How To Repair Potholes And Patches On Bituminous / Asphalt Roads

As asphalt pavement’s age and traffic wear them down, distresses develop. Distresses are exacerbated if maintenance is not conducted on time. Cracks turn into potholes, and potholes become craters. 

The expansion and contraction of water cause potholes during freeze-thaw cycles, as well as the quantity of traffic on the road. Because of the shifting temperatures, potholes are more common in the late winter and early spring.

The continual freezing and thawing of melting snow, mixed with spring rain, wreaks havoc on the pavement, resulting in cracks and potholes.

When an asphalt pavement road or street is in fair to good condition, crack sealing is a smart idea. With adequate drainage, crack sealing is arguably the most significant maintenance activity.

Powered By BEdigitech

Water penetration into the pavement structure causes most pavement distresses, and most can be avoided or delayed if water is kept off the pavement. We will discuss some other ways in this article.

How To Repair Potholes And Patches

Patching is filling potholes or excavated areas in the asphalt pavement. Potholes and other pavement disintegration should be repaired as soon as possible to prevent additional deterioration and costly pavement repairs.

Water can permeate the subgrade and cause more severe pavement failures if not addressed quickly. Some of the ways to repair or patch include:

1. Surface Patching

Surface patches usually are only used for a short period. They’re made by milling a section of the pavement to the point where all degraded material is removed.

At least three times the nominal maximum size of the aggregate should be milled in the patch area. Using a 3/8 or 14-inch aggregate will reduce the amount of milling required, assist the repair to the existing pavement, and give enough hot mix thickness to prevent raveling.

2. Pothole Repair Using Cold Mix Asphalt

Cold mix is made by combining bitumen emulsion or cutback with cold aggregates, with anti-stripping additives added as needed. Cold mix asphalt was used as a temporary mending material or when hot mix asphalt was unavailable.

The following are some of the advantages of cold mix asphalt over hot mix:

  • Its ability to function at low temperatures.
  • It can also be stored in stockpiles for six months following manufacturing.
  • Because of the longer cure time, it remains more flexible than the hot mix.

3. Infrared heater patching

Patching with an infrared heater involves fewer employees and is frequently faster and less expensive than full-depth patching. Truck-mounted infrared heaters heat the asphalt to a depth of 2 to 3 inches, equal to a thin surface patch.

The patch is heated with an infrared heater. The in-place asphalt can then be rejuvenated, or a fresh asphalt mix can be mixed into the current material. The existing asphalt is compacted after it has been reworked.

4. Mill Patching

If the asphalt parking lot only has superficial damage, the second alternative, mill patching, might be used. Crews can mill two inches off the surface surrounding the pothole and replace it with compacted asphalt if asphalt is at the bottom of the holes.

This method of pothole restoration leaves a smooth surface that lasts longer than a pothole patch. Reflective cracking may occur following freeze-thaw cycles, which is a disadvantage of this solution.

Reflective cracking occurs when the fissures in the bottom of the patch show through, creating a condition identical to when the pothole first appeared.

5. Dig-Out Patching

A dig-out patch is the final and most extensive solution for pothole repair. Dig-out patching includes removing all asphalt from a 6’x6′ area around the hole at a minimum.

The aggregate base is then regraded, and four inches of asphalt is applied to the mended area. A roller is then used to compact the asphalt. Because it creates a structurally robust solution, this method is the greatest long-term alternative for pothole repair.

From short-term to long-term, the asphalt patching timeline looks like this: pothole patch, mill patch, dig-out patch. It’s crucial to keep future maintenance plans in mind when selecting what maintenance work should be done now.

Reflective cracking may occur following freeze-thaw cycles, which is a disadvantage of this solution. Reflective cracking occurs when the fissures in the bottom of the patch show through, creating a condition identical to when the pothole first appeared.

6. Patching with Spray-injection

Spray-injection patching is a semi-permanent way of mending tiny pavement flaws, especially in wet or cold conditions. A truck or trailer-mounted unit with an emulsion tank, aggregate tank, heating components, high-volume blower, telescoping boom with injection head, and the necessary controls is required for this approach. 


  • Clean the patch area with compressed air to remove loose material and debris, 
  • Apply a tack coat of hot asphalt emulsion, 
  • Force the combined aggregate and hot emulsion into the patch with forced air, 
  • Finally, place a dry coat of aggregate on top of the patch to prevent tracking.

This process often uses a one-size stone, similar to chip-seal aggregate. As the mix is sprayed into the patch in layers, it is compacted by the force of the air. This method is particularly useful for patching potholes.

7. Provide Unwavering Support

The material in the repair region is removed to the depth required for solid support in full-depth patching. This frequently necessitates the removal of portions of the sub-grade, and a full-depth fix may require some additional drainage.

At least one foot of the good pavement surrounding the repairing area should be excavated. Patches should have a square edge, and cuts should be rectangular, with no variations in length or width inside the patch area.

If the patch’s width is close to the lane’s width, a full lane patch may be the best option because it allows the contractor to use standard paving equipment instead of handwork and eliminates extraneous longitudinal joints. A pavement saw cuts quickly and cleanly.

A dense-graded hot mix asphalt should be used to backfill a full-depth fix. If hot mix asphalt isn’t available, a suitable cold mix, specialty mix, or proprietary mix can be used in its place. If the repair is deeper than six inches, layer the patching material in four-inch layers, compacting each one as you go.

How To Repair Potholes In The Road? 

You can repair potholes in the following ways –

Remove the dirt and debris from the pothole and clean the area. The rehabilitation can be jeopardized if broken pavement parts are mixed with new pavement.

Heat the pothole to remove any excess moisture in the existing pavement as well as soften the region so that fresh asphalt can be placed. After the pothole has softened, reshape it.

Place the new asphalt on top. Hot mix asphalt is commonly used for this type of restoration. 

Compact the newly placed asphalt to reduce water penetration and increase resistance. The old and new asphalt pavements are joined together by compaction.

Allow time for the new asphalt to settle. Remove any debris that has gathered around the repair. The majority of pothole repairs are immediately usable.


Ask many questions to get a good idea of the contractor’s degree of experience, customer satisfaction rate, and technique to fix potholes and asphalt pavement.

It’s critical to obtain various quotations and always inquire about a contractor’s references and recommendations over the last 12 months.

Your contractor’s experience and how they perform the repair process will significantly impact the quality of your pothole repair and how long it will endure.

Also Read

Concrete Road Vs Asphalt Road – Which Is Better?

How To Calculate Asphalt Quantity For Road Construction

For More Updates like our Facebook Page and join our Telegram Channel.

Leave a Comment