Asphalt Safety: 11 Best Practices to Protect Your Paving Crew in 2026

Hot asphalt. Heavy equipment. Tight deadlines. If you run a paving operation, you know the risks your crew faces every single day. Over 500,000 workers are exposed to asphalt fumes annually, and the paving industry consistently ranks among the most hazardous in construction.

However, most asphalt safety incidents are preventable with the right protocols in place. This guide breaks down the hazards your crew actually faces and gives you practical steps to address each one.

11 Best Practices to Protect Your Paving Crew: At a Glance

Why Asphalt Safety Matters More Than You Think

Here's the reality: Construction employs about 5% of the U.S. workforce but accounts for over 21% of workplace fatalities. 

Paving crews face a unique combination of hazards that other trades don't encounter. You're working with material heated to 300°F or higher, operating around heavy machinery, and doing it all just feet from moving traffic.

The stakes go beyond compliance. A single serious injury can sideline your best workers for months, drive up insurance costs, and delay projects that are already running on thin margins. Building asphalt safety into your daily operations protects your crew and your bottom line.

The 5 Major Hazards in Asphalt Paving

Before diving into solutions, let's look at what your crew is actually up against. Understanding these hazards is the first step toward managing them. Let’s zoom in on these 5:

1. Burns from hot asphalt

Hot mix asphalt arrives at temperatures between 275°F and 325°F. At these temperatures, even brief contact causes severe burns. Asphalt also sticks to skin and clothing, which makes burns worse because the material continues transferring heat until it's removed.

The tricky part? You can't just peel hot asphalt off skin. Doing so damages tissue further. This means prevention is everything, because treatment options are limited once contact occurs.

Crews usually learn this fast: hot mix does not forgive distractions. One sloppy handoff with a lute, one slip near the hopper, and you go from “we’re moving” to “stop everything” in seconds.

2. Asphalt fume exposure

When asphalt heats up, it releases fumes containing volatile organic compounds (VOCs) and polycyclic aromatic hydrocarbons (PAHs). 

Short-term exposure causes headaches, throat irritation, fatigue, and skin rashes. Long-term exposure has been linked to respiratory issues and certain cancers.

Workers standing near the paver screed or handling material near the hopper get the highest exposure. Wind direction, ambient temperature, and the specific asphalt mix all affect fume concentrations.

3. Heat-related illness

This one's a double threat. Your crew already works in summer heat, often in direct sunlight. The result? Asphalt surfaces that absorb solar radiation can reach 140°F on hot days, with heat radiating into the work zone, creating conditions significantly hotter than official readings.

Heat cramps, heat exhaustion, and heat stroke cause thousands of injuries every year in construction. These conditions also contribute to accidents indirectly by causing fatigue, dizziness, and impaired judgment.

4. Struck-by incidents

According to CDC data, struck-by incidents account for 13–17% of construction fatalities. And here's the surprising part: 55% of struck-by incidents on paving projects involve crew members, construction vehicles, or equipment. Fellow workers cause more injuries than passing motorists.

Dump trucks backing up, rollers reversing direction, workers stepping into equipment paths. These situations happen constantly on active paving sites. Add in the noise that makes verbal warnings ineffective, and you've got a recipe for serious accidents.

Equipment hazards

Pavers, rollers, milling machines, and material transfer vehicles all create risks of crushing, entanglement, and pinch points. The paver auger alone has caused multiple fatalities when workers reached in to clear material jams without proper lockout procedures.

11 Asphalt Safety Best Practices That Actually Work

Now, let's get into what you can do about these hazards. These practices come from OSHA guidelines, NIOSH research, and contractors who've built strong safety records over decades in the industry. Here’s the first one:

1. Require proper PPE for asphalt work

PPE for asphalt work needs to address burns, fume exposure, and general construction hazards. The minimum setup includes:

• Face shield (8-inch minimum) to protect against splashes
• Thermally insulated gloves with gauntlets extending up the forearm, worn loosely for quick removal if asphalt contacts them
• Long-sleeved shirts and pants without cuffs (cuffs trap hot material)
• Safety boots with 6-inch laced tops to prevent material from entering
• Eye protection when chipping or handling cold asphalt
• Respirator with organic vapor and particulate cartridges when ventilation is inadequate

One important note: Cloth and leather gloves don't cut it for asphalt work. The solvents in many asphalt mixes can soak through these materials and absorb into the skin. Use gloves specifically rated for hot material handling.

2. Control fume exposure at the source

Engineering controls beat PPE every time when it comes to asphalt fumes. Start with these approaches:

• Substitute lower-fuming materials where possible. Warm mix asphalt (WMA) technologies allow paving at temperatures 50 to 100 degrees lower than traditional hot mix, which significantly reduces fume generation.
• Maintain proper temperatures. Overheating asphalt dramatically increases fume production. Use temperature monitoring systems to keep material within spec.
• Position workers upwind when feasible. This simple step reduces exposure during activities like raking and hand work around the paver.
• Use local exhaust ventilation on equipment. Many modern pavers include fume extraction systems. If your equipment has these features, make sure they're functional and actually running.

Everyone talks about fumes as if they are a background problem until the wind shifts and the whole crew feels it at once. If eyes start stinging or guys get quiet and cranky, treat that as a signal, not a personality trait.

When engineering controls aren't enough, respirators become necessary. A full-face respirator with organic vapor and particulate cartridges provides protection against both the fume components and the particulate matter. 

Half-face respirators won't adequately protect against the eye irritation that asphalt fumes cause.

3. Build a heat illness prevention program

OSHA requires employers to protect workers from heat hazards, and that means going beyond "drink water" reminders. An effective heat illness prevention program includes:

• Water, rest, and shade. Provide cool water (under 60°F) at the work site and encourage workers to drink at least 8 ounces every 15 to 20 minutes. Set up shaded rest areas away from the hot zone.
• Acclimatization protocols. New workers and those returning from a week or more off need gradual exposure to heat. Start with 20% of normal workload on day one and increase by 20% each day.
• Modified work schedules. When possible, schedule the most physically demanding work for cooler morning hours. During extreme heat, consider starting earlier or working into evening hours.
• Buddy system. Workers should monitor each other for early signs of heat stress: heavy sweating, pale skin, muscle cramps, dizziness, confusion, or slurred speech. Heat stroke is a medical emergency requiring immediate 911 response and active cooling.
• Training. Everyone on site should recognize heat illness symptoms and know the response procedures. This includes supervisors, who need to watch for workers who may not self-report symptoms.

4. Implement traffic control plans

Traffic management addresses both public vehicle hazards and equipment movement within the work zone. Your plan should cover:

• Clear signage and barriers separating the work zone from traffic 
• Designated walkways for foot traffic within the site 
• High-visibility clothing for all personnel (Class 2 or Class 3 vests, depending on conditions) 
• Spotters for backing operations and equipment movement 
• Speed limits for both public traffic and construction equipment

The internal traffic piece often gets overlooked. Establish travel paths for dump trucks and other vehicles. Designate specific areas where workers should never stand. Use spotters and ground guides for any backing maneuver, every single time.

Backing alarms help, but they do not solve everything on a loud site. A spotter who makes eye contact with the driver and stays in the same place can prevent that classic near-miss where someone steps back to grab a rake and forgets a truck is moving.

5. Enforce lockout/tagout procedures

Before anyone performs maintenance, clears a jam, or works on any equipment, that machine needs to be fully shut down and locked out. This applies to:

• Clearing material from paver augers or conveyors
• Adjusting screed components
• Any work that puts hands or body parts near moving parts

Lockout/tagout isn't optional, and "it'll just take a second" isn't an acceptable reason to skip it. On paving crews, “just a second” is the most expensive phrase you will ever hear. If an auger jams, the machine does not care that the job is behind schedule.  

Some of the most severe injuries in the paving industry happen during quick fixes that go wrong.

6. Establish equipment inspection routines

Daily pre-shift inspections catch problems before they cause injuries. Key areas to check:

• Emergency stop buttons and safety interlocks
• Warning lights and backup alarms
• Fire suppression systems
• Steering and braking systems
• Hydraulic lines and connections
• Guards and shields on moving parts

Document inspections and address deficiencies before the equipment operates. A 10-minute inspection is cheap compared to a day lost to equipment failure or an injury that results from it.

7. Train workers on burn prevention and response

Burn prevention comes down to keeping hot material away from skin. Beyond PPE, that means:

• Never reaching into hoppers or augers while equipment is running
• Using long-handled tools for manual spreading and raking
• Staying alert to splash hazards when material is being transferred
• Keeping work clothing in good condition (holes and worn areas compromise protection)

When burns do occur, the response differs from typical first aid. For hot asphalt burns:

• Apply cold water or ice packs immediately
• Do NOT attempt to remove asphalt from skin (this causes additional tissue damage)
• Do NOT bandage the burn
• For burns covering more than 10% of body surface, use lukewarm water instead of cold to prevent shock
• Get medical attention for any significant burn

8. Control fire and explosion risks

Asphalt becomes flammable when overheated or when cut-back asphalts with volatile solvents are exposed to ignition sources. Fire prevention measures include:

• Eliminate ignition sources near asphalt operations. No smoking, no open flames, no unshielded electrical equipment in areas where asphalt is heated or applied.
• Keep distributors clean. Asphalt buildup on distributor trucks creates fuel for fires. Regular cleaning removes this risk.
• Shut off burners before spraying. When applying cut-back asphalt with a distributor, turn off burners before beginning spray operations.
• Maintain fire extinguishers. Keep dry chemical or CO2 extinguishers on all equipment handling hot asphalt. Train crews on spray bar fire response.

9. Make safety data sheets accessible

Every crew member should have access to Safety Data Sheets (SDS) for the materials they work with. These documents contain critical information including:

• Flash points and fire hazards
• Health effects of exposure
• Recommended PPE
• First aid procedures
• Emergency response information

Keep SDS documents in a known, accessible location on site. For projects using multiple asphalt mixes or sealcoat products, make sure the relevant sheets are available for each material.

10. Conduct regular safety meetings

Weekly safety meetings keep hazards top of mind and give crews a forum to raise concerns. Effective meetings:

• Address hazards specific to current work conditions
• Review recent incidents or near-misses
• Cover seasonal topics (heat illness in summer, slip hazards in cold weather)
• Allow time for worker questions and input

The best safety meetings are conversations, not lectures. Keep it short and specific. 

Talk about the one thing that could bite you today, like backing paths, heat, or a sketchy crossover near the paver. If you want full participation, ask one simple question: “What felt unsafe last week?” 

Then let the crew answer. Workers who feel heard are more likely to report hazards and follow protocols.

11. Take advantage of manufacturer training

Equipment manufacturers and dealers offer training that goes beyond what most contractors can develop in-house. 

Companies like Wirtgen, BOMAG, and Sakai provide hands-on instruction covering safe operation, maintenance procedures, and feature-specific training. If you want a faster ramp for new hires, asphalt certification online gives them a baseline before they ever work next to a hot screed.

Use weather-related downtime to bring in manufacturer representatives or send key personnel to training facilities. The investment pays off in reduced accidents and more efficient equipment use.

First Aid Essentials for Asphalt Work Sites

Every paving site needs personnel trained in first aid and materials readily available to respond to common injuries. Stock your first aid supplies with:

• Burn gel and sterile dressings
• Eye wash station or portable eye wash solution
• Cold packs
• Basic first aid supplies (bandages, antiseptics, etc.)
• Emergency contact information posted visibly

For serious injuries, call 911 immediately. Asphalt burn victims and heat stroke patients need professional medical care, not improvised treatment.

Building a Culture of Asphalt Safety

Protocols on paper mean nothing without buy-in from supervisors and crews. Building a genuine safety culture requires:

• Leadership commitment: When supervisors enforce rules consistently and model safe behavior themselves, crews follow. When supervisors cut corners, the message is clear: safety is optional.
• Accountability without punishment: Workers need to report hazards and near-misses without fear of retaliation. Punishing honesty guarantees you'll stop hearing about problems until someone gets hurt.
• Recognition: Acknowledge crews and individuals who maintain strong safety records. Positive reinforcement works better than negative consequences for building lasting habits.
• Continuous improvement: Review incidents and near-misses to identify systemic issues. Update procedures based on what you learn. Safety programs that don't evolve become stale and ineffective.

Manage Your Crews, Jobs, and Asphalt Safety in One Place

Running an asphalt business means managing crews across multiple sites, coordinating equipment, sending estimates, and tracking invoices. When administrative chaos takes over, safety suffers; you're constantly putting out fires instead of planning ahead.

You know the feeling. It's 9 p.m., you're staring at scattered notes, trying to remember which crew had the tight site with the tricky entrance. When planning lives in texts and paper, safety prep falls through the cracks.

That's where OneCrew comes in. OneCrew gives paving contractors one platform to manage everything from estimate to invoice. Here's what you can do:

• Build accurate estimates without the guesswork: The estimating features let you measure from PDFs or aerial maps and apply labor, material, equipment, and subcontractor line items with built-in calculators. 

Accurate job planning means realistic timelines and properly staffed crews, not last-minute scrambles that lead to safety shortcuts.

• Keep every customer interaction organized: The CRM tracks leads and communications from first contact through project completion. When you're not digging through emails to find job details, you have more bandwidth for safety planning.
• Send professional proposals that move faster: Create polished proposals your clients can review, approve, and sign through a customer portal. Less time chasing paperwork means more time for pre-job safety briefings and site assessments.

A solid asphalt paving contract helps you lock in scope and responsibilities before the first truck shows up.

• Schedule crews with the full picture: The scheduling features let you assign crews and roles to specific job phases. Plan for heat acclimatization, rotate workers through high-exposure tasks, and make sure everyone knows their responsibilities before they arrive on site.
• Give field crews the information they need: Field management tools put job details, site information, and schedule updates in your crews' hands. When workers know what's expected and have time to prepare, they're more likely to follow proper asphalt safety protocols.
• Get paid without the administrative pile-up: The invoicing features sync with QuickBooks, so you skip the double-entry. When billing runs smoothly, you're not distracted from job site oversight and safety walkthroughs.

When your operations run smoothly, you have time to focus on what matters: keeping your crews safe and your projects profitable.

Book a free demo and see how OneCrew helps paving contractors take control of their business from takeoff to final payment.

FAQs

1. What are the biggest asphalt paving safety hazards?

The biggest asphalt paving safety hazards are burns from hot mix, asphalt fume exposure, heat illness, struck-by incidents, and equipment pinch points. These hazards stack up fast when crews work around moving trucks, hot material, and tight work zones.

2. How hot is hot mix asphalt when it arrives on site?

Hot mix asphalt arrives on site around 275°F to 325°F. That temperature causes severe burns from brief contact, and the material can stick to skin and clothing, which makes the injury worse.

3. What PPE do asphalt workers need?

Asphalt workers need PPE that protects against splashes, burns, and fumes. Most crews start with a face shield, insulated gloves with gauntlets, long sleeves and pants without cuffs, and safety boots with high tops, then add a respirator when ventilation and wind position do not control fumes.

4. How do you reduce asphalt fume exposure on a paving crew?

You reduce asphalt fume exposure by controlling it at the source. Warm mix options, temperature control, working upwind, and equipment fume extraction systems cut exposure, then respirators fill the gap when those controls cannot.

5. What should you do if someone gets a hot asphalt burn?

If someone gets a hot asphalt burn, cool the area with cold water or ice packs and get medical help for significant burns. Do not try to peel asphalt off skin, because that can damage tissue further.