From two-operator machines, regular overspray property claims, and reactive-only patching — to one operator, zero overspray incidents, full road sections repaired in a single pass, and repair lifespan up from 3 months to 12+. Labour cost per machine halved.
The problem with what came before
Before Kier adopted the Roadmaster, Leon Jolly tried machines from an alternative supplier. “We had two machines from another supplier originally, but I didn’t like them. We needed two men to operate them, and we had a lot of problems with over-spraying and damage to property that was costing us.” Two operators doubled labour cost. Overspray created ongoing liability. Both compounded the margin problem.
The operational shift
Rather than responding to reported defects one by one, Kier now runs proactive sweeps — closing a 2km stretch of road, completing all defect repairs along the section, and reopening it quickly, often within the hour. The road holds for another year. The cost per intervention falls as the programme matures, because the same sections stop reappearing.
“For us, quality control is the key. The application settings support consistent material delivery, which gives us durable, long-lasting repairs.”
— Leon Jolly, Senior Operations Manager, Kier Highways
From reactive to preventative — and the cost savings that follow
Leon’s team started by using the Roadmaster to address their worst reactive backlog — the potholes that kept coming back. Once those were cleared properly, capacity opened up for pre-surface dressing preparation and proactive defect sealing. Sections they now treat preventatively don’t become emergency callouts.
| Metric | Previous machines | Roadmaster |
|---|---|---|
| Operators required | 2 | 1 |
| Overspray incidents | Frequent | Eliminated |
| Repair consistency | Variable | Calibrated every time |
| Proactive maintenance | Not viable | Standard approach |
| Repair lifespan | ~3 months | 12+ months |
| Property damage claims | Regular | Eliminated |
“Roadmaster has helped us to take a preventative approach to maintenance, rather than being on the back foot with reactive defect repair.”
— Leon Jolly, Senior Operations Manager, Kier Highways