Pothole Repair and Asphalt Patching Safety

• Workers struck by passing traffic or moving work vehicles
• Burns from hot asphalt, tack coat, tools, or equipment surfaces
• Caught-between and struck-by hazards around compactors and trucks
• Musculoskeletal strain from shoveling, raking, lifting, and repetitive work
• Dust, flying debris, noise, and silica exposure during cutting or removal
• Slips, trips, and unstable footing around broken pavement and loose material

Pothole repair places a small crew in a changing work zone where traffic, construction equipment, hot materials, and uneven pavement are often close together. The crew should review the repair method, traffic-control plan, equipment positions, and escape routes before work begins.

Temporary traffic controls should be installed in the approved sequence and positioned to provide drivers enough warning and workers enough protected space. Crews should remain alert for motorists who enter the work area despite signs, cones, arrow boards, or flaggers.

Trucks, compactors, skid steers, and other equipment should be positioned to reduce backing and prevent workers from being trapped between vehicles, equipment, and fixed objects. Operators should stop when visual contact with workers on foot is lost.

Hot-mix asphalt, tack products, heated tools, exhaust components, and fresh pavement can cause burns. Workers should use suitable PPE and handling tools, avoid direct skin contact, and understand the first-aid and spill procedures for the products being used.

Saw cutting, jackhammering, milling, and removal can create dust, flying fragments, vibration, and high noise. Water, ventilation, distance, guarding, and suitable eye, face, hearing, and respiratory controls should be used as required by the task.

Shoveling and raking should be organized to avoid overexertion and workers striking one another with tools. Loads should be kept manageable, body position should be changed periodically, and mechanical assistance should be used when available.

Loose aggregate, broken pavement, hoses, tools, and irregular edges create trip hazards. The crew should maintain a clear walking path and keep workers from stepping backward into traffic, open holes, or equipment travel paths.

Before reopening the lane, the repair should be compacted and stable, loose material and tools should be removed, and traffic controls should be taken down using the approved sequence. Workers should remain protected until the final device is removed.

• Review the repair plan and traffic-control layout before starting.
• Maintain a protected work area and a clear escape route.
• Minimize backing and keep workers out of equipment blind spots.
• Protect against hot asphalt, tack products, dust, debris, and noise.
• Use safe lifting, shoveling, and raking techniques.
• Keep broken pavement, tools, and loose material out of walkways.
• Remove traffic controls only after the repair area is ready for traffic.

• How will traffic be separated from the patching crew?
• Where will trucks and compactors move or back?
• What hot-material, dust, and noise controls are needed?
• Where are the crew's safe standing areas and escape routes?
• Who will verify the lane is ready before traffic controls are removed?