Compaction using vibratory rollers, pneumatic rollers, and plate compactors is essential for achieving the required density in road sub-base, binder course, and surface course layers. Rollers are heavy machines with limited visibility and significant blind spots. Workers on foot near active rollers face serious crush risks. Whole body vibration affects roller operators during prolonged operation. The compaction sequence, number of passes, and roller selection must follow the specification to achieve the required density results.
Key Hazards
Workers on foot crushed by rollers with limited visibility and blind spots
Whole body vibration exposure for operators during sustained roller operation
Burns from contact with hot asphalt material during rolling of surface courses
Inadequate compaction from incorrect roller selection or insufficient passes
Control Measures
Maintain a strict exclusion zone around the roller and prohibit pedestrian access during operation.
Use a banksman to control all roller reversing movements near workers or confined areas.
Select the correct roller type and weight for the material layer as specified in the method statement.
Monitor operator vibration exposure and rotate operators to stay within daily exposure limits.
Ensure the roller operator has a current CPCS or equivalent card for the roller category.
Keep all workers clear of the mat during roller compaction of hot asphalt materials.
Complete the specified number of passes at the correct speed to achieve the required compaction density.
Inspect the roller at the start of each shift including brakes, steering, and vibration mechanism.
Carry out compaction testing at the specified frequency and record results for quality records.
Remember
Rollers have severe blind spots and limited manoeuvrability — stay well clear during all operations.
A banksman must control all reversing movements where workers or obstacles are in the vicinity.
Whole body vibration from sustained roller operation must be monitored and operator rotation used.
Hot asphalt being compacted can cause severe burns to anyone who stumbles onto the fresh mat.
Compaction specification defines the roller type, number of passes, and speed — follow it exactly.
Compaction test results must be recorded because insufficient density causes premature road failure.
Applicable Legislation: CDM Regulations 2015 · PUWER 1998 · Control of Vibration at Work Regulations 2005 · Specification for Highway Works (MCHW)