Roofer Safety Site: Kettle Operations

KETTLE OPERATIONS

Part I

SET UP AND START UP

Position the kettle carefully in relation to the building:

Keep the kettle away from windows, air intakes, and exit doors.
In the vicinity of an air intake, consider covering the intake with fire resistive tarpaulin.
The kettle lid should open away from the wall of the building; or any other type of structure that causes a confined space, must be set up with enough space for the kettle man to do his task.
Keep the kettle lid closed whenever you are not loading asphalt so not as many fumes are released.

Position the kettle in the most stable location:

Preliminary single ply and Environmental Protection:

Controlled Access Zone to kettle:

Page 2 – Set Up and Start Up.

Controlled Access Zone to Kettle –continued:

No flammable, combustible materials such as ISO trash, plastics, safety gas cans are allowed inside the CAZ.
Postings: Hot, Danger, No smoking Signs.

Propane Tanks:

Cylinders must be marked Flammable Gas and should be in good operating conditions.
Keep Propane Tanks 10 feet away from the kettle.
When storing, transporting and using cylinders keep them fastened securely in an upright position.
When storing or transporting cylinders be sure that the container valve is closed with a safety cap and / or collar in place.
Cylinders should not be dropped or allowed to strike each other.
Cylinders should be moved by means of hand trucks. If it is absolutely necessary to move them by hand, roll them on the bottom edge; never dragged them.
Do not hoist cylinders to roof areas by attaching lines to valves or to collars at the top.
Check the pressure regulator prior to use and adjust accordingly.
Never open the valve completely: two, three turns could be enough.
Check the hose prior to use for cuts, cracks, or worn places. Replace immediately if any of these are present.

Page 3 – Set up and Start Up.

When in doubt always consider cylinders full and handle them accordingly.
When not in use turn off the fuel supply at the tank.
Keep all bulk propane and storage tanks at least 25 feet away from the kettle.
Keep three 20 lbs. ABC Fire Extinguishers inside the CAZ away from the kettle and the Propane Tanks.
Be careful not to overfill propane tanks especially in hot weather.
Check MIA NTD / MDAD local Fire Regulations: Telephone number in the MADAD Hot Work Permit; 911 plus Project Site Safety Manager mobile phone number.

Always wear the PPE:

Hardhat, Safety Glasses, Face Shield, Long Sleeved Shirt; long sleeved shirt cuffs should button over the cuffs of appropriate gloves; long pants without cuffs should come over the top of sturdy hard work boots.
A face shield attached to a hardhat should provide eye and face protection; safety glasses or goggles under the face shield will provide additional protection and it is mandatory at all times when operating the kettle.

Page 4

Hot Pipe from the Kettle to the Roof:

Be careful and precise when lighting burners:

Light up burners out of the kettle’s chamber if the kettle is not equipped with an auto light feature.
Do not use matches or lighters –use a striker / spark generator device.
Put the burners back into the chamber with the flame regulated.
Start the burners slowly, and gradually increase the temperature until the asphalt is free flowing around the tubes.
Make sure that the “Pull Out Burners” are aimed directly down the tubes so that the tubes do not get warped or cracked.
Inspect the connections on the Propane Tanks and Kettle.

KETTLE OPERATIONS

Part II

Loading and Heating Asphalt

Add Bitumen and increase kettle temperature slowly:

Chop the bitumen –the asphalt stick- into small manageable chunks and lower them into the kettle carefully to avoid splashing.
Never allow the kettle tubes to be exposed –maintain a steady supply of coal tar / asphalt chunks for the tubes to be covered.
Do not overfill the kettle.

Make sure the Bitumen is kept within its Equiviscous Temperature (EVT) range at the point of application:

Heat up the asphalt up to 525 Degrees Fahrenheit.
Maintain the temperature between 525 and 550 degrees Fahrenheit.
Never overheat the kettle always maintain the temperature below the flashing point -25 degrees below the flash point check the asphalt packaging.
If it is about to reach the flashing point put into the kettle one or two chopped sticks of asphalt to cool it down; and / or turn off the burners.

Always wear your personal protective equipment –PPE.

FIRE PREVENTION AND FIRE EXTINGUISHING

Part III

Fire Prevention:

During refueling shut off engines.
Propane tanks need to be upright and secured.
Equipment in good operable condition –asphalt kettle, propane tanks, hoses, cylinder valve, and regulators.
Keep the kettle temperature up to 525 degrees Fahrenheit.
No smoking around the kettle and propane tanks area.
Postings: Hot/Danger/ No Smoking Signs in place.
No flammables/combustibles around the kettle.
On going housekeeping; do not store trash inside the CAZ.
Inside CAZ completely clean.
No bitumen stains on top of the kettle –continuous cleaning.
Always check the color of the asphalt fumes –it should be white at all times.
A yellowish fume means the kettle is overheated and about to catch fire –act accordingly to prevent the fire.

Fire Extinguishing:

Know how to put out fires in case one occurs.
Close the lid/s immediately and turn off the burners.
If closing the lid/s is not enough then pour about one ounce of water into the vent hole and the steam it produces will douse the fire.
DO NOT USE more than one ounce of water or the kettle may boil over.
Be prepared with three 20 pounds ABC Fire Extinguishers in case you have to use them.

Page 7 –Fire Extinguishing.

Roofer Safety Site