Pothole Repair Safety

Toolbox Talk Record

Ref: TBT-ROA-009  |  Issue: 1  |  Date: March 2026
PresenterProject
LocationDate

What?

Why?

Vehicle strikePothole repair crews working in live carriageways are struck by vehicles at close range every year.
Burn injuriesHot asphalt at 150°C causes instant severe burns. Raking and hand-laying bring workers into close contact.
Dust and vibrationCutting out potholes with disc cutters generates silica dust and hand-arm vibration above safe exposure levels.
Do Don't
  • Set up signing and guarding to the Code of Practice before entering the carriageway.
  • Wear Class 3 hi-vis clothing at all times while working on the highway.
  • Use water suppression when cutting out with disc cutters to control silica dust.
  • Wear thermal gloves and long sleeves when handling hot asphalt material.
  • Limit disc cutter and breaker use to stay below vibration exposure action values.
  • Hold a valid NRSWA card before carrying out any work in the public highway.
  • Position the works vehicle as a physical barrier between traffic and the work area.
  • Brief the team on the traffic management plan and escape routes before starting.
  • Apply tack coat with care and avoid skin contact; use gloves and eye protection.
  • Compact the repair thoroughly to prevent premature failure and reinstatement defects.
  • DON'T enter the carriageway without signing and guarding in place first.
  • DON'T turn your back to approaching traffic while working in the road.
  • DON'T cut out potholes without water suppression for silica dust control.
  • DON'T handle hot asphalt without thermal gloves and protective clothing.
  • DON'T exceed vibration exposure limits when using breakers and disc cutters.
  • DON'T work in the highway without a valid NRSWA competency card.
  • DON'T leave the repair site without removing all traffic management signing.
  • DON'T stand between the works vehicle and live traffic lanes.
  • DON'T allow tack coat to contact unprotected skin; it causes irritation.
  • DON'T leave an incomplete repair open overnight without protection and signing.

See also: Working in Live Carriageways | Hand Laying Asphalt Safety