| Step | Potential Hazard | Control |
|---|---|---|
| Assess work area | Traffic exposure, pedestrians, uneven roadway, soft shoulders | Conduct walk through; identify hazards; set up MUTCD compliant work zone; post flaggers if needed |
| Inspect tack truck and equipment | Leaking nozzles, pump failure, clogged spray bar, faulty alarms | Perform pre operation inspection; test spray bar, pump pressure, heating system, mirrors, lights, and backup alarm |
| Don required PPE | Chemical exposure, fumes, eye injuries | Wear chemical resistant gloves, safety glasses or face shield, and high visibility vest |
| Position tack truck | Backing hazards, blind spots, traffic conflicts | Use spotter when backing; activate beacons; align truck for straight, steady passes |
| Heat tack material | Burn hazard, pressure buildup, fume exposure | Follow manufacturer temperature guidelines; heat gradually; maintain ventilation; stay clear of heating ports |
| Test spray pattern | Inconsistent coverage, overspray, material blowback | Test on small section; adjust nozzles and pressure; ensure even fan pattern before full application |
| Apply tack coat | Slips on fresh tack, overspray onto vehicles or crew, inhalation hazards | Maintain slow uniform speed; keep crew away from spray zone; use low wind settings; control overspray with shields if needed |
| Keep ground crew clear of traffic | Crew stepping into live traffic or tack path | Establish exclusion zone; assign lookout; workers must stay behind tack truck unless necessary |
| Prevent contamination of tack coat | Dirt, loose material, or tires tracking tack | Sweep surface before application; restrict access until tack is cured; limit truck crossings |
| Monitor material usage and temperature | Under or over application, tack cooling too fast | Watch gauges; maintain manufacturer recommended temperature; avoid stopping mid pass |
| Handle clogs or nozzle issues | Contact with hot asphalt, pressure release, spray back | Shut off pump; relieve pressure; clean nozzles with proper tools; never use hands near pressurized lines |
| Finish pass and move truck | Tracking tack onto clean roadway, spills | Move slowly; keep tires off freshly sprayed areas; ensure all valves and spray bars are closed |
| Clean spray equipment | Contact with hot or sticky material, chemical fumes | Use approved solvents; wear gloves and eye protection; clean in well ventilated area |
| Final site cleanup | Slips, environmental contamination | Check for drips or spills; place absorbent material if needed; ensure roadway is ready for paving |
| Remove traffic control | Exposure to passing vehicles | Remove cones and signs in reverse order; maintain lookout; keep PPE on until area is safe |
Hard hat
Safety glasses or face shield
High visibility vest or jacket (Class 3 recommended)
Chemical resistant gloves
Steel toe boots
Long pants and long sleeves
Hearing protection near equipment
Respirator when working with solvents or heavy fumes
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, pedestrians, uneven roadway, soft shoulders | Conduct walk through; identify hazards; set up MUTCD compliant work zone; post flaggers if needed |
| Inspect tack truck and equipment | Leaking nozzles, pump failure, clogged spray bar, faulty alarms | Perform pre operation inspection; test spray bar, pump pressure, heating system, mirrors, lights, and backup alarm |
| Don required PPE | Chemical exposure, fumes, eye injuries | Wear chemical resistant gloves, safety glasses or face shield, and high visibility vest |
| Position tack truck | Backing hazards, blind spots, traffic conflicts | Use spotter when backing; activate beacons; align truck for straight, steady passes |
| Heat tack material | Burn hazard, pressure buildup, fume exposure | Follow manufacturer temperature guidelines; heat gradually; maintain ventilation; stay clear of heating ports |
| Test spray pattern | Inconsistent coverage, overspray, material blowback | Test on small section; adjust nozzles and pressure; ensure even fan pattern before full application |
| Apply tack coat | Slips on fresh tack, overspray onto vehicles or crew, inhalation hazards | Maintain slow uniform speed; keep crew away from spray zone; use low wind settings; control overspray with shields if needed |
| Keep ground crew clear of traffic | Crew stepping into live traffic or tack path | Establish exclusion zone; assign lookout; workers must stay behind tack truck unless necessary |
| Prevent contamination of tack coat | Dirt, loose material, or tires tracking tack | Sweep surface before application; restrict access until tack is cured; limit truck crossings |
| Monitor material usage and temperature | Under or over application, tack cooling too fast | Watch gauges; maintain manufacturer recommended temperature; avoid stopping mid pass |
| Handle clogs or nozzle issues | Contact with hot asphalt, pressure release, spray back | Shut off pump; relieve pressure; clean nozzles with proper tools; never use hands near pressurized lines |
| Finish pass and move truck | Tracking tack onto clean roadway, spills | Move slowly; keep tires off freshly sprayed areas; ensure all valves and spray bars are closed |
| Clean spray equipment | Contact with hot or sticky material, chemical fumes | Use approved solvents; wear gloves and eye protection; clean in well ventilated area |
| Final site cleanup | Slips, environmental contamination | Check for drips or spills; place absorbent material if needed; ensure roadway is ready for paving |
| Remove traffic control | Exposure to passing vehicles | Remove cones and signs in reverse order; maintain lookout; keep PPE on until area is safe |
Hard hat
Safety glasses or face shield
High visibility vest or jacket (Class 3 recommended)
Chemical resistant gloves
Steel toe boots
Long pants and long sleeves
Hearing protection near equipment
Respirator when working with solvents or heavy fumes