Surface Dressing Operations

Surface dressing applies a layer of bitumen binder followed by stone chippings to seal and texture road surfaces.
The process uses specialist spray tankers and chipping spreaders operating in a coordinated convoy on live roads.
Hot bitumen binder is sprayed at temperatures between 160°C and 190°C, creating severe burn risk on contact.
Loose chippings are projected from the spreader and by traffic, causing eye injuries to unprotected workers.
The convoy operates on live carriageways with traffic management, creating vehicle strike risks for the crew.
Manual raking and hand dressing at junctions and edges involves repetitive bending and heavy physical effort.
Bitumen fume from spraying contains polycyclic aromatic hydrocarbons that are harmful to respiratory health.
The operation moves continuously along the road, requiring traffic management to advance with the convoy.
Slippery conditions from fresh binder and loose stone create vehicle skid risks for both site and public traffic.
COSHH 2002 and the Safety at Street Works Code of Practice both apply to surface dressing operations.

Severe burns	Hot bitumen binder at 180°C causes instant third-degree burns. Splash contact with skin or eyes is extremely serious.
Vehicle strike	Working on live roads with a moving convoy exposes the crew to being struck by passing or site vehicles.
Fume exposure	Repeated exposure to bitumen fume during spraying increases long-term respiratory disease and cancer risk.

Do

Don't

Wear long sleeves, gloves, face shield, and safety boots during binder spraying.
Maintain traffic management protection around the convoy at all times.
Position yourself where vehicle operators and passing traffic can always see you.
Stand upwind of the spray bar to minimise bitumen fume inhalation.
Wear safety glasses during chipping operations to protect against flying stone.
Keep first aid burn kits and cold water immediately available on the spray tanker.
Brief the full crew on the convoy sequence, signals, and emergency procedures.
Monitor wind direction and adjust your position to stay clear of fume drift.
Use barrier cream on exposed skin areas as additional bitumen splash protection.
Report any binder splash on skin immediately and treat with cold running water.

DON'T touch hot binder equipment, hoses, or spray nozzles without thermal gloves.
DON'T stand downwind of the spray bar where bitumen fume concentration is highest.
DON'T walk on freshly sprayed binder; it sticks to boots and burns through clothing.
DON'T work in the convoy without traffic management protecting your position.
DON'T remove eye protection during chipping operations; flying stone causes eye injury.
DON'T eat or drink near the spray tanker where fume and binder contaminate surfaces.
DON'T approach the spray bar while it is pressurised without the operator confirming safe.
DON'T cross live traffic lanes without banksman assistance and vehicle stop.
DON'T ignore a bitumen burn, even a small one; cool with water for 20 minutes.
DON'T operate the spray tanker without checking all hose connections for leaks.

See also: Asphalt Laying Safety | Machine Laying Asphalt Safety

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