Asphalt Paver and Roller Safety

Key Hazards

• Workers struck or crushed by pavers, rollers, trucks, or support equipment
• Burns from hot asphalt, screeds, exhaust, and heated machine components
• Caught-in and pinch-point hazards around hoppers, conveyors, augers, and screeds
• Equipment rollover or loss of control on slopes, edges, and soft shoulders
• Workers exposed to traffic while guiding trucks or checking the mat
• Falls while mounting, dismounting, or working on contaminated platforms

2–3 Minute Talk Script

Paving operations bring trucks, pavers, rollers, and ground workers into a narrow moving work area. A pre-job briefing should establish the paving direction, equipment order, truck exchange method, hand signals, pedestrian routes, and emergency stop expectations.

Operators should inspect brakes, steering, alarms, cameras, mirrors, lights, access steps, guards, and controls before use. Asphalt buildup, damaged handrails, and slippery platforms should be corrected before the equipment enters the lane.

Ground workers should stay outside blind spots and never assume an operator sees them. Eye contact or an agreed signal should be established before approaching, and operators should stop when a worker's location is uncertain.

Truck exchange at the paver creates a high-risk interaction. Drivers, spotters, and paver operators should use one communication method, avoid standing between the truck and paver, and control tailgate opening and material release.

Hoppers, slat conveyors, augers, screeds, rollers, articulation points, and moving linkages create severe pinch and caught-in hazards. Guards should remain in place, and cleaning, adjustment, or jam clearing should follow the required shutdown and energy-control procedure.

Hot asphalt and heated machine parts can cause serious burns. Workers should use suitable gloves, long clothing, footwear, and tools and should avoid walking on freshly placed material unless the task and protection allow it.

Rollers and pavers should be operated at controlled speeds with attention to pavement edges, drop-offs, slopes, overhead obstructions, and soft shoulders. Seat belts and rollover protection should be used as designed.

At the end of the operation, equipment should be parked on stable ground, attachments lowered or secured, controls neutralized, and hot or pressurized systems allowed to cool before cleaning or maintenance begins.

Safety Reminders

• Establish equipment order, truck exchange, and communication methods.
• Inspect alarms, cameras, mirrors, access points, and controls.
• Stay out of blind spots and never stand between a truck and paver.
• Keep clear of hoppers, conveyors, augers, screeds, and articulation points.
• Protect against hot asphalt and heated surfaces.
• Control speed near slopes, edges, drop-offs, and soft shoulders.
• Park, lower, secure, and cool equipment before service.

Ask the Crew

• How will trucks approach, unload, and leave the paver?
• Where are the paver and roller blind spots and pinch points?
• What is the agreed signal for stopping equipment?
• What slope, edge, or soft-shoulder hazards are present?
• How will hot components be handled during cleanup?