ROA/General/TBT-ROA-011

Paver Operation Safety

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Paver Operation Safety

Toolbox Talk Record

Ref: TBT-ROA-011  |  Issue: 1  |  Date: March 2026
PresenterProject
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What?

  • Asphalt pavers are large, slow-moving machines that lay and level hot asphalt material on road surfaces.
  • The screed at the rear of the paver operates at temperatures exceeding 150°C, causing severe contact burns.
  • Operatives working behind the paver are exposed to asphalt fumes, UV radiation, and radiant heat.
  • The feed hopper at the front receives hot material from tipping lorries, creating crush and burn hazards.
  • Pedestrian workers around the paver must be coordinated to avoid being struck or trapped by moving plant.
  • Asphalt fume contains polycyclic aromatic hydrocarbons (PAHs) that are linked to skin and lung cancer.
  • Paving operations on live carriageways require Chapter 8 traffic management to protect workers and road users.
  • Night paving is common to minimise traffic disruption, adding fatigue and visibility risks.
  • The roller following the paver compacts the hot material — workers must stay clear of the compaction zone.
  • PUWER 1998 requires the paver to be maintained, inspected, and operated only by trained personnel.

Why?

Burn injuriesHot asphalt at 150°C+ causes severe burns on contact — the screed, augers, and material are all dangerously hot.
Fume exposureAsphalt fumes contain carcinogenic PAHs — prolonged exposure increases the risk of skin and lung cancer.
Plant interactionOperatives on foot working around pavers and rollers face constant risk of being struck or crushed.
Do Don't
  • Ensure only trained and competent operators control the paving machine
  • Wear heat-resistant gloves and long sleeves when near the screed or hot material
  • Position yourself where the paver operator can see you at all times
  • Use fume suppression additives or extraction where available to reduce exposure
  • Apply barrier cream to exposed skin to reduce absorption of asphalt fumes
  • Maintain clear communication between the paver operator, rakers, and roller drivers
  • Implement Chapter 8 traffic management before paving on any public road
  • Take regular breaks away from the fume zone and stay well hydrated
  • Keep the work area behind the paver free from trip hazards and loose tools
  • Report any burns, skin irritation, or respiratory symptoms to your supervisor
  • DON'T touch the screed, augers, or conveyor without heat-resistant PPE
  • DON'T stand between the paver hopper and a reversing delivery lorry
  • DON'T walk behind the roller during compaction operations
  • DON'T remove RPE or barrier cream while working in the asphalt fume zone
  • DON'T clean asphalt from skin with diesel or solvents — use proper cleaners
  • DON'T ride on the paver unless designated seating and handholds are provided
  • DON'T allow unauthorised pedestrians into the paving operation area
  • DON'T operate the paver on a public highway without traffic management in place
  • DON'T ignore fatigue during night paving shifts — take scheduled rest breaks
  • DON'T leave hot asphalt tools on surfaces where others could be burnt

See also: Asphalt Laying Safety | Compaction and Rolling Procedures
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