This resource does not replace the Occupational Health and Safety Act (OHSA) and its regulations and should not be used as or considered legal advice. Health and safety inspectors apply the law based on the facts in the workplace.

Hazard summary

In 2020 a worker received burns to the right side of his face, neck, ear, and hands because of hot asphalt over 260°C (500°F). The asphalt sprayed on him while he was in the process of receiving the asphalt from a hot asphalt kettle into a lugger.

The incident occurred because a flex hose was used, rather than a rigid elbow, to change the upward flow of hot asphalt from the hot pipe to a downward flow and into a lugger. When the hot asphalt flow started, the pressure from the flow of hot material up the pipe pushed the flex hose upward and out of the lugger opening. The asphalt kettle is typically located on the ground at a roofing project and is heated by propane burners. When hot asphalt is required on the roof, a delivery valve is opened, and material is pumped up to the roof through the hot pipe. The opening and closing of the delivery valve must be controlled at the roof top by a rope (or cable) attached to the valve. This ensures that the operator, at the roof level, has complete control of the flow of hot asphalt up to the roof.

Typical hot pip set-up

The hot pipe set-up typically consists of a length of straight piping connected to a rigid elbow. The hot pipe is the thin wall tubing that runs from the kettle pump discharge up to the lugger on the roof surface. At the roof level, a flex hose is attached at the end of the rigid hot pipe elbow.

Potential for injury

The potential for an injury may occur if:

  • a rigid elbow is not installed prior to using the flexible hose at the end of the pipe
  • a flexible hose is mounted directly to the end of the straight pipe
  • hot asphalt is quickly put through the pipe, in which case the flexible hose may “straighten” or move, causing it to come out of the lugger opening spraying hot asphalt uncontrollably over the area

Recommended precautions

Use a rigid elbow

Ensure the proper degree of rigid elbow (for example, 120° elbow) is used before a flex hose is attached to the downstream end of the elbow, as specified by the manufacturer of the asphalt kettle.

If the manufacturer’s operating manual does not provide specific instructions about the setup of a rigid elbow, including the related hazard precautions, contact the supplier or manufacturer to obtain information. A rigid elbow may be available from the supplier or manufacturer as a separate item.

Follow manufacturer’s operating instructions

It is important to follow the manufacturer’s operating manual when using the equipment. The manual must also be followed for instructions about inspecting the pipes and performing regular maintenance.

Take precautions when handling hot asphalt

Skin contact with hot asphalt can result in serious burn injuries. Proper handling precautions must be followed, and appropriate personal protective equipment (PPE) must be worn.

When there is a risk of injury from contact between the worker’s skin and radiant heat or a hot object or a hot liquid, the worker should wear the following PPE to protect themselves:

  • hard hat
  • protective footwear
  • gloves
  • eye or face protectors
  • suitable clothing

What you’re required to do by law

Among other responsibilities set out under section 25 of the Occupational Health and Safety Act (Act) employers must make sure that:

  • measures and procedures set out in the regulations, including the Construction Projects Regulation (O. Reg. 213/91), are followed
  • the equipment, materials and protective devices provided by the employer are maintained in good condition
  • workers are trained to work safely
  • every precaution reasonable in the circumstances is taken for the protection of a worker

Among other responsibilities set out under section 27 of the Act supervisors must make sure that:

  • measures and procedures set out in the regulations, are followed
  • protective devices and clothing required by the employer are used or worn
  • workers are advised of the existence of any potential or actual danger of which the supervisor is aware, such as this hazard alert
  • every precaution reasonable in the circumstances is taken for the protection of a worker

Among other responsibilities set out under section 28 of the Act, workers must ensure that equipment is used in a manner that won’t endanger himself, herself, or any other worker.

Equipment — general

Under section 93 of Ontario Regulation 213/91 - Construction Projects, all tools and equipment must:

  • be maintained in a condition that does not endanger a worker
  • not be used while defective or hazardous
  • be used in accordance with any operating manuals issued by the manufacturers

Roofing

Under sections 207, 208 and 209 of Ontario Regulation 213/91 - Construction Projects, if a built-up roof is being constructed, repaired or resurfaced:

  • a barrier must be placed in the immediate work area at least two metres from the perimeter of the roof
  • the barrier must consist of portable weighted posts supporting a taut chain, cable or rope that is located 1.1 metres above the roof level
  • a pipe that supplies hot asphalt or bitumen to a roof must be securely fixed and supported to prevent its deflection
  • if a pipe discharges hot asphalt or bitumen two metres or less from the edge of a roof, a guardrail must be provided at the edge of the roof
  • a hoist used on a roof must have a guardrail installed on both sides of the frame at the edge of the roof; and shall be positioned in such a way that the hoist cable is always vertical while a load is being hoisted
  • only a competent worker must operate a hoist used on a roof

Hot tar (asphalt) or bitumen road tankers or kettles

Under section 211 of Regulation 213/91 - Construction Projects:

  • only a competent worker shall operate a hot tar (asphalt) kettle
  • if a hot tar (asphalt) kettle is fitted with a propane-fuelled heater, the storage cylinder for propane shall not be placed closer than three metres to a source of fire or ignition
  • the lines connecting the storage cylinder for propane to the heating device shall be located so that they do not come into contact with the hot tar in the case of a spill or a failure of a component of the system
  • a fire extinguisher with an Underwriters’ Laboratories of Canada rating of at least 4A40BC shall be provided with the kettle
  • a propane burner used on a kettle, shall have a thermal rating no greater than that recommended by the manufacturer and shall consist of components that are adequate for their intended use
  • hot tar (asphalt) shall be transferred from a road tanker to a kettle through enclosed piping

Working at heights training

Under section 26.2 of Regulation 213/91 – Construction Projects, an employer must make sure:

  • that workers who may use a fall protection system receive:
    • working at heights training required under O. Reg. 297/13 (Occupational Health and Safety Awareness and Training), for example, training provided by a Chief Prevention Officer (CPO) approved training provider
    • specific training by a competent person about the fall protection system to be used on site
  • a signed written training and instruction record is kept for each worker

The site-specific training can include:

  • the right equipment and procedures to be used.
  • how to take care of the equipment
  • what to do in an emergency

Contact us

If you need more information about safety requirements, please contact the Health & Safety Contact Centre at 1-877-202-0008, Monday to Friday, from 8:30 a.m. to 5 p.m., or email webohs@ontario.ca.