Bulk Asphalt Materials
Section A: Partial Plant Inspection of Bulk Bituminous Materials
In this type of inspection, the primary duties of the Inspector are to sample storage tanks of bituminous materials and to submit the samples to the OMM. It is the responsibility of the plant or terminal personnel to prepare the forms certifying that shipments have been made from tested and approved stocks. Since the installations for storing bituminous materials vary among the plants and terminals, the methods of inspection are to be modified accordingly. The methods of inspection are as follows:
The simplest installation consists of one storage tank equipped with one line for charging the tank and with a separate line for loading transports or distributors for shipments. The tank may be charged with material produced at the same location or it may be charged with material from a different location with material that has not been previously tested by OMM. At this type of installation, the Inspector is to seal the inlet valve to the storage tank, obtain a sample of the bituminous material and submit the sample, along with the prescribed forms, to OMM. When the tank is empty, the Inspector, at the request of the plant's personnel, will remove the seal from the inlet valve, informing OMM of this action by means of a TE-51 Report Form. The Inspector may be required to check samples from the storage tank in accordance with the requirements described later in this Appendix.
At a location where the installation consists of several storage tanks and each tank is equipped with its separate charging and loading line, the procedure given in the previous paragraph is used for each tank.
At locations where a large storage tank is so situated that it is impossible to directly load truck transports from it, the large storage tank inlet is sealed and the tank sampled. After the material has been approved by OMM, it may be transferred, as needed, to a smaller "marketing" or shipping tank provided this method of operation has been approved by OMM. In this type of operation, more check samples are required than for the operation described before.
At some terminals, material produced at a different location, tested and approved by OMM, is received in tank cars, tank trucks or river barges and transferred to a "marketing" or shipping tank. Detailed instructions regarding the periodic sampling of the shipping tank are given in section dealing with, "Check Samples".
If it appears desirable to establish inspection at a location, OMM, with the cooperation of the District Engineer of Tests, will make a preliminary survey of the plant's facilities. Where the survey is favorable, the Producer will be advised by a letter from OMM of his responsibilities in the shipping of inspected, approved bituminous materials.
When an Inspector is assigned to perform sampling at a plant or terminal, he shall inform himself of the safety regulations in effect at the plant or terminal. The Inspector shall cooperate with the management of the plant or terminal by carefully observing the safety regulations, which may require the use of safety equipment, such as hard hats, goggles, gloves, etc.
Control of Sealed Tanks
Each time an Inspector makes a call at a plant, he shall check the seals on all of the tanks. The Inspector shall record the seal numbers of the TE-51 Report and note as to whether or not the seals were intact. The Inspector is the only one authorized to break the seals on the storage tank. The numbers of the broken seals shall be recorded on the TE-51 Report. When the Producer requests that the seals be broken on a storage tank, the matter shall be handled promptly.
If the Inspector finds that the Producer's personnel has broken the seals on a storage tank, he shall immediately notify the District Engineer of Tests who will in turn inform OMM.
At locations where the inlet valves of the storage tanks are not sealed, the Inspector shall examine the pumping log and transfer record each time he calls at the plant or terminal. The purpose of this examination is to check as to whether or not the plant or terminal is conforming to the inspection procedure established by OMM. Any apparent deviation shall be promptly reported to the District Engineer of Tests.
Where the Producer or Supplier considers it necessary to periodically mix the contents of a storage tank by circulating the contents with a pump, the Inspector shall break the seal on the inlet lines and remain at the plant until the operation is completed. Then the Inspector shall seal the inlet line, submit a check sample and make a record of the operation on a TE-51 Report. This operation must have prior approval of OMM..
Ohio Department of Transportation metal seals are to be used to seal the inlet valves of the storage tanks. If the construction of the valve is such that it can not be effectively sealed with one seal, secure the valve in the closed position with a short piece of chain and then use the seal on the chain.
Methods of Sampling Bituminous Materials
These methods apply to the sampling of liquid, semi-solid, or solid bituminous materials from bulk storage, tank cars, tank truck, distributors, drums or packages.
Sampling is equally as important as the testing and every precaution shall be taken to obtain samples that show the true nature and condition of the materials. Test results are valuable only when the tests are performed on a sample truly representative of the material.
Samples may be taken for either of two purposes:
To represent as nearly as possible an average of the bulk of material sampled.
To ascertain the maximum variation in characteristics which the material may possess.
Size of Sample
The size of the sample shall be not less than one quart for the following liquid bituminous materials:
702.03 Cut-Back Asphalt Emulsions
702.04 Emulsified Asphalts
702.05 Asphalt Primer for Waterproofing
702.09 Tars, RT-1 to RT-12, inclusive
702.10 Creosote for Priming Coat
The size of the sample shall be not less than one pint for the following semi-solid bituminous materials:
702.01 Asphalt Cements
702.06 Asphalt for Waterproofing
702.11 Coal-Tar Pitch for Waterproofing
702.10 Bituminous Pipe Joint Filler
The size of sample shall not be less than 10 pounds or one gallon for the following materials:
705.04 Hot Applied Joint Sealer
Protection and Preservation of Samples
Care shall be taken that the samples are not contaminated with dirt or other extraneous matter and that the sample containers are perfectly clean and dry before filling. Sampling apparatus shall likewise be clean and dry before being used.
Immediately after filling, the sample container shall be tightly closed and properly marked for identification on the container itself and on the TE-31 attached to the container.
Volatile materials shall be protected from evaporation and at once placed in tightly closed containers.
To allow for expansion or contraction of the samples, the sample containers shall be nearly, but not quite, completely filled.
Sampling from Bulk Storage
The inlet and outlet of the storage tank shall be closed. When so instructed, the Inspector shall seal the inlet to the storage tank before proceeding with the sampling.
Drain Valve Sampling
If the storage tank is equipped with a drain or sampling valve, the sample may be taken from this drain or sampling valve providing the contents of the storage tank have been thoroughly mixed by mechanical agitation, or by recirculating by pumping, or by blowing with air. The drain valve assembly shall be thoroughly flushed by opening the valve and permitting at least one gallon of the material from the tank to flow through it. This material shall be discarded. The flushing of a drain valve before taking a sample is very important and must never be omitted.
If the storage tank is equipped with drain valves located at the bottom third, middle and top thirds of the tank, samples shall be taken from each of the drain valves. However, before taking a sample, each drain valve assembly shall be thoroughly flushed by the procedure given in paragraph
Equal parts of these three samples shall be blended thoroughly in a clean, dry container and from this blend the sample taken for submission to OMM. The purpose of this method of sampling is to represent as nearly as possible an average of the bulk of material sampled.
If the Inspector is instructed to obtain samples for purposes set forth earlier, then samples taken in accordance with the procedure given in Drain Valve Sampling shall not be composited but must be submitted in separate sample containers and each sample shall be clearly identified as to which part of the storage tank it was taken, i.e., bottom, middle, and top.
Throw-Away Container Method
If the storage tank is not equipped with drain or sampling valves, the sample shall be secured by lowering into the material a clean container in a suitable weighted holding device. The container shall be fitted with a stopper which shall be removed by a string or wire after it has been lowered to the proper depth. The container shall be completely filled at the level selected. The samples may be composited as described in Drain Valve Sampling depending upon instructions from OMM.
All Level Sample
As an alternative, the weighted container shall be lowered to near the "draw off" level of the storage tank, the stopper removed from the container by a sharp jerk of the string or wire, and the container raised a such a rate that it is nearly but not quite full, when it emerges from the top surface of the liquid.
Sampling Tank Cars, Tank Trucks or Distributors.
Sampling shall be done by the Throw-Away Container Method or by means of a "submerged sampling device" or valve installed in the bulkhead of the tank truck or distributor.
Sampling Drums, Barrels or Packages.
Where the material is obviously a single lot or batch, a sample of liquid bituminous material shall be secured, after thorough mixing of the contents, by taking one quart of the material from a drum or barrel selected at random. Where it is not possible to differentiate between the various lots or batches, sample each container.
Sampling Semi-Solid or Solid Materials
Where the material to be sampled is obviously a single lot or batch, one package or container shall be selected at random for sampling. Samples shall be taken from at least 3 inches below the surface and at least 3 inches from the side of the container. A clean hatchet may be used if the material is hard enough to shatter and a broad, stiff putty knife if the material is soft. Where it is not possible to differentiate between the lots or batches, sample each container.
Taking of Samples
The Superintendent, Chief Chemist, Process Foreman, or other responsible refinery or plant representative shall assign a sampler to perform the sampling. The Inspector shall seal (unless instructed otherwise) the inlet valve (or valves) of the storage tank before sample is taken. Record the seal number (or numbers) on the TE-51 Report Form. The Inspector shall not perform the sampling himself but shall be present to witness the sampling. The Inspector shall be sure of the following:
That the correct stock is being sampled.
That all the steps of the sampling procedure have been performed correctly.
That the sample secured is representative of the stock being sampled.
That the sample container is correctly identified.
Identification and Numbering of Samples.
If top, middle and bottom samples from a storage tank are to be sent to the OMM, clearly indicate on the TE-31 from which portion of the tank the particular sample was taken.
A TE-31 completely filled out, shall be attached to each sample. In addition, the sample tank number shall be marked on each sample container.
Refer to the batches or lots of drums, barrels, etc., by the refinery's batch or lot numbers. Where the individual drums are assigned numbers, record the drum serial numbers for each batch or lot on the TE-31's. (If additional space is required, use remarks.)
Submitting Samples to OMM
The outside of the sample container shall be clean and free from bituminous material. However, the sample container shall not be submerged in a solvent, nor shall it be wiped with a solvent saturated cloth. Any spilled material on the outside of the container shall be wiped with a clean dry cloth immediately after the container is sealed. A trace of solvent in a semi-solid material, such as asphalt cement, may change the properties of the material to such an extent that it is no longer representative of the material sampled.
The lids of the sample containers are to be firmly seated in place. in addition, screw top lids are to be secured in place by a strip of masking tape. The lid of a pint friction top container can be easily seated in place by placing the container on the floor and stepping on the lid. It is not necessary to use masking tape on the lid of the friction top pint can if it contains a sample of semi-solid bituminous material.
The samples shall be sent to OMM in the quickest way possible by one of the following:
Packed in a cardboard shipping carton and sent by Fourth Class Parcel Post, Special Delivery. Samples sent in this manner shall not be accompanied with any written matter except that which is on the TE-31's.
Sent by the District's sample delivery service.
Sent by Special Messenger when it is imperative that the Producer obtain approval of the material quickly.
Where some of the approved material in a sealed storage tank has not been shipped for a period of a month, a check sample shall be taken at the end of the interval of a month and submitted to the OMM. (Write "Monthly Check" on the upper left corner of TE-31.)
Shipments from the storage tank may continue to be made after the monthly check sample is taken, i.e., shipments shall not be held up until the OMM has completed its tests on the check sample.
When an Inspector is instructed to take check samples at shorter intervals than a month, write "check" on the upper left hand corner of the TE-31's.
At locations where approved material is transferred from a large storage tank to a smaller "marketing" or shipping tank, the Inspector shall take a check sample from the "marketing" or shipping tank each time he calls at the plant, even though the purpose of his call may be to sample another storage tank or to break the seals on a tank.
The monthly check sample shall be submitted from the large storage tank if no new material has been added to it in the interval of a month.
At terminals where previously approved material is transferred to a shipping tank, check samples are taken at intervals designated by the OMM. The inlet lines of the shipping tank are not sealed and the check samples taken are an exception to the preceding check sample instructions.
Packaged Bituminous Materials
Section B: Partial Plant Inspection of Packaged Bituminous Materials The Partial Plant Inspection Plan consists of the written agreement between material manufacturer or supplier, to comply with the requirements herein, filed with the Ohio Department of Transportation Office of Materials Management.
Partial Plant Inspected packaged bituminous materials will be maintained by the manufacturer or supplier in accordance with the procedures outlined herein. Such inspection is limited to materials which will be shipped directly from the manufacturer's plant to an Ohio Department of Transportation project construction site or the delivery point specified in a Department Purchase Order, or to a supplier's warehouse or storage yard where a similar cooperative agreement is currently in force.
The manufacturer or supplier shall provide and perform the following:
Provide all samples requested by OMM to perform the specified tests. Prior to sampling, present for visual inspection and numerical accounting all containers and packages of a packaged bituminous material product produced and marked as specific lots or batches of manufacture.
Withhold shipment to Ohio Department of Transportation work until notification is received from the OMM that the material is approved. This notification will consist of mailing a copy of the Laboratory Report. Maintain the identification by Laboratory Report Number of each approved batch or lot of material during storage and shipment. Inventory records are to be maintained showing the quantities of approved stock on hand at all times.
Each container or package shall be legibly marked with the name of the manufacturer, the name of the compound or material, and the manufacturer's batch or lot number. For some materials, the Inspector will place an Ohio Department of Transportation Seal on each container or package.
Each drum containing 706.10 shall be marked with the Ohio Department of Transportation item number and the batch or lot number. The above markings shall appear on the heads and sides of all drums
Each pail containing 702.05, 702.10, or 706.10 shall be marked with the applicable Ohio Department of Transportation item number and batch or lot number.
Each box or crate containing 711.24 shall be marked with the Ohio Department of Transportation Item Number and the batch or lot number. The above markings shall appear on the cover and side of each container.
The markings and seals on the containers or packages shall be in a legible condition when delivered to the project site or Purchase Order destination.
Ship only approved material to Ohio Department of Transportation Projects and Departmental Purchase Orders destinations. Complete and send with each shipment of approved material a copy of the "Notice of Shipment of Plant Tested and Approved Materials" Form TE-24, supplied by the OMM for this purpose.
Ship material per Appendix "E" Plant Sampling and Testing Plan.