Free asphalt paver pre-start checklist

• The MapTrack asphalt paver pre-start checklist contains 25 checks across 7 sections. Sections covered: Screed Assembly, Augers and Conveyors, Hopper, Hydraulic System, Engine and Drivetrain, Controls and Instruments, Safety Devices.
• Machine details: make/model, serial or fleet number, hour meter reading, date.
• Operator details: name, licence or competency number.
• Walk-around inspection: check for leaks, damage, loose components, ground conditions around the machine.

Learn more about pre-start inspections in MapTrack.

• Paving quality: catching screed wear, auger damage or conveyor faults before the shift starts prevents surface defects, segregation and rework.
• Operator safety: confirming guards, emergency stops, reverse alarms and fire extinguishers are functional protects the operator and ground crew working around hot asphalt.
• WHS compliance: documented pre-start records demonstrate the PCBU has met their duty of care for plant inspections under the WHS Regulations.
• Hydraulic integrity: checking hydraulic oil, hoses and fittings prevents leaks that can cause sudden loss of screed control or conveyor failure.
• Reduced downtime: identifying worn conveyor chains, low fluid levels or sensor faults before paving begins avoids mid-shift breakdowns.
• Site compliance: completed pre-start records satisfy principal contractor and road authority safety management requirements.

• Machine details: make/model, serial or fleet number, hour meter reading, date.
• Operator details: name, licence or competency number.
• Walk-around inspection: check for leaks, damage, loose components, ground conditions around the machine.
• Screed assembly: screed plate condition and wear, heaters (gas or electric) function, tamper bars, vibrators, extensions, crown adjustment.
• Auger system: auger flights (wear and damage), bearings, speed control, auger height adjustment, guards.
• Hopper: hopper wings operation, push rollers (condition and alignment), material flow gates, hopper floor.
• Conveyor system: slat conveyor condition, chain tension, sprockets, tunnel cleanliness.
• Hydraulic system: hydraulic oil level, hoses, fittings, cylinders, leak check.
• Engine and fluids: engine oil, coolant, fuel, DEF/AdBlue, air filter, exhaust.
• Controls and instruments: grade and slope controls, levelling system (sonic, averaging beam, 3D), travel speed control, all gauges.
• Electrical and lighting: headlights, work lights, beacons, reverse alarm, camera (if fitted).
• Safety devices: guards in place, emergency stops functional, fire extinguisher charged and accessible, safety signage.
• Defect register: item, description, action required.
• Sign-off: operator and supervisor.

1. Record machine details including make/model, fleet number, hour meter and operator name.

   Enter the paver make, model, serial or fleet number, current hour meter reading and the date. Record the operator name and licence or competency number (such as RIIMPO322F). This information links the inspection to a specific machine, operator and point in time for traceability.

2. Conduct a walk-around inspection with the machine off. Check for leaks, damage, loose components, ground conditions and general cleanliness.

   Walk around the entire paver before starting the engine. Look under the machine for oil, hydraulic fluid or coolant leaks. Check for loose bolts, damaged guards, cracked hoses or any debris caught in moving parts. Confirm the ground surface is stable and the paver is parked on level ground.

3. Inspect the screed assembly: plate condition, heaters, tamper bars, vibrators and extensions.

   Examine the screed plate for wear, gouges or warping that could affect mat quality. Test the gas or electric heaters to confirm they ignite and reach operating temperature. Check tamper bars for wear, vibrators for smooth operation and screed extensions for secure locking and correct crown adjustment.

4. Check the auger system: flights, bearings, speed controls and guards. Inspect the hopper: wings, push rollers, flow gates and floor. Check the conveyor: slats, chain tension, sprockets and tunnel.

   Inspect auger flights for wear and damage, bearings for play or noise, and speed controls for smooth response. Operate hopper wings through their full range, check push roller condition and alignment, and confirm flow gates move freely. Examine conveyor slats for cracks, measure chain tension against the manufacturer specification and inspect sprockets and the conveyor tunnel for material build-up.

5. Inspect the hydraulic system, engine fluids, controls, electrical system, lights and all safety devices.

   Check hydraulic oil level on the sight glass, inspect hoses and fittings for leaks, and verify cylinder operation. Confirm engine oil, coolant, fuel and DEF/AdBlue levels are within range. Test grade and slope controls, the levelling system, travel speed control and all gauges. Verify headlights, work lights, beacons, reverse alarm and camera (if fitted) are operational. Confirm all guards are in place, emergency stops are functional and the fire extinguisher is charged.

6. Record any defects and report per site procedures. Do not operate until safety-critical defects are rectified. Sign off and save as PDF or submit digitally in MapTrack.

   Document each defect with a description and the action required. If any safety-critical defect is found, isolate the paver with a tag-out notice and inform the supervisor immediately. The operator and supervisor both sign the completed checklist. Save the form as a PDF or submit digitally in MapTrack so the record is linked to the asset.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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