The Washington State Department of Labor and Industries notes that operators of roofing kettles are at risk of being seriously burned by hot tar being splashed by the act of feeding kegs or chunks of tar into the basin. Hot tar cools, solidifies and then adheres to surfaces, and the material causes severe burns when exposed to bare or lightly covered skin. These injuries need professional medical attention, and victims of tar burns may suffer from permanent scars, anxiety or chronic pain.
Falls resulting from spilled tar near the kettle are also listed by the Washington State Department of Labor and Industries as a safety issue. Passersby can trip over chunks of unmelted tar, slip on puddles of slick, still-hot tar or get caught up in sticky puddles of tar that has begun cooling. Be aware of the condition of the floor around the place a roofing tar kettle is set up to avoid injuries.
The vapors released by heated tar are highly flammable, and kettles used to heat roofing tar should be kept far away from ignition sources or open fires. Fires that break out on or near tar kettles should be contained and put out as quickly as possible, as these "hot-luggers" have pieces of equipment that maintain extremely high temperatures that can explode or cause new fires themselves.
Injuries to the eyes can result from even minor contact with hot tar or fumes from a kettle. In addition to extreme pain or discomfort, temporary or permanent damage to sight can occur, even if the amount of hot tar is very small. The Washington State Department of Labor and Industries notes than you should always consult an ophthalmologist if you suffer an eye injury from contact with tar.