Patching - The Different Types of Repairs

Patching is an extremely common form of asphalt repair and maintenance work. However, there are several different forms of patching commonly used. Each form has its pros and cons, and some are better suited to address certain issues than others. In order to better help you understand the differences between these patching types, Black Pearl Asphalt has written up this quick guide to help.

IR Patching

IR Patching, or infrared patching, is the quickest and most inexpensive form of patch repair. This is a newer process, which involves using a special machine that uses infrared to reheat existing asphalt to a point of malleability. Once the asphalt is hot enough, it can be molded and rolled back to a flat, clean surface. This process, often called a "heat", is repeated until the pavement is heated as deep as necessary to repair damaged areas. In some cases, additional new hot mix asphalt can be added to the reheated surface to accommodate for missing material.

IR Patching is best used for smaller scale deformations or damages, such as alligator cracks (you can see more about this in our crack seal article) or shallow potholes. The lack of additional materials and the ability to perform it quickly and cleanly makes this option fairly inexpensive, especially when compared to other forms of patching. However, it is not the best option for more extensive damages. When too much material is missing or the depth of the damage is too great for the infrared machine to reach, IR Patching cannot fully address the issue. Deep or large potholes, extensive cracks or buckling of pavement, and deteriorated asphalt prevent IR Patching from successfully repairing damages.

Rotomill Patching

Sometimes referred to as "surface patching", Rotomill patching is a balanced medium between IR and R&R patching. Unlike infrared, this process is more intensive. A layer of asphalt, generally less than 6 inches deep, is milled out by machine. After removing the damaged layer of asphalt, the spoils are hauled away for recycling. A new layer of hot mix asphalt is then laid in the milled out space, adhering to the remaining asphalt and creating a new paved surface. This process is very similar to that of an overlay, though on a much smaller scale.

Surface patching, like the nomenclature indicates, is best used for surface damages. If an area of damage is too big for an IR machine to cover or if deformations are too deep in the pavement, this is generally the recommended option. This is better serves most pothole repairs than IR can, without requiring the more intensive processes of R&R patching. Because it requires more material and is more labor-intensive than IR, it is a higher price point. However, regular maintenance can prevent the need for more costly repairs down the line.

R&R Patching

As you may have guessed, R&R Patching is the most expensive of commonly used patching methods. Standing for "remove and replace", R&R Patching is the most intensive patch repair process. An entire section of damaged pavement is cut out, removed down to the subsurface dirt, and replaced with entirely new asphalt. Similar to the Rotomill process, spoils are generally hauled away for recycling. Not to be confused with an R&R Pave, this process does not involve an entire paved surface - only a predetermined square patch of a lot or roadway.

Being the most intensive form of repair, this is generally only recommended for the severely damaged asphalt found in an isolated area. Potholes or cracks that extend through the entire depth of a pavement to the subsurface area, large areas of missing material, or instances where subsurface erosion is seen in a specific are scenarios where R&R might be the best option. This is the most expensive patching option due to the material and labor costs, so it is only recommended in instances of severe damages that other forms of patching are unlikely to adequately address.

Cold Patch

This is the cheapest option, and is rarely offered by most seasonal companies. This is because, most of the time, an individual can accomplish this type of patching on their own. A cold mix asphalt, often sold in bags similar to quick mix concrete, is poured into a pothole or similarly damaged area. This process does not require any heat or special equipment to do. However - it is very temporary. Because a cold patch does not use heat, it never adheres to the existing asphalt. This makes it stand out visually, but also is what lends to its temporary nature - both the cold patch and the surrounding pavement will continue to erode or split apart.

This process is generally only recommended for emergency fixes of potholes in asphalt off-seasons, when hot-mix repairs are unavailable. Cold patches only last a matter of weeks to months, unlike the other forms which can last upwards of a year. When using a cold patch, you should always plan on getting a more permanent repair for the upcoming asphalt season.

Each type of patching addresses specific concerns and has its own positives and negatives. Asphalt companies, like Black Pearl Asphalt, will make suggestions for which method might be best for your needs when giving an estimate. If you have more specific questions, or want your own estimate, you can always contact our office -- we're happy to help in any way we can.