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NIOSH Publication No. 2003-112:

Asphalt Fume Exposures During
the Application of Hot Asphalt to Roofs

 

This document represents a collaborative effort of the National Institute for Occupational Safety and Health (NIOSH), the National Roofing Contractors Association (NRCA), the Asphalt Roofing Manufacturersí Association (ARMA), the Asphalt Institute (AI), and the United Union of Roofers, Waterproofers, and Allied Workers (UURWAW) to reduce worker exposures to asphalt fumes during the application of hot asphalt to roofs. The document describes the application of hot asphalt to roofs, identifies steps in the process that may involve worker exposure to asphalt fumes, and identifies current engineering controls and work practices used to reduce exposures.

Contents


Foreword
Abstract
Abbreviations
Glossary
Acknowledgments

1 Introduction

2 Background
  2.1 Composition and Uses of Asphalt
2.2 The Roofing Industry
2.3 Types and Grades of Roofing Asphalts
2.4 Asphalt Roofing Products and Systems
  2.4.1 Asphalt Shingles and Roll Roofing
2.4.2 BUR Systems
2.4.3 Modified Bitumen Roofing Systems
3 Sources of Asphalt Fume Exposure
  3.1 Typical BUR System
3.2 Delivery and Heating of Asphalt
  3.2.1 Kettles
3.2.2 Tankers
3.2.3 Asphalt Heating and Application Temperature
  3.3 Installation Operations on the Roof
4 Exposure to Asphalt and Asphalt Fumes
  4.1 Occupational Exposure Limits
4.2 Exposure During Asphalt Roofing Operations
4.2.1 Airborne Exposures
4.2.2 Dermal Exposures
5 Methods for Reducing Asphalt Fume Exposure
  5.1 Substituting Low-Fuming Asphalt
5.2 Kettle Selection
5.3 Steps to Isolate the Process and Minimize Generation of Fumes
  5.3.1 Placing the Kettle at the Worksite
5.3.2 Maintaining Asphalt Temperature in the Kettle
5.3.3 Applying Asphalt on the Roof
  5.4 Control Devices for Reducing Asphalt Fume Emissions
5.5 Training and Education
5.6 Use of PPE
  5.6.1 Personal Protective Clothing and Gear
5.6.2 Respiratory Protection

6 Research Needs

References
Appendices
  A. Asphalt Fume Exposures for Various Occupations during Roofing Operations
B. Respirators

Asphalt Fume Exposures During  the Application of Hot Aphalt to Roofs Document Cover

Related Resources/Publications:

Asphalt Fume Exposures During the Manufacture
of Asphalt Roofing Products
 
Hazard Review: Health Effects of occupational Exposure to Asphalt
 
Criteria for a Recommended Standard: Occupational Exposure to Asphalt Fumes
 
Engineering Control Guidelines for Hot Mix Asphalt Pavers


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FOREWORD

The Occupational Safety and Health Act of 1970 (Public Law 91–596) assures, insofar as possible, safe and healthful working conditions for every working man and woman in the Nation. The act charges the National Institute for Occupational Safety and Health (NIOSH) with recommending occupational safety and health standards and describing exposure concentrations that are safe for various periods of employment—including but not limited to the concentrations at which no worker will suffer diminished health, functional capacity, or life expectancy as a result of his or her work experience.

This document represents the collaborative efforts of industry, labor, and government to protect the health of workers exposed to asphalt fumes during the application of hot asphalt to roofs. Current engineering controls and work practices are presented for reducing worker exposures to asphalt fumes during the application of hot asphalt to roofs. Prevention methods such as these are the cornerstone of public and occupational health.

This document is the result of a public meeting convened on July 22 and 23, 1996, in Cincinnati, Ohio. Participants discussed engineering controls and work practices for controlling exposures to asphalt fumes in the roofing industry. Although the health risks from asphalt exposure are not yet fully defined, all partners agreed that prudent action was needed to reduce worker exposures. They decided to produce a joint document that would describe engineering controls and work practices to reduce worker exposure to asphalt fumes during the application of hot asphalt to roofs. The willingness of all partners to work together in this effort should serve as a model for others who are developing occupational safety and health recommendations. This document was truly a joint effort. I would like to thank the National Roofing Contractors Association (NRCA), the Asphalt Roofing Manufacturers’ Association (ARMA), the Asphalt Institute (AI), and the United Union of Roofers, Waterproofers, and Allied Workers (UURWAW) for their cooperation and hard work.

Image of Signature John Howard  Director  NIOSH
John Howard, M.D.
Director, National Institute for
Occupational Safety and Health
Centers for Disease Control and Prevention

 



ABSTRACT

This document represents a collaborative effort of the National Institute for Occupational Safety and Health (NIOSH), the National Roofing Contractors Association (NRCA), the Asphalt Roofing Manufacturers' Association (ARMA), the Asphalt Institute (AI), and the United Union of Roofers, Waterproofers, and Allied Workers (UURWAW) to reduce worker exposures to asphalt fumes during the application of hot asphalt to roofs. The document describes the application of hot asphalt to roofs, identifies steps in the process that may involve worker exposure to asphalt fumes, and identifies current engineering controls and work practices used to reduce exposures. In addition, the document lists relevant research needed for further reducing asphalt fume exposures during the application of hot asphalt to roofs.


ABBREVIATIONS

ACGIH
American Conference of Governmental Industrial Hygienists
AI
Asphalt Institute
APP
atactic polypropylene
ARMA
Asphalt Roofing Manufacturers’ Association
B(a)P
benzo(a)pryene
BUR
built-up roofing
EC
degrees Celsius
CFR
Code of Federal Regulations
cm
centimeter(s)
EID
Education and Information Division
EVT
equiviscous temperature
EF
degrees Fahrenheit
f
filter
Fed. Reg
Federal Register
ft
foot (feet)
gal
gallon(s)
GC/MS
gas chromatography/mass spectrometry
GM
geometric mean
GSD
geometric standard deviation
HEPA filter
high-efficiency particulate air filter
HPLC
high performance liquid chromatography
hr
hour(s)
in.
inch(es)
kg
kilogram(s)
lb
pound(s)
LEL
lower flammable or explosive limit
m
meter(s)
mg
milligram(s)
min
minute(s)
ND
not detected
ng
nanogram(s)
NIOSH
National Institute for Occupational Safety and Health
NRCA
National Roofing Contractors Association
OSHA
Occupational Safety and Health Administration
OV
organic vapor
PAH
polycyclic aromatic hydrocarbon
PBZ
personal breathing zone
PEL
permissible exposure limit
PIB
polyisobutylene
PPE
personal protective equipment
REL
recommended exposure limit
s
sorbent tube
SBS
styrene-butadiene-styrene
TLV
threshold limit value
TWA
time-weighted average
UEL
upper flammable or explosive limit
UURWAW
United Union of Roofers, Waterproofers, and Allied Workers
%
percent
mg
microgram(s)


GLOSSARY

Air blowing: The manufacturing process in which air is blown through an asphalt flux to make oxidized roofing asphalts. An exothermic oxidation reaction occurs, yielding an asphalt that is harder, more viscous, less volatile, and less temperature-susceptible than the asphalt flux used as the feedstock to the process.

Asphalt (CAS number 8052–42–4): A dark brown to black, cement-like semisolid or solid that is the product of the nondestructive distillation of crude oil in petroleum refining. Depending on the crude oil used as a feedstock, the distillation residuum may be further processed, typically by air-blowing (sometimes with a catalyst) or solvent precipitation to meet performance specifications for individual applications [AI 1990b]. Asphalt is a mixture of paraffinic and aromatic hydrocarbons and heterocyclic compounds containing sulfur, nitrogen, and oxygen [Sax and Lewis 1987].

Asphalt, cutback: An asphalt liquefied by the addition of diluents (typically petroleum solvents) [AI 1990b; Roberts et al. 1996; Speight 1992].

Asphalt flux: The residuum (heated sufficiently to flow) that results from the atmospheric and vacuum distillation processes used by petroleum refineries and independent asphalt manufacturers. Asphalt flux is used in the manufacture of some asphalt roofing materials such as saturant asphalts and some modified bitumen products. Asphalt flux is also used as a feedstock in the air-blowing process used to make oxidized roofing asphalt.

Asphalt fumes: The cloud of small particles created by condensation from the gaseous state after volatilization of asphalt [NIOSH 1977].

Asphalt, oxidized-blown or air-refined (CAS number 64742–93–4): Asphalt treated by blowing air through it at elevated temperatures to produce physical properties required for the industrial use of the final product. Oxidized asphalts are used in roofing operations, pipe coating, undersealing for Portland cement concrete pavements, hydraulic applications, membrane envelopes, some paving-grade mixes [AI 1990b], and the manufacture of paints [Speight 1992].

Asphalt, roofing: Asphalt that is refined or processed to meet specifications for roofing.

Built-up roofing (BUR): A system of asphalt-impregnated felt plies sealed and surfaced with hot mopping-grade asphalt. BUR is primarily used in low-slope commercial roofing. The felt plies can be organic (e.g., cellulose), fibrous screen or mat, or polyester fabric

Coating-grade asphalt: An air-blown or oxidized asphalt used to manufacture roofing materials used in a variety of roofing systems such as asphalt shingles, polymer-modified bitumen roofing, reinforcing and underlayment felts, and roll roofing products.

Fire point: The lowest temperature at which a substance can give off vapors fast enough to support continuous combustion. The fire point is often 5EF (2.8EC) above the flash point [NSC 1996].

Flammable or explosive limits:
Lower flammable or explosive limit (LEL): The minimum airborne concentration of a flammable substance needed to propagate a flame after contact with an ignition source (i.e., the concentration below which the mixture is too lean to propagate a flame) [NSC 1996].

Upper flammable or explosive limit (UEL): The maximum airborne concentration of a flammable substance that will permit propagation of a flame on contact with an ignition source (i.e., the concentration above which the mixture is too rich to propagate a flame) [NSC 1996].

Flash point: The lowest temperature at which a substance can give off enough vapors to form an ignitable mixture with air and produce a flame if an ignition source is also present [NSC 1996].

Flood coat: The surfacing layer of asphalt into which surfacing aggregate is embedded on an aggregate-surfaced built-up roof. A flood coat is generally thicker and heavier than a glaze coat and is applied at approximately 45 to 60 lb/100 ft2 (2 to 3 kg/m2).

Modified bitumen system: A roofing system based on membranes manufactured by impregnating or coating one or more fabric plies with a straight run or oxidized asphalt modified using a polymer, usually atactic polypropylene (APP) or styrene-butadiene-styrene (SBS). Modified bitumen systems may be torch-applied or installed by adhesion in hot asphalt or a cold-applied, solvent-based asphalt adhesive (cutback asphalt). Modified bitumen systems are used on low-slope (primarily commercial or industrial) roofs.

Mopping-grade asphalt: An oxidized asphalt used principally in the construction of built-up roofing and some modified bitumen systems; mopping-grade asphalts are produced in four grades (Types I through IV), according to the steepness of the roof.

Saturant asphalt: A nonoxidized or oxidized asphalt, typically an AC-10 or AC-20 grade material, used to manufacture saturated organic felt plies used in the construction of built-up roofing systems, organic felt shingles, and other roofing materials such as roll roofing.

Straight-run asphalt: The residuum of atmospheric and vacuum distillation processes used by petroleum refineries and independent asphalt manufacturers. This asphalt is used in the manufacture of some asphalt roofing materials (e.g., saturant asphalts and some modified bitumen products); it is also used as a feedstock in the air-blowing process used to make oxidized roofing asphalt.


ACKNOWLEDGEMENTS

This document was prepared by the staff of the National Institute for Occupational Safety and Health (NIOSH) in collaboration with representatives of the Asphalt Institute (AI), the Asphalt Roofing Manufacturers’ Association (ARMA), the National Roofing Contractors Association (NRCA), and the United Union of Roofers, Waterproofers, and Allied Workers (UURWAW). Paul A. Schulte, Director, Education and Information Division (EID), had overall responsibility for the document. Joann Wess (NIOSH) was the project director.

The following contributors are gratefully acknowledged: Heinz Ahlers, J.D. (NIOSH); Tom Calzavara (ARMA); Bill Fayerweather, Ph.D. (ARMA); Bill Good (NRCA); Bob Krul (UURWAW); David Marlow (NIOSH); Bernie McCarthy (AI); Leroy Mickelsen (NIOSH); Dennis Mueller (ARMA); Larry Olsen, Ph.D. (NIOSH); Klaus Rosinski, Ph.D. (ARMA); Arthur Sampson (ARMA); Tom Shanahan (NRCA); Richard Snyder (ARMA); Russ Snyder (ARMA); Marie Haring Sweeney, Ph.D. (NIOSH); Alex Teass, Ph.D. (NIOSH); and Ralph Zumwalde (NIOSH).

Vanessa Becks, Richard Carlson, Judy Curless, Susan Feldmann, Anne Hamilton, Susan Kaelin, and Jane Weber (NIOSH) provided editorial support and contributed to the design, graphics, and layout of this document.

 
 
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