ROA/General/TBT-ROA-023
Pothole and Patch Repair Safety
Road Construction & Surfacing › General › Pothole and Patch Repair Safety
Toolbox Talk
Pothole and Patch Repair Safety
Pothole and patch repair work is often carried out on live roads with traffic passing close to the work area. The tasks involve cutting out damaged material, applying tack coat, placing hot asphalt, and compacting with a roller or plate. The combination of live traffic, hot materials, and powered cutting tools makes this a high-risk operation. This talk covers the controls needed for safe pothole and patch repair on highways.
Key Hazards
Workers struck by passing vehicles while working in or near the live carriageway
Burns from contact with hot asphalt or tack coat during material placement
Silica dust inhalation from dry cutting the existing road surface without suppression
Noise and vibration injuries from sustained use of breakers and cutting equipment
Control Measures
- Set up traffic management in compliance with Chapter 8 before starting any work on the carriageway.
- Wear Chapter 8 compliant high-visibility clothing at all times during highway repair work.
- Use water suppression on all saw cutting and breaking operations to control silica dust at source.
- Wear heat-resistant gloves and safety boots when handling hot asphalt and applying tack coat.
- Position an impact protection vehicle upstream of the work area as specified in the traffic management plan.
- Keep the work area compact and minimise time spent on the live carriageway for each repair.
- Rotate operatives on breaking and cutting tasks to control noise and vibration exposure.
- Ensure all tools, materials, and vehicles are removed from the carriageway promptly after each repair.
- Brief the team on the traffic management layout, escape routes, and emergency procedures each shift.
Remember
- Set up Chapter 8 compliant traffic management before starting any work on the carriageway
- Wear Chapter 8 high-visibility clothing at all times during all highway repair operations
- Use water suppression on all saw cutting and breaking to control silica dust at source
- Position an impact protection vehicle upstream of the work area as the traffic plan specifies
- Minimise time on the live carriageway and keep the work area as compact as possible
- Remove all tools, materials, and vehicles from the carriageway promptly after each repair
Applicable Legislation: Traffic Signs Manual Chapter 8 · CDM Regulations 2015 · COSHH Regulations 2002 · Health and Safety at Work etc. Act 1974
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