burn prevention, fire and explosion control, fume exposure management, and spill response. It also addresses traffic management interfaces, contractor coordination, and environmental protection, helping organisations demonstrate due diligence under WHS legislation and road authority requirements. By implementing this procedure, businesses can reduce incident rates, improve crew competence, and provide clear evidence of a systematic approach to managing the risks of bitumen handling.

Key Benefits

• Reduce the risk of serious burns, fires and explosions during bitumen storage, heating and transfer.
• Ensure consistent compliance with Australian WHS legislation and road authority requirements for hot bitumen work.
• Standardise training for crews and contractors with clear, step-by-step instructions for all bitumen handling tasks.
• Minimise worker exposure to hazardous fumes and vapours through defined engineering and PPE controls.
• Improve incident response capability with documented procedures for spills, burns, equipment failure and traffic-related emergencies.

Who is this for?

• Asphalt Plant Managers
• Road Construction Supervisors
• Civil Construction Workers
• Spray Seal and Asphalt Crew Leaders
• Bitumen Truck and Tanker Operators
• WHS Managers and Advisors
• Project Engineers (Civil and Roadworks)
• Local Government Works Supervisors
• Maintenance and Workshop Technicians
• Contractor Compliance Managers

Hazards Addressed

• Thermal burns from contact with hot bitumen, pipes, hoses and equipment surfaces
• Fire and explosion risks from flammable vapours and ignition sources near heating and transfer equipment
• Inhalation of bitumen fumes, vapours and combustion products
• Pressurised line failures, hose bursts and uncontrolled release of hot product
• Slips, trips and falls around overspray, spills and uneven road surfaces
• Traffic interaction hazards when working on or adjacent to live roadways
• Manual handling injuries from handling hoses, fittings, lids and ancillary equipment
• Chemical exposure from bitumen additives, solvents and cleaning agents
• Environmental contamination from spills to soil, drains and waterways

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Bitumen Types
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Guidance
• 5.0 Required PPE and Safety Equipment
• 6.0 Plant and Equipment Requirements (Tanks, Burners, Sprayers, Hoses)
• 7.0 Pre-Start Checks and Site Preparation
• 8.0 Bitumen Storage, Heating and Temperature Control Procedures
• 9.0 Safe Transfer and Loading/Unloading of Bitumen
• 10.0 On-Site Application Procedures (Spray, Spread, Compact)
• 11.0 Traffic Management and Worksite Access Controls
• 12.0 Hazard Identification and Risk Control Measures
• 13.0 Fume, Vapour and Ventilation Controls
• 14.0 Spill Prevention and Environmental Protection Measures
• 15.0 Cleaning, Flushing and Decommissioning of Equipment
• 16.0 Emergency Response (Burns, Fires, Spills, Equipment Failure)
• 17.0 Incident Reporting and Investigation
• 18.0 Training, Induction and Competency Verification
• 19.0 Inspection, Maintenance and Recordkeeping Requirements
• 20.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1801: Occupational protective helmets
• AS/NZS 2161: Occupational protective gloves
• AS/NZS 2210: Occupational protective footwear
• Austroads Guides and state/territory road authority specifications for bituminous surfacing (as applicable)