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What Goes into an Effective Pothole Repair Program?

Posted on by Emily Webber

Contrary to popular opinion, pothole patching is not as easy as the public makes it out to be. Unfortunately, all the general public usually gets to see is a crew of 3–4 employees driving down the road shoveling material out of a dump truck or trailer and then traffic driving over those potholes and displacing the material for the process to be done all over again the next day or week — it is a vicious cycle. And as much as the public tends to disagree on a lot of topics, the one thing they generally agree on is potholes suck. Every year it seems like a local or regional news station does a feature story on the state of the roads, specifically potholes, and a negative limelight is cast upon those who repair potholes, mainly municipal organizations and asphalt contractors.

However, what the public fails to realize is all the different aspects that go into an effective pothole repair program. The employees, the safety hazards, the trucks, the material, the budget constraints, and the asphalt repair equipment required to perform pothole patching each have their own intrinsic challenges that those filling potholes must account for. Taking these challenges into consideration isn’t a choice, it is a necessity, and truthfully some municipal organizations aren’t set up to deal with these challenges internally. Whether it be labor shortages, budget challenges, or simply not having an effective process, there are some common factors that any organization should consider when trying to improve their pothole repair program.

Why Pothole Repair Is More Complex Than It Looks

Employees

Pothole repair is no different than any other job — it starts with the people. Finding a good, hard-working group of laborers not afraid to get out there and get their hands dirty is key, but more importantly finding those people who take pride in their work and want to do a better job. While this is easier said than done, none of the other factors matter unless you have buy-in from employees to make your pothole repair program successful.

Materials

When filling potholes, particularly during the winter, a majority of municipal organizations rely on cold patch. While there is a time and place for cold patch, it is widely recognized as a temporary repair material. Hot mix asphalt, on the other hand, is the preferred material and is considered a long-term solution. However, hot mix asphalt is only available seasonally in most parts of the country, forcing municipalities to rely on cold patch.

The Repair Process

Unlike regulated roadway construction, pothole patching lacks standardized procedures. The two most common methods are throw-and-go and semi-permanent repair. Throw-and-go involves placing material into the pothole with minimal compaction, making it faster and cheaper but far less effective.

Semi-permanent repair includes cleaning the pothole, applying material, and using an asphalt compactor or plate compactor. While more time-consuming, it produces significantly better long-term results.

Equipment

Modern pothole patching crews should leverage available tools and technology. A typical medium-to-large municipal setup includes:

  • 2 trucks (one for towing an asphalt hot box trailer and one for towing a safety arrow board)
  • Arrow board
  • Asphalt hot box trailer
  • Hand tools (including asphalt shovels and rakes)
  • Compaction device (hand tamp, asphalt compactor, plate compactor, etc.)

An asphalt hot box maintains asphalt temperature for 48–72 hours, allowing material to stay within the optimal 300–350°F application range. Without one, asphalt cools quickly, reducing repair effectiveness—especially during colder months.

Ineffective pothole repair programs rarely stem from negligence. More often, deficiencies in staffing, materials, process, or equipment are the cause. Despite unique challenges, most organizations are doing the best they can with the resources available.

At KM International, we manufacture and supply innovative pothole repair equipment and asphalt hot boxes, while also providing education, training, and industry expertise.

Got questions? Call us today – 810-688-1234

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