Hand Laying Asphalt Safety

Hand laying asphalt involves spreading, raking, and compacting hot asphalt material by hand tools.
Asphalt is delivered to site at temperatures between 130°C and 180°C — severe burn risk on contact.
The work is physically demanding, combining heavy manual handling with exposure to heat and fumes.
Bitumen fumes released from hot asphalt are a respiratory irritant and potential carcinogen.
COSHH 2002 requires assessment and control of exposure to bitumen fumes during laying operations.
Workers face traffic risks when hand laying asphalt in live carriageways or adjacent to traffic.
UV exposure is increased by working outdoors for extended periods during summer asphalt seasons.
The Manual Handling Operations Regulations 1992 apply to shovelling, raking, and carrying operations.
Burns to knees from kneeling on freshly laid asphalt are common and require heat-resistant knee pads.
Hand tools including rakes, lutes, and shovels must be maintained to reduce unnecessary physical effort.

Burn prevention	Contact with asphalt at 150°C+ causes immediate deep burns requiring hospital treatment.
Fume exposure	Bitumen fumes cause respiratory irritation and are linked to long-term health effects.
Manual handling	Repetitive shovelling and raking causes back, shoulder, and arm injuries.
Traffic danger	Hand layers working near live traffic face the constant risk of vehicle strike.

Do

Don't

Wear heat-resistant gloves, boots, and trousers when handling hot asphalt material.
Use heat-resistant knee pads if kneeling near freshly laid or compacted asphalt.
Work upwind of the hot material to minimise inhalation of bitumen fumes.
Ensure traffic management is in place before working near any live carriageway.
Stay hydrated — heat from the asphalt combined with sun increases dehydration risk.
Rotate personnel on raking and shovelling tasks to manage physical fatigue.
Apply sunscreen and wear UV-protective clothing during prolonged outdoor work.
Inspect hand tools before use — damaged rakes and lutes increase physical strain.
Report any respiratory symptoms, skin irritation, or burns to your supervisor.
Wear high-visibility clothing compliant with Chapter 8 when working on highways.

DON'T handle hot asphalt without heat-resistant gloves and protective clothing.
DON'T stand or kneel on freshly laid hot material without heat-resistant protection.
DON'T breathe in bitumen fumes — position yourself upwind of the work.
DON'T work near live traffic without full traffic management in place.
DON'T skip hydration breaks during hot weather asphalt laying operations.
DON'T use worn or broken hand tools — they increase strain and injury risk.
DON'T allow hot material to contact bare skin — burns develop instantly.
DON'T rush the compaction process — uneven surfaces require rework and more effort.
DON'T ignore skin irritation from contact with bitumen products — report it.
DON'T throw or flick hot asphalt material — it can strike and burn nearby workers.

See also: Asphalt Laying Safety | Manual Handling Awareness

Presenter		Project
Location		Date

Toolbox Talk Record