PLT/Specific Plant/TBT-PLT-013

Roller and Compaction Plant

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Roller and Compaction Plant

Toolbox Talk Record

Ref: TBT-PLT-013  |  Issue: 1  |  Date: March 2026
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What?

  • Rollers include ride-on tandem rollers, pneumatic rollers, and pedestrian-operated vibrating rollers.
  • These machines compact soil, aggregate, and asphalt in roads, foundations, and earthworks.
  • The primary hazard is crushing — rollers have limited visibility and cannot stop quickly.
  • Pedestrian rollers can override the operator on slopes if control is lost.
  • Whole-body vibration must be assessed under the Control of Vibration at Work Regulations 2005.
  • PUWER 1998 requires all compaction plant to be maintained and suitable for the task.
  • Operators must hold a valid CPCS or NPORS card for the specific roller type.
  • Rollers must not operate near unsupported excavation edges or on unstable ground.
  • Hot rollers on asphalt present burn risks from the drum and fresh material.
  • Daily pre-use checks must cover brakes, steering, lights, mirrors, and vibration mechanisms.

Why?

Prevent crushingRollers cause fatal crushing injuries to operators and nearby pedestrians.
Vibration exposureWhole-body vibration from rollers causes long-term back and spinal damage.
Operator competenceUntrained operators are more likely to lose control on gradients.
Legal compliancePUWER and vibration regulations require maintained equipment and trained operators.
Do Don't
  • Complete a daily pre-use inspection before starting the roller.
  • Ensure the operator holds a valid CPCS or NPORS card for the machine.
  • Maintain clear exclusion zones around the roller during compaction.
  • Use a banksman when reversing or working in congested areas.
  • Monitor whole-body vibration exposure and rotate operators as needed.
  • Observe maximum gradient limits specified by the manufacturer.
  • Wear heat-resistant PPE when compacting hot asphalt material.
  • Keep a safe distance from excavation edges and embankment slopes.
  • Park the roller on level ground with the brake applied when not in use.
  • Report any defects to brakes, steering, or safety systems immediately.
  • DON'T allow pedestrians into the compaction zone during rolling.
  • DON'T operate on slopes steeper than the manufacturer's stated limit.
  • DON'T reverse without a clear view behind or a banksman in position.
  • DON'T exceed vibration exposure limits — take breaks and rotate tasks.
  • DON'T operate a roller with defective brakes or steering systems.
  • DON'T compact closer than 1 metre from unsupported excavation edges.
  • DON'T touch the drum or freshly compacted hot asphalt — severe burn risk.
  • DON'T leave the roller unattended with the engine running.
  • DON'T jump on or off a moving roller under any circumstances.
  • DON'T use the roller for any purpose other than compaction work.

See also: Plant Pre-Use Inspections | Hand Arm Vibration Syndrome (HAVS)
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