Asphalt Fumes: Health Effects of Occupational Exposure

Workers in road construction, roofing, and asphalt plants face exposure to asphalt fumes that cause coughing, headaches, and long-term health risks. This guide covers who's at risk and how to stay safe.

What Are Asphalt Fumes?

Asphalt fumes are vapors released when asphalt gets heated. Asphalt is a thick, sticky petroleum product used to pave roads and seal roofs. When workers heat it for application, it releases gases and particles into the air.

These fumes contain polycyclic aromatic hydrocarbons (PAHs), hydrogen sulfide, and other chemicals. Your body absorbs these substances through breathing and skin contact.

The hotter the asphalt, the more fumes it releases. Workers face significant exposure during normal paving operations, which typically occur at temperatures between 270–330° F. Fume generation increases with temperature, making proper ventilation and protective equipment essential at all working temperatures.

Health Effects of Asphalt Fumes Exposure

Asphalt fumes exposure causes immediate health effects like coughing, eye irritation, and headaches, whereas long-term exposure can lead to cancer, lung disease, and skin damage.

Short-term health effect

Short-term effects appear within hours of exposure and often happen during or right after a work shift.

Long-term health effects

Long-term exposure builds up over months or years and can cause lasting or permanent health problems.

Who Is Exposed to Asphalt Fumes?

Road construction and paving workers

Road construction crews work with hot asphalt daily. They heat asphalt to pave roads, patch potholes, and seal cracks. Paving machine operators, rakers who spread asphalt, and laborers who work directly with hot material face the highest exposure.

These workers spend hours near asphalt that releases continuous fumes. Wind conditions and outdoor ventilation help reduce exposure, but workers still breathe significant amounts of fumes during their shifts.

Roofing professionals

Roofers use heated asphalt to seal and waterproof roofs. They work directly over hot asphalt with limited air circulation on rooftops, increasing their exposure to rising fumes. Applying hot asphalt in enclosed or poorly ventilated areas creates significantly higher concentrations of fumes that can cause respiratory and eye irritation.

Roofing work often happens during hot summer months when temperatures amplify fume release. Workers may spend entire days applying hot asphalt with limited air circulation.

Manufacturing facility workers

Asphalt manufacturing plants produce paving and roofing materials in large batches. This releases massive amounts of fumes, often inside warehouses or other enclosed spaces.

Manufacturing workers face higher exposure than outdoor construction workers because indoor facilities trap fumes. Without proper ventilation systems, these workers breathe concentrated fume levels throughout their shifts.

How Do Asphalt Fumes Enter Your Body?

1. Inhalation is the primary exposure route. You breathe fumes directly into your lungs where they enter your bloodstream. The chemicals spread throughout your body, affecting multiple organs.

Workers breathe faster when doing physical labor, which increases the amount of fumes they inhale. Heavy breathing during paving or roofing work pumps more contaminated air into your lungs.

2. Skin absorption occurs when fumes settle on exposed skin or when hot asphalt comes into contact with your body. The chemicals penetrate your skin and enter your bloodstream.

Wet or hydrated skin can increase chemical absorption for some compounds. Workers with skin exposed to moisture may experience enhanced dermal exposure to asphalt fume components.

3. Heat amplifies exposure because higher temperatures release more fumes. The hottest asphalt produces the highest concentrations of harmful chemicals. Asphalt fume concentrations increase around 3–7 times with every 36 °F (20 °C) temperature rise.

Recognizing Asphalt Fume Exposure Symptoms

Watch for these warning signs during and after work:

• Persistent coughing that continues after leaving the work site
• Burning sensation in your throat, nose, or eyes
• Difficulty breathing or chest tightness
• Headaches that start during work and may continue for hours
• Unusual fatigue or weakness
• Nausea or loss of appetite
• Skin redness, itching, or rashes where asphalt contacted your body
• Dizziness or confusion

Seek medical attention immediately if you experience severe breathing difficulty, chest pain, confusion, or loss of consciousness. These symptoms indicate dangerous exposure levels.

Report all symptoms to your supervisor and document them in writing. This creates a record if you need medical treatment or workers' compensation later.

How to Reduce Asphalt Fume Exposure: The Hierarchy of Controls

Controlling exposure requires multiple strategies working together. Start with the most effective controls and work down the list.

1. Elimination or substitution (most effective)

Remove the hazard entirely by using alternative materials that don't release dangerous fumes. This is the most effective protection because it eliminates the source of exposure.

Ask these questions:

1. Can you use a different paving or roofing material that doesn't require heating? Some cold-mix asphalts release fewer fumes.
2. Can you switch to materials with lower PAH content? Modified asphalt formulations exist with reduced harmful chemicals.
3. Can you eliminate or combine certain jobs to reduce the number of workers you expose? Fewer workers near hot asphalt means fewer people at risk.

Many employers resist substitution because they've always used traditional asphalt. However, alternative materials often cost less when you factor in health costs and liability.

2. Engineering controls

Change the physical work environment to reduce asphalt fumes exposure. These controls don't rely on worker behavior, making them more reliable than training or protective equipment alone.

Key questions to consider:

• Can you use processes that generate fewer fumes? Lower temperature asphalt releases fewer vapors. Warm-mix asphalt technology reduces application temperatures by 20–40°C (36–54°F) degrees and significantly cuts fume exposure.
• Can you modify equipment? Enclosed paving machines with ventilation systems protect operators. Installing local exhaust on applicators and kettles captures fumes right where you generate them.
• Can you design work areas better? Creating physical barriers between workers and hot asphalt reduces exposure. Automation that keeps workers further from fume sources helps.
• Can you improve ventilation? For indoor work, install exhaust systems that capture fumes at the source. Position exhaust hoods directly over hot asphalt to remove fumes before workers breathe them.

For outdoor work, position workers upwind of hot asphalt when possible. Wind naturally carries fumes away from workers if you choose the correct positions.

3. Administrative controls

Change work practices and policies to reduce exposure time and intensity. These controls require consistent enforcement to work effectively.

Worker training

Train all workers in safe work practices and housekeeping. They should understand how fumes affect health, when exposure peaks, and how to clean equipment and materials safely. Well-trained workers take better precautions.

Work scheduling

Plan high-fume tasks when fewer people are present. Rotate workers through high-exposure jobs and schedule breaks away from fume sources to reduce total exposure.

Site signage and procedures

Post clear warning signs in high-exposure areas. Display step-by-step safe work procedures as quick reminders to keep everyone following the same methods.

Monitoring and limits

Regularly check air quality and track exposure time. Use this data to adjust schedules or methods before workers get sick.

4. Personal Protective Equipment (PPE)

Use PPE as your last line of defense, never as your only protection. PPE is the least effective control because it depends on workers using it correctly every time. You must always combine PPE with at least one other control method.

Respiratory protection

• Workers should have half-face or full-face respirators with organic vapor cartridges.
  High-exposure areas require supplied-air respirators for clean air.
• Every respirator must be fit-tested to ensure a proper seal.

Skin and hand protection

• Use nitrile or neoprene gloves to block asphalt absorption.
• Wear long sleeves, pants, or disposable coveralls for tasks with high exposure.

Eye and face protection

• Safety glasses or goggles with side shields prevent splashes and irritation
• Full-face respirators offer both breathing and eye protection

Footwear

• Use chemical-resistant boots with puncture protection to prevent burns and other injuries

Maintenance and training

• Inspect PPE before each use and replace worn-out items
• Train workers on proper use of PPE, as well as the correct fit and maintenance
• Ensure replacement PPE is always available on-site

Employer Responsibilities for Worker Safety

Employers are responsible for training workers, providing protective equipment, controlling exposure, monitoring health, keeping records, and addressing safety concerns without retaliation. 

Employers must provide a safe workplace under occupational safety and health laws. This includes specific duties related to asphalt fume exposure.

Training and education

Employers must train workers before they start asphalt-related jobs. Training should explain health risks, safe work practices, and emergency steps. Provide refresher training every year or whenever procedures change.

Equipment and PPE

Employers must supply respirators, gloves, and protective clothing at no cost to workers. All PPE must fit correctly and stay in good condition.

Workplace controls

Employers should use engineering and administrative controls to reduce fumes and heat exposure. PPE is a backup, not the only line of defense.

Monitoring and medical support

Regular air quality testing measures exposure levels. If results exceed limits, employers must take action right away. Workers with long-term exposure should receive medical checks to catch health issues early.

Record-keeping and response

Employers must keep accurate exposure and health records for each worker. When workers raise safety concerns, employers must respond quickly, fix the problem, and ensure that there is no retaliation.

Best Practices for Working Safely with Asphalt

Pre-work safety checks

1. Inspect all PPE before starting work. Check respirator seals, look for holes in gloves, and verify equipment is clean and functional.
2. Review the day's tasks and identify high-exposure activities. Plan how to minimize exposure during these tasks.
3. Check wind direction for outdoor work. Position yourself upwind of hot asphalt when possible.
4. Verify ventilation systems are running for indoor work. Don't start until exhaust systems operate properly.

During work precautions

When working with hot asphalt, stay as far from the fumes as your job allows; extra distance means breathing in less concentrated fumes. Take breaks regularly by moving upwind or to a clean air area, and drink plenty of water to help your body with heat stress prevention.

Keep an eye on yourself and your coworkers for early warning signs of exposure. Don't eat, drink, or smoke near hot asphalt, as this transfers harmful chemicals from your hands straight to your mouth.

Post-work cleanup and decontamination

1. Remove contaminated clothing before entering vehicles or your home. Don't bring asphalt-covered clothes inside, as they can expose family members.
2. Wash exposed skin thoroughly with soap and water. Pay special attention to your face, neck, arms, and hands.
3. Clean or dispose of contaminated PPE properly. Don't reuse disposable items or damaged equipment.
4. Shower as soon as possible after work. This removes chemicals before they absorb further into your skin.
5. Wash work clothes separately from family laundry. Use hot water and extra rinse cycles to remove any remaining chemical residue.

What to Do If You've Been Exposed

Immediate actions

• Move to fresh air immediately if you experience breathing difficulty, dizziness, or severe irritation. Don't continue working while experiencing symptoms.
• Remove contaminated clothing and wash affected skin with soap and water. If asphalt contacts your eyes, flush with clean water for at least 15 minutes.
• Notify your supervisor about the exposure and your symptoms. This starts the documentation process.

Medical evaluation

Seek medical attention for severe symptoms like chest pain, difficulty breathing, or loss of consciousness. Go to an emergency room or call 911.

For less severe symptoms, see your doctor within 24 hours. Explain that you work with hot asphalt and describe your symptoms.

Ask your doctor to document the exposure and symptoms in your medical records. This creates an official record linking your health problems to work exposure.

Follow all medical advice and attend follow-up appointments. Some exposure effects don't appear immediately.

Documentation for workers' compensation

Write down everything about the exposure: date, time, what you were doing, how long you were exposed, what symptoms you experienced, and who witnessed it.

1. Report the incident to your employer in writing. Keep a copy for your records.
2. File a workers' compensation claim if you need medical treatment. Don't wait to file because time limits apply.
3. Keep all medical bills, prescriptions, and records related to the exposure. You'll need these to support your claim.
4. Contact a workers' compensation attorney if your employer denies your claim or retaliates against you for reporting.

How OneCrew Helps You Work Safer and Smarter

Working safely around asphalt fumes takes more than good equipment and training. It also takes clear organization and strong communication.

OneCrew's all-in-one platform completely changes how paving contractors handle operations, from initial estimates to long-term client relationships. Here’s how OneCrew helps:

• Safer crew coordination: OneCrew's scheduling and crew management tools help you implement administrative controls to reduce total asphalt fume exposure across your team.
• Better documentation: Keep detailed records of crew assignments, work schedules, and job site conditions in one place, making it easier to track exposure patterns and respond quickly if workers report symptoms.
• Simpler operations: Stop juggling spreadsheets. OneCrew's platform handles everything from initial quotes to project completion. Generate professional proposals in minutes and track job profitability in real time.
• Higher margins through better management: OneCrew's estimating templates confirm consistent pricing, and its project tracking prevents cost overruns. 

Ready to upgrade your asphalt operations? Join hundreds of paving contractors who use OneCrew to manage their businesses more profitably. Book a demo today and see how OneCrew can help you build a scalable asphalt operation.

FAQs

1. How long do asphalt fume symptoms last?

Asphalt fume symptoms typically last from a few hours to up to 24 hours after leaving the area. Mild issues like coughing, headaches, or eye irritation fade quickly, though heavier exposure can make symptoms linger for a day or two. If anything worsens or lasts more than 24 hours, it’s best to see a doctor.

2. Can asphalt fumes cause cancer?

Yes, long-term exposure raises the risk of lung and bladder cancer. Proper respirators, ventilation, and work controls reduce that risk.

3. What respirator should I use for asphalt work?

Use a respirator with organic vapor cartridges for asphalt work. Half-face respirators work for light exposure, but full-face or supplied-air is the best for high exposure. Always get the fit tested.

4. Can asphalt fumes affect my family?

Yes, asphalt fume residue can cling to clothes, skin, and hair. Shower and change before going home, and wash work clothes separately.

5. What if my employer will not provide safety gear?

If your employer will not provide safety gear, then you must report it in writing and request the gear. If nothing changes, contact OSHA or your state safety agency. You have the right to refuse unsafe work.