ROA/Surfacing/TBT-ROA-007
Machine Laying Asphalt Safety
Road Construction & Surfacing › Surfacing › Machine Laying Asphalt Safety
Machine Laying Asphalt Safety
Toolbox Talk Record
Ref: TBT-ROA-007 | Issue: 1 | Date: March 2026
| Presenter | Project | ||
| Location | Date |
What?
- Machine laying asphalt uses a paver to spread hot material at temperatures between 130°C and 180°C.
- Burns from contact with hot asphalt are the most common injury during machine laying operations.
- Bitumen fumes are generated during laying and contain polycyclic aromatic hydrocarbons (PAHs) harmful to health.
- The paver operates slowly but has limited visibility behind; banksmen are essential for safe reversing.
- Tipper trucks reversing onto the paver hopper create crush risks for operatives working alongside.
- Rollers compacting behind the paver are heavy and have restricted visibility in all directions.
- Traffic management must protect the laying crew from passing vehicles on live carriageways.
- Manual handling of raking, levelling, and hand-work around the mat increases musculoskeletal strain.
- COSHH 2002 requires assessment of bitumen fume exposure for all asphalt laying operatives.
- The paver screed plate operates at extreme temperatures and must never be touched without protection.
Why?
| Burn injuries | Hot asphalt at 160°C causes instant severe burns. Contact with the material or screed plate is extremely dangerous. |
| Fume exposure | Long-term exposure to bitumen fumes causes respiratory disease, skin irritation, and is linked to cancer risk. |
| Crush risk | Workers between reversing tippers, the paver, and rollers are struck and crushed every year in the UK. |
| Do | Don't |
|
See also: Asphalt Laying Safety | Compaction and Rolling Procedures |
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