ASPHALT PLANT OPERATIONS

Date Revised: September 2024 Overall Task Risk Rating: Before Controls A After Controls C
Description: All activities that occur at the asphalt plant.
Location(s): Asphalt Plant
Associated Documents: Housekeeping WTS, Hazardous Agents (Chemical) WTS, Hazardous Agents (Physical) WTS, Noise WTS, Driving
and Vehicle Operation WTS, Equipment and Machinery Operation WTS, Hoisting and Rigging WTS, Powered Elevating Working Platforms
WTS, Hazardous Energy Control WTS, Power and Hand Tools WTS

RED FLAGS (HOLD WORK UNTIL CORRECTED):

Note:
- Electrical, pneumatic, mechanical, hydraulic energy not controlled by Lock Out Tag Out as required during maintenance
- Guards removed while equipment is operating
- Guardrails removed without fall protection measures being used
- Confined space work that is not following the SWP
- Failure to follow manufacturer’s safety instructions and/or warnings
- Untrained/certified workers performing working at heights tasks.

PERSONAL PROTECTIVE EQUIPMENT (CSA APPROVED)

Head Foot High-Vis Hearing Hand Eye Respiratory Skin Face Fall
Protection Protection Protection Protection Protection Protection Protection Protection Protection Protection

Note:
- While within the Asphalt Plant Scale building is a PPE free zone
- While within the Asphalt Lab building foot protection must be worn and workers mus wear all PPE listed in the MSDS / SDS for the specific
hazardous products that they are to handle
- Additional PPE such as hand protection (i.e. gloves) and respiratory protection (i.e. a full face respirator) may be required depending on
the task.
- The noise level exceeds 85 dB in the production area. Hearing protection should be worn during prolonged exposure.
- Fall protection or travel restraint equipment must be worn when guardrails are removed and in the PEWP.
- A face shield, arm protection (e.g. long sleeve shirt) and heat resistant gloves are required when transferring hot tack coat and hot asphalt
cement.
- Workers must wear all PPE listed in the MSDS / SDS for the specific hazardous products that they are to handle

SAFE WORK PRACTICES (SWP)

Asphalt Plant Key Practices:
• Start the work only when you are certain that you understand the work, the hazards and you have implemented the appropriate
controls
• Unsafe conditions and situations must be reported to Foreman/Superintendents immediately (and stop work until the hazard is
controlled)
• Workers must not wear loose fitting clothing and/or jewelry that could come into contact with moving parts
• Minimize high repetitions, high loads, and awkward postures when working
• Visitors must report to the plant office and sign in and out

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Guarding:
• Ensure all moving components are guarded during operations
• Ensure guarding is in adequate condition
• Ensure guarding is present at all pinch points and beneath conveyors
Hoisting and Rigging:
• Ensure chains and slings are labelled, rated, in good repair and are stored properly
• Ensure a competent signal person is used when required
• Ensure come along chains and safety latches on hooks are in good repair
Aggregate Pile Management:
• Freezing/thawing, changing moisture content and other conditions can affect pile stability
• Piles shall be kept at the ‘angle of repose’ and not be ‘undercut’
• Pile stability will be maintained using excavators and bulldozers as required
• Pile haul roads and ramps must have berms or barriers to prevent vehicle tipping
• Pile dumping areas should be kept level to prevent truck tipping when dumping
Access / Egress:
• All walkways, stairways, access / egress points, and access to emergency equipment are to be kept clean and free of obstructions at
all times (remove any build of up debris or snow / ice that may accumulate)
• Keep walkways, halls and stairs clear of tripping hazards (i.e. electrical cords, hoses)
• “Authorized Entry Only” “Danger” & “Warning” Signs as required
Vehicles / Equipment / Machinery/Traffic:
• Maximum speed limit while on the asphalt property is 10 kph
• All trucks must follow signage and ensure one way travel in designated areas
• Ensure back up alarms are functioning (sound horn twice before reversing)
• Signalers are required when ground workers are present
• Signallers are required when the dump truck with a raised box is within the 3 meters of overhead powerlines/structures
• Use three points of contact when mounting and dismounting the machine
• Workers and equipment operators will follow the Safe Limit of Approach – not entering within 10 metres of mobile equipment
• One-way traffic signage is in place and must be followed. Trucks will give way for front end loaders
Path of Travel:
• Be aware of the sequence of operation and stay out of the Path of Travel of moving vehicles and equipment
Confined Space Entry:
• Only confined space entry trained personnel are permitted to enter the confined space.
• Confined spaces must have signage indicating the hazard and be secured from access.
• Refer to the Confined Space WTS for more details
Fire Safety:
• Cold mix asphalt can be made with cutback asphalt and these mixes will catch fire at much lower temperatures than hot mix asphalt
and are highly susceptible to ignition
• Fire extinguishers will be readily available during hot work
• Propane, Oxygen and Acetylene cylinders, regulators, valves, connections and hoses shall be regularly inspected to ensure proper
function and that there are no leaks
• Bag house fires are most commonly caused by unburned fuel and liquid asphalt. The unburned fuels can accumulate in the baghouse
and explode when a spark or flame enters the bag house or due to the fuel reaching its flashpoint temperature
Loading/Unloading Trucks:
• Truck drivers must remain in the cab of the truck and visible to the loader operator at all times during loading.
Working at Heights:
• Only use ladders that are in adequate condition
• Ensure Cat-Walks and Ramps have adequate fall protection in place

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• Guard Rails must have a toe board, mid rail and top rail and be securely fastened in place
• Refer to the Working at Heights WTS for more information
Hazardous Agents:
• Consult SDS and follow the requirements set out therein (i.e. handling, storage, & disposal procedures)
• Ensure products are stored in appropriate containers and locations as indicated in the SDS
• Supplier or workplace labels must be affixed to containers of controlled products
Environmental Considerations:
• Ensure puddles / sitting water due to rain or flooding is dealt with
• Ensure salt is used in areas where ice can build up potentially causing a trip hazard
• Ensure adequate lighting (functional lights for night work)
Storage:
• Keep designated storage areas free from clutter. Keep stacked items accessible
• Ensure material is stored so that it cannot topple or fall (and is protected from wind if outside)
Extension Cords:
• There must not have any cuts or exposed wires
• The ground pin on the plug must be intact
WHMIS:
• Ensure all chemicals are stored correctly and identified (i.e. away from overhead powerlines &/or trenches)
• Consult SDS for specific material considerations (ensure SDS present for every hazardous product onsite)
• Have an appropriate spill kit ready and available for use
• Refer to Hazardous Agents SWP for more detail
Dust Control:
• Silica dust is hazardous
• Airborne dust is controlled using waster distributed by the mister machine, water tank trucks and wet sweeping
Housekeeping:
• Housekeeping shall be ongoing during operations
• Each employee is responsible for maintaining and cleaning their work area on a daily basis (or more frequently if necessary)
• Aggregate fallout shall not be allowed to accumulate to the point of becoming a hazard
• Refer to Housekeeping WTS for more detail
Inspections:
• A pre-operational safety inspection is to be completed prior to using equipment
• Do not use defective equipment or machinery, inform your foreman / superintendent & note the defect on the Equipment Inspection
Form
• Before starting machines or equipment, ensure guards and safety devices are in place, adjusted and functioning properly
• Before using Working at Heights PPE, inspect it for defects / wear-and-tear – do not use unless it is in adequate condition
Training:
• Employee Orientations (including roles, responsibilities, applicable workplace task standards, WHMIS, etc.)
• Workers exposed to, required to work with, or required to clean up / dispose of WHMIS controlled hazardous products, must be
trained in WHMIS and have supplemental task specific training
• Workers exposed to fall hazards, must be trained in ‘Working at Heights’ by an MOL approved training provider
• All workers must be trained in the use and maintenance of any PPE they are required to wear including fall protection
• Ensure workers entering a confined space have adequate training and that the rescue workers are trained in confined space rescue,
and on how to operate the rescue equipment
• Only trained, authorized personnel are allowed to operate or perform maintenance on vehicles / machinery / equipment
Personal Protective Equipment:
• Mandatory minimal PPE to be worn at the Asphalt Plant includes head, foot, eye and high visibility protection

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• The noise level exceeds 85 dB in the production area. Hearing protection should be worn during prolonged exposure
• Additional PPE required when filling the Tack Coat Truck includes a face shield and long sleeve shirt
• Eye protection is required when completing tasks that may cause debris / objects to dislodge or become airborne
• Workers must adhere to all requirements of legislated regulations when handling specific designated substances
• Workers must wear all PPE listed in specific materials MSDS / SDS
Plant Maintenance:
• Plant maintenance and repairs must only be performed by trained and authorized personnel in accordance with the manufacturers’
instructions and the plant manager’s service and repair log.
• The Asphalt Plant undergoes seasonal maintenance every year between December and March.
• Some plant items/equipment may require more frequent maintenance than the regular seasonal maintenance such as replacing the
scalping screens (Twice a year) or servicing the conveyors’ skirts (Twice a year).
• Some plant items/equipment are serviced/maintained exclusively by subcontractors such as service of the transfers, silos and the
dryer. All subcontractor work is performed in accordance with the requirements of the Procurement & Contractor Management
Procedure on Gazzola’s H&S Program.
• A decision to perform service/maintenance may also be taken as a result of the daily visual inspections by the Plant Manager during
start-up or during the weekly adjustment of belts. Maintenance activities include, but are not limited to:
Belts Adjustments/Replacement:
• Before removing the conveyor guards, ensure the Lockout Tagout procedure has been followed properly and that all sources of
energy have been neutralized.
• Adjust belts using hand tools as required. For belts replacement, use an impact gun to loosen motors and re-adjust after replacement.
All hand and power tools must be used in accordance with the (Power & Hand Tools WTS) and using the appropriate hand protection
(Work Gloves)
• Test conveyors to ensure proper adjustment of belts. Ensure all guards are back in place before removing the locks and tags.
Greasing:
• The Asphalt Plant utilizes Auto-Greasing machines with ports adjusted to accommodate different greasing requirements of various
bearings.
• A few parts of the plant equipment are still greased manually by trained and authorized personnel on the Asphalt Plant crew.
• When greasing manually, consult the SDS before handling grease or any WHMIS controlled substance to ensure all controls
measures are in place including all PPE requirements. The SDS is available onsite either in the SDS Binder, or via the online
database.
Maintenance at height:
• Catwalks are installed in most areas of the Asphalt Plant for easy access during inspections, service or maintenance. Always maintain
3 points of contact while using ladders to access catwalks.
• Where catwalks are absent, elevating working platforms are used to ensure safe access. Elevating Working Platforms must be
inspected daily before use and must be used only by authorized personnel trained on fall protection and the use of the specific
equipment.
• Lift trucks such as Forklifts/Zoom Booms may be used to handle heavy material required for performing service/maintenance
activities. Lift trucks must be inspected daily and used only be competent operators with a valid operating license.
Changing Oil:
• Wear proper PPE including safety glasses and work gloves and any other required PPE in accordance with the requirement of the
SDS.
• Ensure the Lockout Tagout procedure has been followed properly and that all sources of energy have been neutralized.
• Drain the used oil using an appropriate dip tank or similar. Ensure used oil is transported to the Shop for proper disposal.
• Fill out oil to the proper level.
Replacing Screens:
• Ensure the Lockout Tagout procedure has been followed properly and that all sources of energy have been neutralized.
• All workers on elevating working platforms must be tied-off to the designated point on the platform at all times. Lift trucks used for
handling screens must only be used by competent operators.
• Wear proper PPE including work gloves before removing bolts and replacing screens to avoid pinch injuries.

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Changing Motors:
• Ensure Lockout Tagout procedure and PPE requirements are strictly followed before motor replacements.
• During replacements, motors may be handled by mobile cranes. Only authorized and trained operators are allowed to operate mobile
cranes and in accordance with the requirements of the Hoisting & Rigging WTS
• An exclusion zone must be set-up for the operation of mobile cranes. Only workers directly involved in the lifting operations are
allowed inside the exclusion zones. All workers involved in the maintenance operation will be required to use head protection.
Inspecting/Replacing Bearings:
• Ensure Lockout Tagout procedure and PPE requirements are strictly followed before inspecting/replacing bearings.
• Wear appropriate work gloves before taking out the bolts of the housing to protect your hands from smashing injuries.
• For inspections of bearings, ensure wearing proper gloves and safety glasses before clearing the grease out of the housing to avoid
splashes of grease into eyes and skin.
• For replacement of bearings on the main conveyor, the lift truck (Zoom Boom) and the plant service truck may be used. Ensure all
proper control measures are being used as mentioned above on the maintenance activities requirements,
• After inspection/replacement, ensure locks and tags are only removed after re-assembly.
AC Sampling:
• All visitors must sign-in and inform the plant operator of the type of sample required.
• Wear appropriate PPE including long sleeves, work gloves and safety glasses and/or face shield to protect yourself from any
splashing incidents of hot AC.
• Place the sampling can underneath the valve and open slowly, apply a little heat using a heat gun only. Never use a torch inside the
designated AC area.
• Ensure your safety by keeping your distance from the direct sampling zone.
• Ensure the valve is closed-off completely after sampling and that the plug is secured at the end of the pipe to avoid any AC leaks.
• Inform the plant operator that the sampling activity is completed.

High risk of injury or

JOB HAZARD AND RISK ANALYSIS

A
equipment / property damage.
RISK RATING B
Medium risk of injury or
SYSTEM equipment / property damage.
Low risk of injury or
C
equipment / property damage.

RATING RATING
TASK HAZARDS BEFORE TASK CONTROLS AFTER
CONTROLS CONTROLS

• Maximum speed limit while on the asphalt property is 10 kph

Mobile Equipment and
Vehicles / Traffic
A • All trucks must follow signage and ensure one way travel in designated C
areas
• Inform the plant operator of the sampling activity before you start and
after you finish sampling
• Stay out of the direct sampling zone
• AC Sampling A C
• Protect yourself from any potential hot AC splashes by wearing full PPE
including long sleeves, eye and hand protection
• Close-off the sampling valve completely to avoid any AC leaks
• Lock-out Tag-out tags shall be placed, conspicuously, at the location of
the operation switch and the Lock-out devices
• Only trained and authorized workers shall perform Lock-out Tag-out
• Lockout Tagout procedures
Hazards
A C
• Ensure all sources of hazardous energy are de-energized, and that all
remaining energy has been discharged
• Test de-energized sources of hazardous energy prior to commencing the
task

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• Verify Zero-Energy, test the operation switches and verify that the
equipment cannot be restarted, if lockout has not occurred, do not
proceed

• A complete fall protection system must be used at any time a worker is in

• Inadequate Fall danger of falling
Protection
A C
• A daily visual inspection of all Working at Heights PPE must be
completed prior to beginning the task
• Mobile cranes are only operated by authorized and trained operators
• Falling Objects (Use of • Have complete control of the load (use a tag line as needed)
mobile Crane)
B • The load must be evenly balance when lifted
C
• Do not pass raised loads over workers
• All energy containing devices, must be Locked-out and Tagged-out prior
commencing the task
• Electrocution B • Removing a fuse, closing a valve or turning a switch is not an acceptable
C
isolation from the energy source
• Signalers are required when ground workers are present
• Lack of Spotter B • Signallers are required when equipment is within the safe limits of C
approach to overhead powerlines
• Poor Housekeeping • Packaging and debris must not conceal dangerous hazards underneath
and Site Planning
C such as protruding nails, faulty wiring or damaged flooring
C
• All hazardous waste materials must be correctly disposed of with
• Improper Disposal of accordance to Provincial Regulations.
Hazardous Materials
C • Never pour chemicals down drains, onto the ground or into sewers.
C
• Consult MSDS / SDS for specific material considerations
• Material Exposure to • Tying down material for securement whenever leaving site where
Weather
C conditions dictate.
C
• Store and/or stack material in such a manner as to prevent tipping
• Improper Storage C • Products such as diesel will be stored in appropriate containers and C
labelled indicating the contents
• Poor Housekeeping in • Trucks and company vehicles should be cleared daily of any garbage so
vehicles
C as not to obstruct brakes, accelerator pedals, stick shifts or windows.
C
• Ensure any PPE as mandated by the MSDS / SDS is worn while handling
the respective hazardous product
• Lack of / Improper
PPE
C • A CSA approved full body harnesses and shock absorbing lanyard, must C
be worn at heights of 10 feet (or more), unless properly protected (by
scaffolding, guardrails or floor covers)

• Lack of, or Improper, • Machine Operators must be authorized and trained

Training and C • Only trained and competent personnel are permitted to perform C
Education maintenance
• A pre-operational safety inspection is to be completed
• Lack of Inspection C • Do not use defective equipment or machinery, inform your foreman / C
superintendent
• Consult SDS and follow the requirements set out therein (i.e. handling,
storage, & disposal procedures)
• Material Handling and • Ensure products are stored in appropriate containers and locations as
Storage Procedures C indicated in the SDS C
not Followed
• Supplier or workplace labels must be affixed to containers of controlled
products

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SAFE JOB PROCEDURES (SJP)

Pre-Task Commencement:
1. For plant operation the plant operator/foreman performs a daily plant equipment walk around looking for unfinished maintenance and
hazards.
2. All workers gather in the scale house and are accounted for prior to plant start up.
3. Plant foreman briefs the workers on the planned production and delegates the work for the day. No work is to be started prior to the arrival
of the plant operator/foreman.
During Task:
1. Plant operator starts and zeroes the conveyors remotely from the scale house.
2. The burner and blower are started remotely. Operator ensures that there are no ‘troubles’ or limit switches activated.
3. Start the bucket elevator for the batch plant remotely.
4. Turn on and warm the dryer to operating temperature drum remotely.
5. Start the cold feed bin gathering conveyors remotely.
6. Start the augers serving the bag house, cyclone and dust silo).
7. Start the coater and silo drags.
8. Loader operator then begins loading the cold feed bins according to instructions from the plant operator/foreman
9. Trucks to be loaded with asphalt are directed verbally and/or with lights and signage. Trucks park under the silo indicated. The scale
master sets the quantity to be loaded. The safety doors are opened and then the chute doors open to fill the truck.
10. The Scale Master then allows the correct mix to be dispensed into the truck
11. The driver exits their vehicle (wearing the required PPE) and enters the scale house.
12. The Scale Master gives the driver the ticket
13. The driver walks back to their truck
14. The driver then exits the premises
In the event of a Bag House Fire:
1. Oils from liquid asphalt cement can distill off and accumulate on the bags which can then ignite from a spark or flame
2. Notify all workers of the emergency and order an evacuation to the muster point
3. The plant operator is to shut off the burners and exhaust fan to stop the flow of heat and oxygen
4. Close all the baghouse inlet and outlet dampers to isolate the fire (do not attempt to fight the fire by opening any baghouse doors)
5. Stop the flow of liquid asphalt and recycled asphalt product
6. Continue to flow aggregate into the drum and continue drum rotation to absorb heat
7. After the fire department confirms that the fire is extinguished and the area is clear of danger, start the exhaust fan to purge hazardous
gases (combustible gases or materials may explode or burn when exposed to air)
8. Use extreme caution when opening access doors or distributing dust following a fire
For all maintenance activities:
1. Wear proper PPE including safety glasses and work gloves and any other required PPE in accordance with the requirement of the
repair task and/or SDS in case of chemicals.
2. Ensure the Lockout Tagout procedure has been followed properly and that all sources of energy have been neutralized before
removing any guarding.
3. Verify Zero-Energy, test the operation switches and verify that the equipment cannot be restarted, if lockout has not occurred, do not
proceed.
4. All workers on elevating working platforms must be tied-off to the designated point on the platform at all times. Lift trucks must only be
used by authorized and trained operators.
5. All hand and power tools must be used in accordance with the (Power & Hand Tools WTS) and using the appropriate hand protection
(Work Gloves)
6. After repairs, ensure all guards are back in place before removing the locks and tags.

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Task Completion:
1. The Foreman/Plant Operator shuts down the equipment safely
2. Ensure all equipment / machinery / tools are maintained and stored appropriately in the designated locations
3. Implement any housekeeping or maintenance as required

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