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Bitumen cleaning - correct maintenance of machines, rollers and tools in asphalt construction

What it's all about

Bitumen is sticky. It is precisely what it does in the mix that makes it a nuisance in the construction yard: bitumen residues stick to roller drums, tyres, screeds, troughs, tools and painted surfaces. If this coating is not removed regularly and with the right agent, subsequent problems accumulate: release agent adheres less well, drums become misaligned, tools become unwieldy, painted surfaces become dull and lose their protective function in the long term. This article shows how bitumen cleaning works in modern construction yard operations: which cleaner classes are available, why water-based bitumen cleaners can now replace most classic solvent products, and how you can establish a pragmatic cleaning routine that extends machine service life and reduces the workload on personnel.

1. why bitumen residues become expensive if you leave them lying around

At first glance, bitumen residue on machines looks like a cosmetic problem. At second glance, they are the exact opposite:

Effect of the release agent decreasesThe freshly applied release agent can no longer adhere evenly to a roller drum area coated with old bitumen. This results in roller marks, adhesion to the next mix and reworking.
Paint damage in time lapseIf you leave bitumen splashes on the bodywork for days, there is a risk that some of the paintwork gloss will be removed later.
Unsafe toolsVerbitumised shovels, rakes and rammers are more unwieldy, heavier and promote fatigue injuries.
Additional costs for repair and cleaningEncrusted bitumen is more difficult to remove than fresh bitumen - every hour it takes for a coating to harden costs three hours of cleaning later on.
Negative external impactHeavily soiled machines convey an unkempt impression - relevant for customers, clients and in tenders.

Planned, regular cleaning with the right agent is therefore not a chore, but a way of preserving the value of the systems.

2 Which cleaner classes are there - and which one is suitable for what?

In asphalt construction, three main cleaner classes are used for bitumen, tar and asphalt residues:

2.1 Solvent-based cold cleaners (classic)

The oldest representatives are hydrocarbon solvents or mixtures with aromatics. They act quickly, but are often subject to labelling according to CLP, frequently hazardous goods according to ADR, and cause VOC emissions with significant odour pollution. More and more companies are phasing them out for storage, occupational safety and image reasons.

2.2 Water-based bitumen cleaners with plant-based active ingredients (state of the art)

These cleaners use plant-based surfactants and solubilisers in an aqueous matrix. They are generally CLP-free, ADR-free, VOC-free and gentle on paintwork, rubber and most plastics. When used correctly, they have the same effect as classic solvent-based cleaners - but require a little more reaction time. Our product in this class is Bituclean Extra.

2.3 Mechanical and thermal processes

Hot water, high pressure, dry ice blasting and mechanical scraping complement chemical cleaning - but they rarely replace it. They work best in combination: allow the cleaner to take effect, then remove mechanically or with high pressure.

2.4 Comparison at a glance

Feature	Classic solvent	Water-based vegetable	Mechanical/thermal
Effect against fresh bitumen	Very good	Very good	Limited
Effect against hardened bitumen	Very good	Good (with reaction time)	Very good
Material compatibility paint/rubber	Restricted	Very good	Risk of mechan. Damage
Hazardous substance labelling	Frequently	As a rule no	-
ADR / Dangerous goods	Often dangerous goods	No dangerous goods	-
VOC / odour	Strong	Low	-
Skin stress	High	Low	Mechanical load
Costs	Medium	Medium	High (devices, working time)

In practice, for most construction yards and asphalt mixing plants, a Hybrid approach has become established: Water-based cleaners as standard, supplemented by high pressure and - less frequently - dry ice blasting for stubborn areas.

3 Bituclean Extra - how the cleaner works

Bituclean Extra is a water-dilutable cleaner based on plant-based active ingredients. The way it works can be described in three steps:

Contact and wettingThe agent is applied in the appropriate dilution for the soiling. Vegetable surfactants wet the bitumen surface.
Swelling and solutionSolubilisers penetrate the bitumen structure and weaken the bond to the substrate. The bitumen swells and detaches from the surface.
AcceptanceHigh pressure, water jet, wiping cloth or brush are used to remove the dissolved bitumen.

Dilution as a rule of thumb:

Degree of soiling	Recommendation Dilution Bituclean Extra
Fresh, light splashes	1 : 20 with water
Medium soiling	1 : 10
Heavy, older soiling	1 : 5
Very strong, encrusted	Pure or 1 : 2, longer exposure time

The exact dilution recommendations can be found in the product data sheet. For sensitive paints, we recommend cleaning a small test area in an inconspicuous place.

→ To the product Bituclean Extra

4. cleaning routine in asphalt construction - the practical guide

Effective bitumen cleaning follows a simple choreography. If you stick to it, you save cleaner, time and nerves.

Step 1: Cleaning starts at the end of the shift

Fresh bitumen can be removed orders of magnitude faster than hardened bitumen. The most important rule of the day in the construction yard is to roughly clean the rollers, screed and tools as soon as possible after the end of the shift - not the next morning.

Step 2: Rough mechanical cleaning

Remove loose bitumen crumbs and larger adhesions with a spatula or scraper before using the cleaner. This saves cleaner and accelerates the effect.

Step 3: Apply cleaner and allow to take effect

Apply Bituclean Extra in a suitable dilution to the soiling using a low-pressure sprayer, spray bottle or damp cloth. Reaction time 5 to 30 minutes, depending on soiling. Important: Do not allow the cleaner to dry - work in the shade in direct sunlight or re-spray if necessary.

Step 4: Remove with high pressure or cloth

Rinse off swollen bitumen with a high-pressure cleaner (cold or lukewarm). Alternatively, for painted surfaces or sensitive components, remove with a soft cloth or sponge.

Step 5: Rinse

Rinse off cleaner residues with clear water. On painted surfaces, check whether a wax application or polish is advisable to maintain the shine.

Step 6: Check - and repeat if necessary

A second round of cleaner may be necessary for very old floor coverings. Patience pays off: two shorter passes with sufficient contact time are better than a single pass with too high a concentration.

5. routine per machine component

5.1 Rollers (drums, tyres)

Clean bandages daily at the end of the shift.
Remove release agent residues with Bituclean Extra before reapplying.
If necessary, clean the sides and tread of the tyres to prevent bitumen being dragged onto the finished layer.

5.2 Road paver (screed, spreading auger, material intake)

Clean the screed after each layer with release agent and - in the case of bitumen residue - with Bituclean Extra.
Clean the auger regularly while it is stationary, especially at the transition to the bearings.
Check the painted surfaces on the body every 2-4 weeks and remove splashes.

5.3 Transport skips and lorry bodies

Spray skips with release agent before each loading.
Clean bituminised welding seams or corners regularly with Bituclean Extra.
Check flaps, seals and hydraulic piston rods separately.

5.4 Asphalt cooker and thermal container

Clean the outside when stationary, pay particular attention to weld seams and visible edges.
Interior cleaning only by specialised personnel - most manufacturers specify special procedures.

5.5 Hand tools

Place shovels, rakes and tampers in a bucket provided for this purpose with diluted Bituclean Extra or spray them at the end of the layer.
Leave on overnight and rinse off with water the next morning - this saves a lot of working time compared to layers that have been left on for days.

6 Safety and the environment - what to consider

Even though Bituclean Extra is CLP-free and ADR-free, a few basic rules apply that should be a matter of course in every building yard:

Protective gloves (chemical-resistant, e.g. nitrile). Even mild detergents degrease the skin when used continuously.
Safety goggles when working with high pressure and when mixing concentrated solutions.
Do not discharge cleaning waste water into the ground or unfiltered drainsEven if the cleaner is biodegradable, the dissolved bitumen, oil and grease is not. Cleaning waste water belongs in a sludge trap or a suitable collection facility.
Keep containers tight and away from direct sunlight.
Spillages with cloths or a universal binder.

Detailed information can be found in the safety data sheet for Bituclean Extra, which you can request via the contact form or by e-mail.

Frequently asked questions FAQ

Is Bituclean Extra a fully-fledged replacement for solvent-based cold cleaners?

Yes, in most applications. Water-based cleaners often require a little more contact time, but are CLP-free, ADR-free, VOC-free and gentler on paint and rubber. In construction yards with a high seasonal staff ratio, this property is a considerable safety benefit.

Does Bituclean Extra attack painted surfaces?

No, if used correctly. We recommend a test cleaning on an inconspicuous area before the first major application. On intact paint surfaces, Bituclean Extra in the usual dilutions leaves the paint untouched.

How long does Bituclean Extra have to work?

Depending on the degree of soiling, between 5 and 30 minutes. In the case of very old, hardened coatings, longer exposure times or a second pass may be advisable. Important: do not allow to dry.

Can I apply Bituclean Extra directly with a high-pressure cleaner?

Yes, many users apply the product via foam lances or low-pressure nozzles on the high-pressure cleaner. Ensure that the dilution is within a sensible range - too concentrated an application wastes product, too diluted an agent has too little effect.

How do I dispose of the cleaning waste water?

The waste water contains dissolved bitumen, oil and grease - even if the cleaner itself is biodegradable. It must be channelled through a sludge trap or oil separator and disposed of in accordance with local regulations. Have the following ready for collection: safety data sheet, origin of contamination, quantities if applicable.

Can Bituclean Extra also be stored and used in frosty conditions?

Storage ideally protected from frost. When used in winter, we recommend cleaning in heated halls or when the outside temperature is not frozen - otherwise the cleaning water on the machine may freeze.

Conclusion

Consistent, regular bitumen cleaning protects assets - machines, tools, painted surfaces and ultimately also personnel. If you work early and with the right product, you will save significantly more time and money than any savings on the cleaner bottle can ever bring.

In recent years, water-based, plant-based cleaners such as Bituclean Extra have opened up technically and now completely replace solvent-based products in most building yard applications - with significantly lower requirements for storage, transport and occupational safety.

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