Construction

Toolbox Talk

Asphalt Fumes:

Roofing Operations

Asphalt fumes cause health effects such as headaches, 

nausea, and drowsiness. They are also linked to lung 

cancer. Asphalt kettles used in roofing operations cause 

both continuous exposure to fumes that escape and 

occasional exposures when the lid is opened for filling or 

loading. In general, the higher the asphalt temperature, 

the more fumes are produced.

Bill’s Story 

Bill is operating an asphalt kettle for a roofing 

company. He is careful to use personal protective 

equipment, including a hardhat, face shield, 

long-sleeved shirt, gloves, goggles, and leather 

work boots. He keeps the work area cleaned up and 

has a fully charged ABC fire extinguisher nearby. Bill 

started having headaches, drowsiness, and 

nausea while working and went home sick. When 

he returned, his co-workers showed him the new 

kettle bought because the old one had a damaged 

lid and was leaking fumes.

# What caused this incident? 

# How could this have been prevented?

# Have you ever had any of the symptoms Bill had, 

or known someone who has? If so, what happened? 

Remember This

• Place the kettle:

– Downwind, where the operator and others will be 

least exposed to fumes.

– In an area with plenty of cross-breezes, with the lid 

kept closed as much as possible. 

– On firm, level ground to avoid tipping or spilling.

• Do not place the kettle in a confined space where 

fumes can accumulate.

• The supervisor must mark the immediate area around 

the kettle with warning tape, traffic cones, and/or signs 

to keep other workers away.

• Make sure the kettle is in good operating condition. 

Report any defects to your foreman or superintendent.

• Make sure the kettle has working temperature controls 

and the proper pumping capacity for its size.

• Keep temperatures to the minimum required to do the 

task. Avoid turning temperatures up for faster melt.

– Maintain temperatures at least 25 degrees below the 

asphalt’s flash point to prevent fires.

– Remove all potential fire hazards from the area.

– Keep a fully charged ABC-type fire extinguisher near 

the kettle.

• Pre-chop the asphalt into easily handled, easily melted 

pieces before filling or refilling the kettle. Use a safety 

loading door, not the lid, to fill the kettle.

• Ask your employer to use fume-suppressing asphalt.

How can we stay safe today?

What will we do at the worksite to prevent exposure to asphalt fumes and related hazards on residential 

roof jobs?

OSHA Standard: 1926.59 and OSH General Duty Clause, Section 5(a)(1) of the OSH Act
Construction

Toolbox Talk

Asphalt Fumes:

Roofing Operations

; Make sure the kettle is in good operating condition and report any defects to your supervisor.

; Keep the kettle lid closed as much as possible and place kettle in an open area with plenty of natural cross breezes. 

Do not place in a confined space where fumes can accumulate. Place the kettle downwind, where the operator and 

others will be least exposed. 

; Set the kettle on firm, level ground to avoid tipping or spilling.

GET 

INFORMATION 

CDC/NIOSH INFO: 1-800-CDC-INFO (1-800-232-4636) | TTY: 1-800-232-6348 | cdc.gov/info | cdc.gov/niosh

CPWR: Contact 301-578-8500 | cpwr-r2p@cpwr.com | cpwr.com/toolbox-talks

DHHS (NIOSH) Publication No. 2022-138 | DOI: https://doi.org/10.26616/NIOSHPUB2022138 | August 2022