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The Health and Safety Hub for the Mineral Products Industry - aggregates, asphalt, cement, concrete, contracting, dimension stone, lime, precast concrete, masonry, mortar, readymix, recycling, silica sand, transport & logistics

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Fatal 5 - Bitumen pipe failure causes loss of hot bitumen at asphalt plant.

LOCATION:
ASPHALT/COATING PLANT
ACTIVITY:
LOADING AND UNLOADING
SUB ACTIVITY:
NO SUB ACTIVITY AVAILABLE
ALERT STATUS:
Normal
DATE ISSUED:
18/11/2025 18:33:24
INCIDENT No:
04945

TITLE
Fatal 5 - Bitumen pipe failure causes loss of hot bitumen at asphalt plant.
COUNTRY OF ORIGIN

WHAT HAPPENED

 

Bitumen (an aggregate binder used in asphalt stored at 150?) was being pumped from the asphalt plant back into the storage tank when a pipe burst and sprayed bitumen, no one was injured.

Immediately prior to the incident the bitumen storage tank was switched and pipework changed.

The failure occurred on an exposed non-insulated bend in the pipework which had a blockage causing the pipe to rupture.  A visual inspection was completed prior but a full management of change considering all the potentials risks was not.

The first image below captures the moment the pipe ruptured and began to spray the tanker and the ground,  and the second shows the section of the pipe where the blockage occurred.

      

ACCIDENT / INCIDENT IMAGES




LEARNING POINTS / ACTIONS TAKEN


  • Management of change process should be followed, and all potential hazards considered as part of the changes.

  • Review the 'Guidance for Safe Bitumen Tank Management' available on Safequarry


https://www.safequarry.com/hotTopics/Guidance%20for%20Safe%20Bitumen%20Tank%20Management%20-%20MPA-EBUK%20November%2019.pdf
LEARNING POINTS / ACTIONS IMAGES


LOCATION:
ASPHALT/COATING PLANT
ACTIVITY:
LOADING AND UNLOADING
SUB ACTIVITY:
NO SUB ACTIVITY AVAILABLE
ALERT STATUS:
Normal
DATE ISSUED:
18/11/2025 18:33:24
INCIDENT No:
04945


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