| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area and traffic conditions | Approaching vehicles, poor visibility, crew stepping into live lanes | Set up proper work zone with cones and signs; use flaggers if required; assign a lookout to monitor crew and traffic flow |
| Inspect crack sealing equipment | Broken hoses, leaking melter, malfunctioning burners, hot oil leaks | Inspect melter, hoses, wand, and burner system; repair leaks; verify safety shutoffs and pressure controls work |
| Don required PPE | Burns from hot sealant, eye injuries, struck by hazards | Wear full PPE including heat resistant gloves and face protection before beginning operations |
| Prepare cracks for sealing | Flying debris, dust inhalation, tool contact | Use blowers or compressed air from safe position; keep others clear of debris stream; use hand tools carefully and maintain firm footing |
| Heat and prepare crack sealant | Burns, fire hazard, inhalation of fumes | Heat sealant to manufacturer recommended temperature; never overheat; maintain safe distance from melter; keep fire extinguisher nearby |
| Apply hot sealant | Burns from hot material, exposure to fumes, slips on fresh sealant | Apply sealant from upwind position; avoid stepping in fresh material; communicate with crew when moving wand or hose |
| Squeegee or band edges (if required) | Contact with hot material, slips near edge of sealed crack | Use squeegee with long handle; avoid reaching across hot material; maintain stable footing |
| Monitor traffic and crew positioning | Workers wandering too close to moving vehicles or equipment | Assign dedicated lookout; maintain communication; keep crew within safe zone at all times |
| Allow sealant to cool and cure | Slips on uncured material, premature reopening to traffic | Keep cones in place until sealant is firm; visually verify cooling before removing traffic control |
| Clean equipment | Burns from hot components, contact with chemical residue | Allow equipment to cool before servicing; wear gloves; follow manufacturer cleaning instructions |
| Remove traffic control | Workers exposed during takedown, unexpected vehicle movement | Remove cones and signs only after confirming roadway is safe and crew is fully clear; use lookout when working near lane edges |
Hard hat
Safety glasses or face shield
High visibility vest
Heat resistant gloves
Long sleeve shirt and long pants
Steel toe boots
Hearing protection
Respiratory protection if fumes are heavy
Cut resistant gloves for handling hand tools
Always have a complete, well-stocked first aid kit available.
JSA Category: Roadway Maintenance Operations
* The steps, hazards, and controls displayed above may be incomplete or not suit your department's needs. All job safety analyses should be a completed with frontline worker input to ensure that each potential hazard is identified and mitigated.
Please read about The Essentials Elements of a Solid Job Safety Anaylsis here.
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| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area and traffic conditions | Approaching vehicles, poor visibility, crew stepping into live lanes | Set up proper work zone with cones and signs; use flaggers if required; assign a lookout to monitor crew and traffic flow |
| Inspect crack sealing equipment | Broken hoses, leaking melter, malfunctioning burners, hot oil leaks | Inspect melter, hoses, wand, and burner system; repair leaks; verify safety shutoffs and pressure controls work |
| Don required PPE | Burns from hot sealant, eye injuries, struck by hazards | Wear full PPE including heat resistant gloves and face protection before beginning operations |
| Prepare cracks for sealing | Flying debris, dust inhalation, tool contact | Use blowers or compressed air from safe position; keep others clear of debris stream; use hand tools carefully and maintain firm footing |
| Heat and prepare crack sealant | Burns, fire hazard, inhalation of fumes | Heat sealant to manufacturer recommended temperature; never overheat; maintain safe distance from melter; keep fire extinguisher nearby |
| Apply hot sealant | Burns from hot material, exposure to fumes, slips on fresh sealant | Apply sealant from upwind position; avoid stepping in fresh material; communicate with crew when moving wand or hose |
| Squeegee or band edges (if required) | Contact with hot material, slips near edge of sealed crack | Use squeegee with long handle; avoid reaching across hot material; maintain stable footing |
| Monitor traffic and crew positioning | Workers wandering too close to moving vehicles or equipment | Assign dedicated lookout; maintain communication; keep crew within safe zone at all times |
| Allow sealant to cool and cure | Slips on uncured material, premature reopening to traffic | Keep cones in place until sealant is firm; visually verify cooling before removing traffic control |
| Clean equipment | Burns from hot components, contact with chemical residue | Allow equipment to cool before servicing; wear gloves; follow manufacturer cleaning instructions |
| Remove traffic control | Workers exposed during takedown, unexpected vehicle movement | Remove cones and signs only after confirming roadway is safe and crew is fully clear; use lookout when working near lane edges |
Hard hat
Safety glasses or face shield
High visibility vest
Heat resistant gloves
Long sleeve shirt and long pants
Steel toe boots
Hearing protection
Respiratory protection if fumes are heavy
Cut resistant gloves for handling hand tools