814 Heavy Equipment Safety

Asphalt Paving Safety Measures

Asphalt paving operations involve exposure to bituminous materials that pose several hazards to workers.

While general heavy equipment safety measures apply to paving operations, additional precautions must be taken to protect against heat, fumes, moving machinery, and contact with hot materials.

Understanding Asphalt and Its Hazards

One of the greatest hazards is the extreme heat required to liquefy asphalt for paving. Workers may be burned by contact with hot asphalt or exposed to intense radiant heat. Proper planning, equipment use, and personal protective equipment (PPE) are essential for preventing injury.

Key Safety Measures for Asphalt Paving

• Use proper PPE. Workers must wear flame-resistant or heat-resistant clothing, gloves, long sleeves, safety boots, eye protection, and high-visibility vests. A face shield may be required when working near spraying or pouring operations.
• Avoid direct contact with hot asphalt. Never attempt to remove hot material with bare hands. Use tools designed for high-heat environments and follow safe handling procedures.
• Maintain proper ventilation around equipment. When working near asphalt heaters, pavers, or hot mix plants, ensure there is adequate airflow to reduce exposure to asphalt fumes. Avoid standing in the path of rising vapors.
• Control ignition sources. Keep open flames, sparks, and smoking materials away from hot asphalt, fuel storage, and heating equipment. Bitumen is flammable under certain conditions.
• Use caution around moving equipment. Asphalt paving sites often include pavers, rollers, dump trucks, and distributors. Always maintain awareness of surroundings and use spotters when backing vehicles or equipment.
• Stay clear of the screed and auger areas. The rear section of a paving machine contains moving parts and heated surfaces that can cause serious injury if contact occurs.
• Monitor for signs of heat stress. Working around hot asphalt and machinery in warm weather can lead to dehydration or heat illness. Provide shaded rest breaks, drinking water, and training to recognize symptoms of heat-related illness.
• Inspect hoses, tanks, and valves before use. Pressurized systems that handle hot asphalt must be checked for leaks or blockages. A failure could result in burns or asphalt spray incidents.
• Provide traffic control measures. In roadwork zones, proper barriers, signs, and flaggers must be used to keep unauthorized vehicles and pedestrians out of the work area.

Fume and Exposure Controls

Employers must assess worker exposure to asphalt fumes and implement controls to reduce risks. This includes:

• Using lower-temperature asphalt mixes when possible
• Positioning workers upwind of fume sources
• Rotating workers to limit prolonged exposure
• Providing NIOSH-approved respirators when engineering and administrative controls do not reduce exposures to safe levels

Training workers on safe paving procedures, chemical hazards, and emergency response is essential. A job hazard analysis (JHA) should be performed before paving starts to identify site-specific risks and ensure all controls are in place.

Asphalt Paving Safety Checklist

Use this checklist before and during asphalt paving to ensure safe working conditions and procedures are being followed.

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