First, describe the work and worksite
A roofing crew will install built-up roofing plies with hot asphalt on a released low-slope building roof. Hot material reaches the roof through the separately planned delivery system; this example covers roof receiving, controlled movement and mopping of plies. This fictional learning example describes planned controls; it records no actual inspection or work authorization.
- Roof condition, loading, edge/opening protection and protected access are released before roofing starts.
- The actual roofing specification, asphalt product and delivery equipment establish temperature, exposure and handling criteria.
- Kettle operation, fuel transfer, supply-equipment maintenance, coal-tar roofing and torch-applied membranes are excluded.
Questions before work
- Who controls the roof receiving point and hot-material route?
- Where are the actual asphalt temperature and exposure criteria recorded?
- How will workers leave the roof and summon help after a burn or other emergency?
Build the analysis one step at a time
What will the worker do? How could someone be harmed? What prevents or reduces that exposure? Who checks the control, and when?
1. Release the roof work area
Hazard: Unprotected edges, weak deck areas or concentrated material loads can expose the crew before mopping starts.
Control: Confirm released deck and loading limits, the actual fall-protection arrangement, protected access and emergency arrangements. Position the receiving point and roofing stock so loading and hot-liquid routes do not compromise these controls.
Verification: Roofing lead records deck, access, loading and protection findings before delivery.
Why this belongs in the analysis: Hot asphalt handling leaves little room to recover from an unsafe walking route.
2. Coordinate hot material receipt
Hazard: Unplanned discharge or damaged containers can expose workers to severe burns and fumes.
Control: Identify the delivery-system operator and agreed stop signal. Inspect roof-side receiving equipment and suitable covered containers; exclude bystanders and receive only through the actual authorized method within its product and equipment limits.
Verification: Assigned receiver checks container condition, communication and required temperature findings.
Why this belongs in the analysis: A temperature or receiving method from another product is not the release criterion.
3. Move material to the mopping area
Hazard: Hot liquid can spill when a worker encounters congestion, unstable footing or unsuitable handling equipment.
Control: Keep the designated route clear and controlled. Use suitable handling aids and contained quantities under the approved method, with task-specific splash protection; prevent passing workers from entering the handling zone and pause if stability or visibility deteriorates.
Verification: Roofing lead observes route condition and handling before the next transfer.
Why this belongs in the analysis: A clear route protects both the handler and people beyond the mopping area.
4. Mop asphalt and place plies
Hazard: Burns, fumes, awkward tool movement and contact with others can occur as hot asphalt is spread.
Control: Maintain the specified application conditions and work sequence with suitable long-handled tools. Separate mopping and ply-setting positions, keep workers out of splash paths, and apply the assessed fume controls; reassess wind and ventilation changes instead of relying on odor.
Verification: Lead checks application conditions, crew spacing and exposure-control findings.
Why this belongs in the analysis: Temperature, air movement and worker position affect both exposure and the installed roof.
5. Manage interruptions and changing conditions
Hazard: Rain, heat stress, a fume concern or equipment trouble can undermine the planned operation.
Control: Stop receipt and handling through the agreed communication when conditions exceed the plan. Keep hot material secured under the equipment procedure, maintain the exclusion and arrange first aid or emergency response; repair or restart only after the responsible people resolve the change.
Verification: Lead records the reason for stopping, responsible person and restart criteria.
Why this belongs in the analysis: Continuing a hot-liquid operation can magnify a small change before the crew can react.
6. Close the roof operation
Hazard: Uncontrolled hot residue, tools or incomplete edges can expose the next crew.
Control: Follow the actual equipment and product procedure for remaining hot material and cleanup; do not improvise disposal or maintenance. Secure tools and containers, maintain protection and transfer unfinished roof sections and access restrictions to the receiving lead.
Verification: Lead confirms remaining-material status, housekeeping and the next crew’s handover.
Why this belongs in the analysis: The end of mopping is not the end of the hot-material or roof-access hazard.
What does a useful control look like?
| Needs improvement | More useful for this scenario |
|---|---|
| Work carefully and wear PPE. | Keep the designated route clear and controlled. Use suitable handling aids and contained quantities under the approved method, with task-specific splash protection; prevent passing workers from entering the handling zone and pause if stability or visibility deteriorates. |
| Check that everything is ready. | Confirm released deck and loading limits, the actual fall-protection arrangement, protected access and emergency arrangements. Position the receiving point and roofing stock so loading and hot-liquid routes do not compromise these controls. |
Decisions that change the analysis
Can the example supply one safe temperature for every asphalt?
No. Use the actual product information, roofing specification, equipment instructions and exposure assessment. Record applicable criteria and findings; the example supplies no universal kettle or roof-application setting.
What must the crew record for actual use?
Identify the actual equipment and work boundaries, responsible people, applicable criteria, inspection findings and open actions. Resolve changes with affected crews and obtain required project authorization before work.
Agree when the crew will pause
- Receiving equipment, communications or product temperature criteria cannot be verified.
- Rain, unstable route, changed fumes, heat illness concern or compromised fall protection.
- Spill, burn, blocked access or an unplanned equipment/maintenance task.
After a pause, correct the condition, reassess the work, and obtain required authorization before restarting. Keep unresolved actions visible.
Download the worked example and free template
No account or paid membership required. The worked example contains planned controls. The blank template is for your own work; neither includes fabricated inspection results, signatures or approval.
Your editable working copy
Build and download your draft
Start blank or load the learning example. Replace its assumptions with your actual conditions and involve the people doing the work. Your entries stay in this browser tab; download a copy before leaving or refreshing.
1. Describe your work and site
2. Work through each task
Describe an observable step, how someone could be harmed, and the control that acts on that hazard. Identify who checks it and what evidence is needed.
3. Record changes, checks, and open actions
Walk the work area, review with the crew, and resolve missing controls. Follow the required approval process. This tool does not judge completeness, verify signatures or authorize work.
Open the downloaded file in a browser, then use Print → Save as PDF for a printable copy.
Training needs to confirm
- Roof hot-asphalt receiving, contained handling, splash protection and burn/emergency response instruction.
- Product hazard communication, fume/exposure controls, heat-stress response and the actual roof fall-protection arrangement.
Confirm applicable qualifications, task instruction and actual training evidence for the people assigned. Related toolbox talks support crew discussion; they do not establish competence.
Common questions
Can this example be used as a JSA?
Adapt its Task | Hazard | Control analysis to the employer’s format and actual conditions. The example is a teaching aid, not evidence that controls were checked.
What changes if the project requires an AHA?
Use the governing AHA format, risk method, supporting records and acceptance process. The published formwork AHA demonstrates that additional structure; changing a JHA title does not supply it.
Are these resources part of a paid course?
This walkthrough, browser draft builder and downloads are free public resources, separate from Academy course enrollment.
References and source note
- NIOSH Reducing roofers exposure to asphalt fumes
- OSHA 1926.501 Duty to have fall protection
- OSHA 1910.1200 Hazard communication
Original instructional scenario with planned controls. Primary references support hazard planning. Use actual equipment and product instructions, project design and employer requirements to establish field criteria. Use actual equipment instructions and site requirements alongside these references. Reference review: October 9, 2026.