ROA/Surfacing/TBT-ROA-005

Compaction and Rolling Procedures

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Compaction and Rolling Procedures

Toolbox Talk Record

Ref: TBT-ROA-005  |  Issue: 1  |  Date: March 2026
PresenterProject
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What?

  • Compaction using rollers is essential for road construction, earthworks, and trench reinstatement.
  • Rollers range from small pedestrian machines to large ride-on tandem and pneumatic rollers.
  • The main hazards are crushing, whole-body vibration, noise, and contact with hot asphalt.
  • Pedestrian rollers can trap and run over the operator if control is lost on slopes.
  • Ride-on rollers have limited rear visibility — banksman assistance may be needed.
  • PUWER 1998 requires rollers to be suitable for the task with operators properly trained.
  • Operating on slopes increases rollover risk — maximum gradients must be observed.
  • Vibrating rollers create significant whole-body vibration that must be managed.
  • Hot asphalt surfaces present burn risks — heat-resistant PPE is required.
  • All rollers must be inspected daily and defects reported before use.

Why?

Prevent crushingRollers cause fatal crushing injuries to both operators and pedestrians.
Vibration healthWhole-body vibration from rollers causes back pain and spinal degeneration.
Burn preventionContact with freshly laid hot asphalt causes severe burns to skin.
Legal compliancePUWER and vibration regulations require training and exposure management.
Do Don't
  • Complete a daily pre-use check on the roller before starting work.
  • Keep all pedestrians clear of the rolling area at all times.
  • Use a banksman when reversing or in areas with limited visibility.
  • Observe maximum gradient limits to prevent rollover on slopes.
  • Wear heat-resistant boots and gloves when compacting hot asphalt.
  • Monitor whole-body vibration exposure and rotate operators as needed.
  • Ensure the operator holds a valid CPCS or NPORS card for the machine.
  • Maintain a safe distance from excavation edges during trench compaction.
  • Use the correct roller type and effort specified for the material.
  • Follow the rolling pattern set out in the method statement.
  • DON'T allow pedestrians into the rolling area during compaction.
  • DON'T operate a pedestrian roller on slopes beyond the manufacturer's limits.
  • DON'T reverse a ride-on roller without checking behind or using a banksman.
  • DON'T stand on or touch freshly rolled hot asphalt surfaces.
  • DON'T exceed vibration exposure limits — rotate tasks and take breaks.
  • DON'T operate a roller with defective brakes, steering, or safety systems.
  • DON'T compact closer than 1 metre to an unsupported excavation edge.
  • DON'T use the wrong roller type for the material being compacted.
  • DON'T leave a roller unattended with the engine running.
  • DON'T allow untrained operators to use any type of compaction equipment.

See also: Road Construction Safety Awareness | Roller and Compaction Plant
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