| Step | Potential Hazard | Control |
|---|---|---|
| Assess work zone and traffic conditions | Vehicles approaching unexpectedly, limited visibility, crew drifting into open lanes | Set up MUTCD compliant work zone; use cones, signs, and arrow boards; assign a lookout to monitor traffic and crew |
| Inspect thermoplastic equipment | Leaking hoses, clogged applicator shoes, malfunctioning burners or pumps | Conduct full equipment inspection; check heating system, bead dispenser, pressures, and safety shutoffs; remove damaged equipment from service |
| Don required PPE | Burns from molten thermoplastic, eye injury, struck by hazards | Wear heat resistant gloves, face protection, long sleeves, and high visibility vest before entering roadway |
| Heat thermoplastic material | Overheating material causing degradation or fire, burns from splatter | Heat only to manufacturer specified temperature; monitor gauges; avoid leaning over kettle; keep fire extinguisher nearby |
| Prepare pavement surface | Loose debris affecting adhesion, trip hazards, dust inhalation | Sweep or blow pavement thoroughly; ensure surface is dry; maintain safe distance from debris stream |
| Position equipment | Backing hazards, blind spots, equipment striking workers | Use a spotter when positioning thermoplastic applicator; verify backup alarms and beacons are functioning |
| Begin applying thermoplastic | Material splashing, contact with molten line, overspray or runoff | Operate at steady speed; maintain smooth applicator movement; keep all workers clear of molten material; use shields as designed |
| Apply reflective beads | Eye exposure, slipping hazard from loose beads | Maintain correct bead drop rate; avoid excessive bead use; keep crew away from bead discharge area |
| Maintain communication | Miscommunication leading to uneven lines, unsafe movements, or traffic conflicts | Use radios or hand signals; ensure operator and ground crew maintain constant coordination |
| Handle traffic around operation | Vehicles entering lane too early, motorists driving through wet thermoplastic | Maintain taper and cones until markings cool; use pilot vehicles if needed; assign lookout to watch for early entry |
| Monitor cooling period | Burns, tracking of uncured markings | Keep crew and traffic away until thermoplastic fully hardens; mark fresh lines with cones if necessary |
| Shutdown and clean equipment | Contact with hot equipment, improper disposal of thermoplastic residue | Allow unit to cool; follow manufacturer cleaning procedures; dispose of waste properly; store materials securely |
| Remove traffic control | Worker exposure to traffic during takedown | Remove devices in reverse order; maintain protective vehicle position; use lookout until all devices are retrieved |
Hard hat
Safety glasses or face shield
High visibility vest (Class 2 or Class 3 depending on roadway)
Heat resistant gloves
Long sleeve shirt and long pants
Steel toe boots
Respiratory protection if required by product or fume conditions
Hearing protection when working near loud equipment
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 zone and traffic conditions | Vehicles approaching unexpectedly, limited visibility, crew drifting into open lanes | Set up MUTCD compliant work zone; use cones, signs, and arrow boards; assign a lookout to monitor traffic and crew |
| Inspect thermoplastic equipment | Leaking hoses, clogged applicator shoes, malfunctioning burners or pumps | Conduct full equipment inspection; check heating system, bead dispenser, pressures, and safety shutoffs; remove damaged equipment from service |
| Don required PPE | Burns from molten thermoplastic, eye injury, struck by hazards | Wear heat resistant gloves, face protection, long sleeves, and high visibility vest before entering roadway |
| Heat thermoplastic material | Overheating material causing degradation or fire, burns from splatter | Heat only to manufacturer specified temperature; monitor gauges; avoid leaning over kettle; keep fire extinguisher nearby |
| Prepare pavement surface | Loose debris affecting adhesion, trip hazards, dust inhalation | Sweep or blow pavement thoroughly; ensure surface is dry; maintain safe distance from debris stream |
| Position equipment | Backing hazards, blind spots, equipment striking workers | Use a spotter when positioning thermoplastic applicator; verify backup alarms and beacons are functioning |
| Begin applying thermoplastic | Material splashing, contact with molten line, overspray or runoff | Operate at steady speed; maintain smooth applicator movement; keep all workers clear of molten material; use shields as designed |
| Apply reflective beads | Eye exposure, slipping hazard from loose beads | Maintain correct bead drop rate; avoid excessive bead use; keep crew away from bead discharge area |
| Maintain communication | Miscommunication leading to uneven lines, unsafe movements, or traffic conflicts | Use radios or hand signals; ensure operator and ground crew maintain constant coordination |
| Handle traffic around operation | Vehicles entering lane too early, motorists driving through wet thermoplastic | Maintain taper and cones until markings cool; use pilot vehicles if needed; assign lookout to watch for early entry |
| Monitor cooling period | Burns, tracking of uncured markings | Keep crew and traffic away until thermoplastic fully hardens; mark fresh lines with cones if necessary |
| Shutdown and clean equipment | Contact with hot equipment, improper disposal of thermoplastic residue | Allow unit to cool; follow manufacturer cleaning procedures; dispose of waste properly; store materials securely |
| Remove traffic control | Worker exposure to traffic during takedown | Remove devices in reverse order; maintain protective vehicle position; use lookout until all devices are retrieved |
Hard hat
Safety glasses or face shield
High visibility vest (Class 2 or Class 3 depending on roadway)
Heat resistant gloves
Long sleeve shirt and long pants
Steel toe boots
Respiratory protection if required by product or fume conditions
Hearing protection when working near loud equipment