Asphalt Poisoning Symptoms: Warning Signs, Health Risks, & When to Act

Asphalt poisoning symptoms usually start when you breathe fumes from hot mix or get hot asphalt on your skin. 

Most crews notice headache, throat or eye irritation, coughing, or nausea first. More serious warning signs include shortness of breath, chest tightness, or burns on the skin or eyes.

This guide breaks down the most common symptoms, what “long-term exposure” looks like on paving crews, and when you should get medical care instead of trying to push through the shift.

Poison Control Hotline: 1-800-222-1222 (available 24/7)

Common Asphalt Poisoning Symptoms to Watch for

The most common asphalt poisoning symptoms are headache, throat or eye irritation, coughing or wheezing, and nausea. Here’s a quick chart explaining each symptom type:

Short-term symptoms (acute exposure)

These asphalt poisoning symptoms usually show up during or shortly after exposure and include headaches, throat and eye irritation, chest tightness, nausea, and drowsiness.

Skin-related symptoms

Direct contact with hot asphalt causes different asphalt poisoning symptoms than inhaling fumes. Skin exposure can cause:

• Severe burns from hot asphalt contact
• Skin irritation and rashes
• Dermatitis (inflamed, red, itchy skin)
• Acne-like lesions
• Skin pigment changes that worsen with sun exposure

Hot asphalt cools quickly once it touches skin, making it difficult to remove. This is why burns from asphalt contact can be particularly severe.

Long-term symptoms (chronic exposure)

Long-term means repeated exposure for 3 months or more (often a full paving season) or symptoms that keep coming back for weeks, even when you’re off the job site.

The most common long-term asphalt poisoning symptoms are ongoing cough or throat irritation, recurring wheeze or shortness of breath, and persistent skin irritation or sun sensitivity.

Persistent respiratory issues:

• Chronic coughing
• Ongoing wheezing
• Long-term shortness of breath
• Bronchitis development (cough with phlegm)

Other chronic effects:

• Permanent skin pigment changes
• Increased sensitivity to sunlight
• Potential lung function decline

What Is Asphalt Fume Exposure?

Asphalt fume exposure happens when you breathe vapors and tiny particles released from heated asphalt (and sometimes from asphalt-based products like tack coats). 

OSHA notes that over half a million workers are exposed to asphalt fumes across paving, roofing, and related work. For a plain-English breakdown, see our guide to OSHA requirements for asphalt.

Health Risks Beyond Immediate Symptoms

Even if symptoms feel “minor” on a given day, asphalt exposure can add up. Repeated irritation can trigger recurring cough, airway inflammation, and breathing flare-ups, especially for workers with asthma or other respiratory issues.

Job conditions that increase risk

Conditions that increase risk include working near heated asphalt, pouring or spraying operations, working in confined spaces, and handling materials during spills or evaporation.

Cancer concerns

The International Agency for Research on Cancer (IARC) has flagged asphalt fumes as a potential concern. It classifies occupational exposures to oxidized asphalt (CAS # 64742-93-4) fumes during roofing as Group 2A (probably carcinogenic to humans) and straight-run asphalt during road paving as Group 2B (possibly carcinogenic to humans). 

These classifications are based on animal evidence and mechanistic data, and do not indicate the level of evidence found for coal tar pitch (Group 1: carcinogenic to humans).

Research suggests asphalt fume exposure may increase cancer risk, though scientists are still studying the exact relationship. This uncertainty is exactly why minimizing exposure matters, even if you're not experiencing obvious asphalt poisoning symptoms right now.

Lung function decline

Studies on road-paving workers show that regular asphalt fume exposure can reduce lung function over time. Some workers develop bronchitis, though researchers are still determining whether fumes are the direct cause or a contributing factor.

Who faces the highest risk?

Workers in these roles have the greatest exposure to asphalt fumes:

• Road paving crews
• Asphalt plant workers
• Roofers working with hot asphalt
• Siding installers
• Concrete and paving contractors
• Asphalt roller operators 

When to Seek Medical Attention

You should seek medical attention for asphalt poisoning symptoms when you have breathing trouble, chest tightness, severe dizziness, confusion, or symptoms that don’t improve after you get away from the fumes. 

Seek immediate medical care if:

• Hot asphalt contacts skin or eyes
• Someone swallows asphalt (rare but serious)
• Breathing becomes severely difficult
• A worker loses consciousness or shows signs of shock
• Symptoms include severe throat pain or vision problems

If asphalt is swallowed:

1. Immediately call Poison Control at 1-800-222-1222. This should be your first action.
2. If the person can swallow safely and Poison Control advises, give water or milk.
3. Do not induce vomiting unless Poison Control specifically instructs you to.
4. Do not give anything to drink if the person is vomiting, having convulsions, or showing decreased alertness.

Important: Milk does not serve as an antidote or provide protective benefits beyond simple dilution. Always follow Poison Control guidance rather than administering fluids on your own.

Schedule a doctor’s visit if:

• Asphalt poisoning symptoms persist after leaving the work area
• Respiratory symptoms keep returning
• Skin changes don't heal
• You've had repeated high-exposure incidents

Medical tests your doctor may recommend

• Lung function tests: These check for a decline in breathing capacity. Workers with frequent or high exposures should get baseline testing before starting work and regular follow-up tests.
• Skin examination: Important if you've had repeated contact or notice pigment changes.
• Respiratory evaluation: Useful for persistent coughing, wheezing, or shortness of breath.

Bring information about your work environment to medical appointments. Details about exposure levels, duration, and protective equipment help doctors make accurate assessments.

How to Protect Yourself and Your Crew

Preventing asphalt poisoning symptoms beats treating them every time. The following strategies reduce exposure on the job, and most are easier to implement than you might think.

Engineering controls

Engineering controls eliminate or reduce fumes at the source:

• Enclose operations where possible
• Install local exhaust ventilation at fume release points
• Use lower-temperature asphalt mixes when appropriate
• Automate pumping from drums to process containers
• Test confined spaces for explosive concentrations before entry

Personal Protective Equipment (PPE)

When engineering controls aren't enough, PPE provides a backup layer of protection:

Respiratory protection:

• For exposures above 0.5 mg/m³: Use a NIOSH-approved full facepiece respirator with organic vapor cartridge and particulate prefilters
• For exposures above 5 mg/m³: Use a supplied-air respirator with full facepiece in pressure-demand mode

Note: OSHA has not established a legal exposure limit for asphalt fumes. Industry guidance recommends:

• ACGIH TLV: 0.5 mg/m³ (8-hour time-weighted average, measured as benzene-soluble aerosol; adopted 2000)
• NIOSH REL: 5 mg/m³ (15-minute ceiling, measured as total particulate; established 1977)

Dust respirators alone don't protect against vapors. If you smell, taste, or detect asphalt fumes through your respirator, leave the area immediately. Either the seal has failed, or the cartridge needs replacing.

Eye protection:

• Indirect-vent, impact- and splash-resistant goggles for liquid work
• Full face shield with goggles for highly irritating operations
• Skip contact lenses when working with asphalt

Skin protection:

• Protective gloves rated for asphalt exposure
• Protective clothing covering exposed skin
• Clean protective gear daily

Work Practices That Reduce Risk

Good habits make a real difference in preventing asphalt poisoning symptoms:

• Wash thoroughly after any asphalt exposure
• Change contaminated clothing promptly
• Don't eat, smoke, or drink in areas where asphalt is handled
• Keep eyewash fountains and emergency showers accessible
• Train all workers on asphalt hazards and emergency procedures, and refresh training before the season starts. If you need options, see our list of online asphalt certifications.

Asphalt vs. Coal Tar: Know the Difference

The biggest differences between asphalt and coal tar exposure are the source material and the cancer risk profile. Asphalt (bitumen) is petroleum-based and IARC’s concern is tied to certain occupational exposure settings. Coal tar and coal tar pitch volatiles are tied to much higher PAH content and are classified by IARC as carcinogenic to humans (Group 1).

• Asphalt comes from petroleum and is used in road paving, roofing, and adhesives. It's the material most paving contractors work with daily.
• Coal tar pitch comes from coal processing and is a known human carcinogen. It requires stricter exposure limits and different safety protocols entirely.

If you’re ever unsure which material you're handling, check the product labels and safety data sheets. This distinction matters for your health and compliance.

Planning Your Paving Operations for Safety

A real safety plan reduces asphalt fume exposure before the first load hits the paver. Use this as a pre-job checklist for the crew lead:

1. Plan for airflow: Work upwind when you can. Keep workers who don’t need to be in the fume zone away from the screed and transfer points.
   
   
2. Control temperature and time held at temperature: Keep asphalt as cool as the spec allows and avoid long idle periods where material sits hot and smoking.
   
   
3. Rotate high-exposure tasks: Don’t park the same person in the highest-fume position all day. Rotate roles on a set schedule (for example, at break intervals).
   
   
4. Schedule high-heat work smarter: When possible, run the hottest tasks in cooler parts of the day and avoid dead-still conditions where fumes hang low.
   
   
5. Control spills fast: Treat spills as an exposure event. Keep a spill kit available and assign who handles cleanup so everyone doesn’t crowd the source.
   
   
6. Make PPE decisions based on the task: Gloves, long sleeves, eye protection, and face shields matter for splash risk. Respirator selection should match the SDS and the exposure conditions (especially in enclosed areas).
   
   
7. Run a 2-minute symptom check at break: Ask directly, “Any headache? Burning eyes? Coughing or wheeze? Nausea?” If yes, move the worker away from exposure and reassess controls.

Run Safer Jobs from Estimate to Invoice with OneCrew

Asphalt poisoning is preventable with proper planning and equipment. The key is organizing operations to prioritize safety over deadlines. That’s where OneCrew comes in. 

OneCrew was built for project-based asphalt and concrete contractors who want to manage everything from takeoff to final invoice without juggling multiple tools.

Here's what you can do with OneCrew:

• Build accurate estimates without the back-and-forth: The estimating features let you measure from PDFs or aerial maps and apply labor, material, equipment, and sub-line items with built-in calculators. 
• Keep customer information organized: The CRM tracks every lead and interaction from first contact through project completion. 
• Send professional proposals that close faster: Create polished proposals your clients can review, approve, and sign through a customer portal. If you want a stronger paperwork baseline, use an asphalt paving contract template during your closeout process.
• Schedule crews with safety in mind: The scheduling features let you assign crews and roles to specific job phases. If scheduling is your bottleneck, here’s a deeper guide to asphalt paving scheduling software.
• Give field crews the information they need: Field management tools put job details, site information, and schedule updates in your crews' hands.
• Get paid without the administrative pile-up: The invoicing features sync with QuickBooks Online, so you skip the double-entry.

You don't need five different apps to run your paving business. You need one platform that ties project management together from takeoff to final invoice. Book a free demo and learn how OneCrew helps you take control of your jobs from start to finish.

FAQs

1. How long do asphalt poisoning symptoms last?

Many short-term symptoms (headache, throat irritation, mild nausea) improve after you get fresh air and reduce exposure. If symptoms last into the next day, keep returning across shifts, or include breathing trouble, you should get medical advice.

2. What should you do if hot asphalt gets on your skin?

What should you do if hot asphalt gets on your skin? Cool the burn immediately with cool running water for at least 20 minutes, and don’t peel stuck asphalt off the skin. Get medical care for blistering burns, large burns, or burns on the face or hands.

3. When should you call Poison Control for asphalt exposure?

Call Poison Control (1-800-222-1222) when asphalt is swallowed, or when you’re unsure what to do after a significant exposure event. If asphalt is swallowed, do not induce vomiting unless Poison Control tells you to.

4. Can asphalt fume exposure cause long-term breathing problems?

Long-term breathing problems are more likely when exposure happens repeatedly over months, especially if a worker has asthma or other respiratory conditions. If coughing, wheezing, or chest tightness keeps recurring across shifts, treat it as a long-term warning sign and address controls and medical follow-up.

5. Do masks help with asphalt poisoning symptoms?

A basic dust mask won’t reliably protect against fumes and vapors. Respiratory protection needs to match the hazard and the job conditions, so it should follow the SDS and your exposure evaluation, especially in low-airflow areas.