Make The Change
The Road Maintenance
Revolution
With the machine technology now available, the move to preventative road maintenance makes sense, but we recognise it’s a big change for authorities and contractors. Here’s some guidance on why and how to make the change.
Why Make The Change to Velocity Patching?
Velocity patching (also known as spray patching or jet patching) is more efficient, effective and durable than traditional methods such as delayed set macadam, manual chip sealing, and cut and fill repairs. It allows preventative repair to be carried out side by side with reactive repair, preventing future potholes.
Velocity Patching vs Manual Repair
| Single operator | Multi-person crew |
| Approx. €8/£7 per repair | Approx €40/£35 per repair |
| Repairs last many years | Repairs often last <3 months |
| Minimal traffic disruption | Significant traffic disruption |
| Mobile works process | Requires traffic management |
| Under 3 minutes | At least 20-minutes per repair |
| Operate year-round | Repairs often seasonal |
| Fully controlled material mix | Inconsistent material mix |
| No material wastage | Significant material wastage |
| Preventative maintenance & repair | Limited preventative ability |
| Approx. 0.8kg of CO₂ per repair | Approx 3.2kg of CO₂ per repair |
| No risk- fully operated from the cab | High risk- crew exposed on the road |
Pothole repair accounts for a third of highway maintenance funding each year, with emergency reactive repairs costing 25% more than planned repairs.
House of Commons Study, UK Parliament, 2024.
Who benefits
from Velocity Patching?
The highest-quality,
most durable repairs.
Quality control is key for us. With the Roadmasters, everything is computerised and precisely calibrated, so there’s no variable mixing. This gives us the highest-quality, most durable repairs.
Multiple Applications
Much more than pothole repair
Preventative maintenance turns the tide on reactive road repair.
Pothole repair
Velocity patching repairs potholes ten times faster using a perfectly calibrated mix of coated aggregate by sealing the patch and adjoining area, without the need for excavation, resulting in a long-lasting durable patch.
Centre Line Joint Repair
Cracks and crazing repair
Repairing cracks at an early stage is the key to avoiding pothole formation. Velocity patching allows you to apply a sealing layer of coated aggregate, filling any depressions and preventing any water ingress, limiting further damage to the road.
Pothole prevention
Edge strengthening
Road edges are prone to damage from excess water and lack of edge support. Velocity patching can be used to apply coated material to strengthen the edge, extending the life of the carriageway.
Pre-Surface Dress Patching
Seasonal pre-surface dressing often results in prolonged road closures. Velocity patching shortens the process by priming the road in advance, levelling any edges and covering raw patches.
A proactive,
preventative approach.
We haven’t looked back since we made the transition to velocity patching. With the Roadmasters, we have a proactive, preventative approach, and we’re not on the back foot with reactive repairs.”
Velocity Patching vs Manual Repair
A 12-month comparison of the cost, efficiency and durability of velocity patching per m2 versus manual repair.
Performance
| Process | Time Taken | Traffic Disruption | After 2 months | After 4 months | After 9 months | After 12 months | |
|---|---|---|---|---|---|---|---|
| Throw and Roll | 4 person crew | 10 mins | Road closure/TM | Signs of wear | Deteriorated | Failed | Refilled |
| Spray/Velocity Patching | 1 operator | <3 mins | Minimal | Perfect condition | Perfect condition | Perfect condition | Perfect condition |
Savings
| Total Labour | Total Cost | Carbon Output | |
|---|---|---|---|
| Throw and Roll | 80 mins | Approx. €80/£68* | 6.4kg* |
| Spray/Velocity Patching | <3 mins | Approx. €8/£7 | 0.8kg |
*The cost and carbon output of 2 repairs within a 12-month timeframe.
How to Make the Change
Switching to velocity patching is a big step involving multiple stakeholders.
Key Considerations
- The large initial outlay required for new machines
- There is often resistance to change within organisations, especially if the preventative maintenance ability of the solution is not understood
- Detailed planning is required to ensure that your fleet is designed to suit your needs perfectly
- Performance must be carefully measured to evaluate and demonstrate ROI
Step 1
Building a Business Case
Building a solid business case to gain stakeholder approval is the first step in the transition.
- With the relevant stakeholders in mind, outline the need for change, focusing on the high cost and carbon output of reactive repair and traditional maintenance methods.
- Detail the benefits of switching to spray patching, highlighting the potential to adopt a preventative maintenance approach. Detail the increased productivity, durability, safety and cost-efficiency to be achieved, as well as the lower carbon output.
- Lay out the broad estimates of time and cost of building and implementing a fleet of spray patchers, followed by the long-term returns. Concentrate on the increased rate of repair, which ultimately leads to better quality road conditions.
- Calculate the payback period, and the long-term ROI in terms of cost and carbon over the lifespan of the machines.
- Predict the ultimate positive impact on the organisation. Consider factors such as reduced manpower necessary for road repair – these individuals can be redeployed to work on other initiatives within the community. Other relevant elements include the ability to repair year-round and eliminating maintenance bottlenecks during summer months.
- Communication: Preventative maintenance is often misunderstood: it can be seen as wasting money “fixing something that isn’t broken”. Once the benefits are quantified and understood, it makes sense.
Step 2
Specifying a Fleet to Suit Your Needs
Once you’ve gained stakeholder approval, you need to determine exactly what you need from your patchers. This will depend on the road type, size and quantity under your control, and the manpower at your disposal. Other important factors are your specific organisational goals for the fleet, and how and when you intend to use the machines.
Elements to specify include machine size, capabilities, engine power, hopper capacity, data capture and optional extras.
Step 3
Choosing a Provider
A new fleet of machines is a big investment, so choose your provider wisely. Some manufacturers simply build machines to spec, while others provide a more turnkey solution including aftersales support and operator training. As you begin the transition to velocity patching, you may need some added support to lean into.
Step 4
Training
Training isn’t just for machine operators. Consider management training to help get the most out of your fleet, as well as routine machine maintenance training to keep your velocity patchers at peak performance.
Step 5
Servicing and Maintenance Scheduling
For more complex machine maintenance, having a detailed plan is the key to maximizing uptime. Schedule maintenance visits early in the year to prepare for busier seasons. Some fleet managers find it beneficial to have dedicated relief machines for use while their regular fleet goes for servicing in rotation.
Step 6
Measuring ROI
Many velocity patchers come with data capture functionality to help with monitoring ROI. Learning how to leverage this technology helps to demonstrate the value of your investment up the chain of your organisation, and it also allows you to measure individual machine productivity, and make any improvements where necessary.
Customer Spotlight
Cork County Council, Ireland
Cork County Council began adopting velocity patching in 2006 to try and meet the demand of maintaining 12,000km on a limited budget.
John Tobin, Plant Stores Superintendent, says: “We use spray patchers for pothole repair, but we also use them for preventative maintenance. Where a road doesn’t require full surface dressing, we use the patchers to fix any edges or raw surfaces. If we can address any issues before a pothole forms, it preserves the integrity of the surface for another 12 months”.
“Velocity patching offers a more durable fix thanks to the calibrated mix of materials and the compaction”.
John accepts that there is some reluctance to change in the industry. “Area engineers and senior council members are hesitant to adopt spray patchers because of the initial outlay, so selling the idea to senior management in local authorities can be tricky.”
However, he maintains that the benefits strongly outweigh the cost, and once the switch is made, you’ll never look back. “The ROI is fantastic, the machines can last up to 20 years if maintained properly, and the carbon savings are also impressive.”
ROADMASTER MACHINE CAPABILITY
LESS TIME, MATERIAL, AND CARBON
MORE DURABLE, EFFICIENT AND COST-EFFECTIVE
DOWNLOAD THE FULL GUIDE
ROAD MAINTENANCE REVOLUTION
WHY AND HOW TO TRANSITION TO MODERN REPAIR
In this 37-page comprehensive guide, you’ll discover:
- The full benefits of spray patching, from cost and carbon savings to efficiency and operator safety.
- How spray patching can help your organisation switch from a culture of reactive to proactive road maintenance.
- The easiest approach to making the change to modern preventative road repair.
- How to build a business case to support your decision.
- The steps to take to design, build, operate and maintain a fleet of spray patchers.
