Choosing the Right Pothole Repair Method: A Guide for Municipalities

Potholes: Every car's worst nightmare

In municipal pavement management, choosing the right pothole repair method goes far beyond filling a void. The severity of the damage, traffic volume, seasonal conditions, and available resources all influence the most effective and cost-efficient approach. Below, we outline the most common pothole repair methods used by municipalities, along with their strengths, limitations, and ideal use cases.

1. Semi-Permanent Patching

Best for: Durability and High-Traffic Roads

Semi-permanent patching is one of the most reliable and durable methods for addressing potholes, especially in primary roads.

Process:

• Cut and Define Edges: Saw or jackhammer a clean-edged rectangle or square around the pothole.

• Clean the Area: Remove all debris and moisture to improve adhesion.

• Apply Tack Coat: Use asphalt emulsion to bind the patch.

• Place Hot Mix Asphalt: Preferred for strength and durability.

• Compact: Use a roller or vibratory compactor; slightly crown the surface for water runoff.

  
  

Pros:

• Long-lasting performance

• Ideal for high-volume traffic areas

  
  

Cons:

• Requires more labor, equipment, and time than temporary fixes

2. Full-Depth Repair

Best for: Structural Failures and Severe Damage

When a pothole indicates deeper structural issues, full-depth repair is necessary. This method addresses not just the surface but also the underlying base and subgrade.

Process:

• Excavate the damaged area

• Rebuild or stabilize the subgrade

• Install and compact new aggregate base

• Place and compact hot mix asphalt in layers

Pros:

• Provides a permanent, structural fix

• Prevents recurrence of failures in the same location

Cons:

• High cost and time-intensive

• May require lane closures or detours

3. Spray Injection Patching

Best for: Quick Repairs with Moderate Durability

This method uses specialized equipment to clean, tack, fill, and finish a pothole in one operation—efficient and ideal for medium-priority roads.

Process:

• Clean pothole with high-pressure air

• Apply tack coat

• Spray a mixture of asphalt emulsion and aggregate

• Top with dry aggregate to reduce pickup

Pros:

• Fast and efficient

• Minimal manual labor required

Cons:

• Equipment-dependent

• Durability varies with conditions and operator skill

4. Throw-and-Roll Patching

Best for: Emergency or Cold Weather Repairs

Often used during winter or high-traffic situations, this temporary method prioritizes speed over longevity.

Process:

• Place cold mix asphalt directly into the pothole

• Compact using vehicle tires or rollers

• Leave a slight crown for future compaction

Pros:

• Quick and requires minimal resources

• Useful in urgent or adverse conditions

Cons:

• Short lifespan; requires follow-up maintenance

5. Edge Repair (Dig-Outs)

Best for: Edge Failures and Pavement Cracking

This targeted repair addresses potholes or damage caused by edge erosion or severe cracking.

Process:

• Mark and cut out the damaged edge area

• Excavate to a stable subgrade

• Apply tack coat

• Replace base and asphalt layers with proper compaction

Pros:

• Effective for restoring pavement integrity at the edges

• Can extend the life of adjacent pavement

Cons:

• Labor- and resource-intensive

Key Factors in Method Selection

Municipalities should consider the following factors when selecting a repair method:

• Traffic Volume: Heavily traveled roads demand more durable solutions like semi-permanent or full-depth repairs.

• Available Resources: Limited staff or budget may necessitate temporary fixes like throw-and-roll.

• Seasonal Conditions: Cold mix or spray injection may be better suited for winter, while hot mix is optimal in warmer, dry weather.

• Severity of Damage: Structural failures require deeper intervention, while surface voids may be patched quickly.

  
  

Data-Driven Repair Planning

A pavement management system (PMS) can help prioritize repairs based on real-time data, such as:

• Pavement Condition Index (PCI)

• Ride quality scores

• Historical maintenance data

• Budget forecasting

  
  

By aligning repair types with data insights, agencies can make strategic decisions that extend pavement life and optimize costs over time.

Best Practices

1. Schedule Regular Inspections: Early detection allows for more cost-effective repairs.

2. Use Quality Materials: Invest in hot mix asphalt for long-term results.

3. Track All Repairs: Logging maintenance activity helps with budgeting and future planning.

4. Aim for Proper Compaction: Poorly compacted patches are prone to premature failure.

   
   

Final Thoughts

Each pothole presents a unique challenge. By understanding the pros and cons of each repair method—and aligning them with pavement condition data—municipalities can make informed, cost-effective choices. Whether you’re managing an urgent winter pothole or planning full-depth reconstruction, integrating repairs into a long-term pavement management strategy will deliver safer, longer-lasting roads.

Need help building a data-backed maintenance plan? Pavement Management Group helps municipalities make smarter infrastructure decisions through expert evaluation, strategic planning, and long-term asset management. Contact us today to get started.