Spray Injection Patching FAQs

Common questions about spray injection patching and Roadmaster road patchers. For technical support, call +353 71 962 4753 (Mon–Fri, 8am–5pm GMT) or get in touch through our support portal.

About spray injection patching

What is the difference between spray patching, spray injection patching, SIP, velocity patching, jet patching and blow patching?

There is no difference between these terms and they can all be used interchangeably. Spray patching and spray injection patching are widely used in the UK and North America. Velocity patching describes the process in Ireland and the UK, jet patching in the UK and Pacific regions, and blow patching principally on the European continent.

What is spray patching?

Spray patching is a process that can be used to fix potholes and other road surface defects, and can also provide preventative treatments to stop potholes from forming in the first place.

How does spray patching work?

Modern machines apply a bitumen-and-aggregate material to the repair area and are designed to support consistent material delivery for reliable results.

Is spray patching efficient?

Spray patching is an efficient road repair and maintenance solution. It allows surface defects to be targeted and treated before they break up into potholes — without excavation.

How long will spray patching repairs last?

Spray patching patches have been recorded as intact five years after being laid.

Using spray patching

Can spray patching be used to prevent potholes?

Yes. Spray patching is widely used as a sealing and repair treatment to prevent potholes.

Can spray patching be used as a pre-surface-dressing treatment?

Yes. Spray patching is widely used to prepare surfaces for surface dressing by levelling and filling cracked areas, depressions, broken edges and worn areas.

Does spray patching generate waste?

Spray patching is a zero-waste treatment, as it does not require excavation. The material is only mixed at the point of use, so any unused material can be used later.

Is spray patching fast?

Spray patching can repair and seal 350m² in a single 8-hour shift, and can complete a single repair in less than 3 minutes.

Do spray patching repairs require rolling?

The process is designed to support effective compaction. It is recommended that repairs be rolled using the on-board roller immediately after they are laid, to consolidate and seal the dry chips and protect the surface.

Is spray patching only suitable for rural roads?

No. Spray patching can be used anywhere, provided suitable application procedures are followed.

Is spray patching carbon efficient?

Spray patching has been shown to be a highly carbon-efficient method of extending the life of a road surface, because of the efficient way it applies sealing repairs across a wide range of repair types.

Is spray patching disruptive to road users?

Spray patching is the ultimate quick-hit repair, completing a single repair in less than 3 minutes. Operating under mobile works regulations, it causes minimal disruption.

Safety, quality and training

Are operatives at risk using spray patching?

The in-cab operation of the Roadmaster machine means the operative is always safe within the cab, avoiding exposure to dust, weather, traffic, and the actions of careless drivers.

What quality control measures are in place?

Three tests are carried out: an affinity test (a laboratory test confirming the material is compatible with the emulsion, generally tested by the emulsion supplier); a snowball test on each new batch of material before loading; and an on-site sample tested from each load as it is dispensed, confirming the material is mixed properly and in the correct proportion.

What training is required to achieve high-quality results?

Training is divided into two categories. Operator training covers use of the machine and delivery of the process. Supervisor training informs supervisory staff on how the process works and what measures are necessary to ensure consistent, high-quality results.

Comparisons and common questions

What is the difference between spray patching and chip seal?

Chip seal covers a surface with one or more layers of emulsion followed by dry gravel deposited by gravity, then compacted. It can cover large widths (several metres) but is not suitable for deep repairs. Spray patching is more limited in width but can effectively fill deep degradations. Both techniques can be used together: spray patching for levelling, then chip seal for surface sealing.

Is the operator in the cab too far from the road to do a good job?

This is often the first question people ask when discovering the Roadmaster. Once inside the cab, the distance is less significant than it appears and visibility is excellent. The effectiveness of the technology lies in the flexibility and manoeuvrability of the application system.

Does the Roadmaster operating while moving forwards and backwards present a danger?

The Roadmaster supports continuous operation across longer sections, with integrated safety systems to support operator awareness (refer to your operator manual for full guidance). This capability allows a more homogeneous finish on large or long sections such as edge breaks and centre joints. The working speed is reduced, and the Roadmaster is equipped with backup radar and rear cameras for constant monitoring of the work area.