ROA/Ancillary/TBT-ROA-009

Pothole Repair Safety

Road Construction & Surfacing › Ancillary › Pothole Repair Safety

All Categories/Road Construction & Surfacing/Ancillary/Pothole Repair Safety

Pothole Repair Safety

Toolbox Talk Record

Ref: TBT-ROA-009  |  Issue: 1  |  Date: March 2026
PresenterProject
LocationDate

What?

  • Pothole repair involves cutting out the damaged area, removing debris, and filling with hot or cold asphalt.
  • Repairs are typically carried out in live carriageways with traffic passing the work at close proximity.
  • Vehicle strike is the primary risk; operatives are exposed to passing traffic for the entire repair duration.
  • Hot asphalt used for permanent repairs is delivered at 130-160°C, creating severe burn risk on contact.
  • Disc cutters and breakers generate silica dust, noise, and vibration during the cutting-out stage.
  • Bitumen tack coat applied before filling produces flammable vapours and causes skin irritation.
  • The Safety at Street Works and Road Works Code of Practice governs all pothole repair operations.
  • Operatives working in the carriageway must wear Class 3 hi-vis clothing to BS EN ISO 20471.
  • Hand compaction with a roller or plate requires physical effort on uneven ground in traffic proximity.
  • NRSWA competency cards are required for all operatives working in the public highway.

Why?

Vehicle strikePothole repair crews working in live carriageways are struck by vehicles at close range every year.
Burn injuriesHot asphalt at 150°C causes instant severe burns. Raking and hand-laying bring workers into close contact.
Dust and vibrationCutting out potholes with disc cutters generates silica dust and hand-arm vibration above safe exposure levels.
Do Don't
  • Set up signing and guarding to the Code of Practice before entering the carriageway.
  • Wear Class 3 hi-vis clothing at all times while working on the highway.
  • Use water suppression when cutting out with disc cutters to control silica dust.
  • Wear thermal gloves and long sleeves when handling hot asphalt material.
  • Limit disc cutter and breaker use to stay below vibration exposure action values.
  • Hold a valid NRSWA card before carrying out any work in the public highway.
  • Position the works vehicle as a physical barrier between traffic and the work area.
  • Brief the team on the traffic management plan and escape routes before starting.
  • Apply tack coat with care and avoid skin contact; use gloves and eye protection.
  • Compact the repair thoroughly to prevent premature failure and reinstatement defects.
  • DON'T enter the carriageway without signing and guarding in place first.
  • DON'T turn your back to approaching traffic while working in the road.
  • DON'T cut out potholes without water suppression for silica dust control.
  • DON'T handle hot asphalt without thermal gloves and protective clothing.
  • DON'T exceed vibration exposure limits when using breakers and disc cutters.
  • DON'T work in the highway without a valid NRSWA competency card.
  • DON'T leave the repair site without removing all traffic management signing.
  • DON'T stand between the works vehicle and live traffic lanes.
  • DON'T allow tack coat to contact unprotected skin; it causes irritation.
  • DON'T leave an incomplete repair open overnight without protection and signing.

See also: Working in Live Carriageways | Hand Laying Asphalt Safety
ebrora.com

RAMS Builder

Generate professional Risk Assessment and Method Statements in minutes. 10 document formats, site-specific content, instant Word download.

Learn More