| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area | Traffic exposure, poor sight distance, uneven pavement | Conduct site walk through; set up MUTCD compliant work zone; use flaggers if needed; assign lookout for approaching vehicles |
| Inspect crack sealing equipment | Leaking hoses, worn wands, malfunctioning melter, faulty burner | Perform pre operation inspection; check hose insulation, wand valve, melter temperature gauges, burner ignition, and fire extinguisher |
| Don required PPE | Burns, fumes, eye injuries | Wear heat resistant gloves, safety glasses or face shield, long sleeves, and high visibility vest |
| Heat crack sealant in melter | Burns from hot material, fire hazards, fume exposure | Heat slowly to manufacturer recommended temperature; never reach into melter; use tools to remove debris; maintain ventilation |
| Prepare cracks (routing or cleaning) | Flying debris, dust inhalation, contact with rotating cutter | Use goggles or face shield; wear hearing protection; use respirator if dust is heavy; keep hands clear of routing heads |
| Use hot air lance or blower | Burns, flying debris, fire hazard | Keep hose away from personnel; avoid pointing at people; maintain safe distance from flammable materials |
| Apply hot sealant using wand | Burns from hot sealant, hose whip, slips on fresh material | Keep steady grip on wand; stand upwind of fumes; avoid excessive sealant that may create tracking hazard; maintain clear communication with melter operator |
| Ensure ground crew stays clear of wand operator | Struck by hose, contact with hot sealant | Establish exclusion zone; assign lookout; maintain awareness of hose movement |
| Maintain traffic control during operation | Motorists driving through hot material, crew exposure | Use cones, signs, and flaggers; ensure roadway is not reopened until sealant cools; adjust work zone as crew moves |
| Conduct quality check of sealed cracks | Contact with hot material, tracking sealant | Allow proper cooling time; do not walk through fresh sealant; inspect visually from safe distance |
| Clean wand, hoses, and melter | Burns, chemical exposure, hose pressure release | Let equipment cool to safe temperature; relieve system pressure; wear heat resistant gloves; follow manufacturer cleaning procedures |
| Final cleanup of site | Trip hazards from tools, leftover debris | Remove loose debris; store tools properly; ensure no sealant globs remain on pavement |
| Remove traffic control | Exposure to moving vehicles | Remove cones and signage in reverse order; maintain lookout; keep high visibility gear on until area is clear |
Hard hat
Safety glasses or face shield
High visibility vest or jacket (Class 3 recommended)
Heat resistant gloves
Cut resistant gloves (for scraping and routing)
Steel toe boots
Long pants and long sleeves
Hearing protection
Respirator if fumes are strong or routing dust is present
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.
Thank you to our primary sponsor, Roadwurx, which is a simple asset management platform for small public works and road departments.
| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area | Traffic exposure, poor sight distance, uneven pavement | Conduct site walk through; set up MUTCD compliant work zone; use flaggers if needed; assign lookout for approaching vehicles |
| Inspect crack sealing equipment | Leaking hoses, worn wands, malfunctioning melter, faulty burner | Perform pre operation inspection; check hose insulation, wand valve, melter temperature gauges, burner ignition, and fire extinguisher |
| Don required PPE | Burns, fumes, eye injuries | Wear heat resistant gloves, safety glasses or face shield, long sleeves, and high visibility vest |
| Heat crack sealant in melter | Burns from hot material, fire hazards, fume exposure | Heat slowly to manufacturer recommended temperature; never reach into melter; use tools to remove debris; maintain ventilation |
| Prepare cracks (routing or cleaning) | Flying debris, dust inhalation, contact with rotating cutter | Use goggles or face shield; wear hearing protection; use respirator if dust is heavy; keep hands clear of routing heads |
| Use hot air lance or blower | Burns, flying debris, fire hazard | Keep hose away from personnel; avoid pointing at people; maintain safe distance from flammable materials |
| Apply hot sealant using wand | Burns from hot sealant, hose whip, slips on fresh material | Keep steady grip on wand; stand upwind of fumes; avoid excessive sealant that may create tracking hazard; maintain clear communication with melter operator |
| Ensure ground crew stays clear of wand operator | Struck by hose, contact with hot sealant | Establish exclusion zone; assign lookout; maintain awareness of hose movement |
| Maintain traffic control during operation | Motorists driving through hot material, crew exposure | Use cones, signs, and flaggers; ensure roadway is not reopened until sealant cools; adjust work zone as crew moves |
| Conduct quality check of sealed cracks | Contact with hot material, tracking sealant | Allow proper cooling time; do not walk through fresh sealant; inspect visually from safe distance |
| Clean wand, hoses, and melter | Burns, chemical exposure, hose pressure release | Let equipment cool to safe temperature; relieve system pressure; wear heat resistant gloves; follow manufacturer cleaning procedures |
| Final cleanup of site | Trip hazards from tools, leftover debris | Remove loose debris; store tools properly; ensure no sealant globs remain on pavement |
| Remove traffic control | Exposure to moving vehicles | Remove cones and signage in reverse order; maintain lookout; keep high visibility gear on until area is clear |
Hard hat
Safety glasses or face shield
High visibility vest or jacket (Class 3 recommended)
Heat resistant gloves
Cut resistant gloves (for scraping and routing)
Steel toe boots
Long pants and long sleeves
Hearing protection
Respirator if fumes are strong or routing dust is present