What Are Patch Packs?
Patch Packs are a cold asphalt patch product designed for fast, permanent pothole and pavement defect repair. They are made from 100% recycled aggregate combined with a non-volatile binder — meaning the formula contains zero VOCs (volatile organic compounds).
Unlike hot mix asphalt, which requires heated material and warm-weather application conditions, Patch Packs work in any weather — including freezing temperatures, rain, and wet conditions. This makes them a critical tool for emergency winter pavement repair when hot mix plants are closed and potholes are at their worst.
How Cold Asphalt Patch Works
The binder in Patch Packs allows the material to expand and compress under vehicle load. When compacted into a pothole, this creates adhesion to the existing pavement surface while simultaneously sealing the top and side edges of the repair area.
This expansion-compression behavior is what makes cold patch fundamentally different from hot mix. Hot mix cures into a rigid mass. Patch Packs remain slightly flexible, which allows them to maintain their bond through freeze-thaw cycles and thermal expansion — the exact conditions that cause most pothole repairs to fail in Northern Ohio.
The repair is traffic-ready immediately after compaction. No curing time, no waiting, no traffic control beyond the time it takes to fill and compact the hole.
Standard vs Flex Variants
Patch Packs come in two variants, each designed for specific applications:
Standard Patch Packs
For typical pothole and spall repairs on asphalt and concrete pavement. Use on roads, parking lots, driveways, and standard pavement surfaces. The workhorse product for routine pothole maintenance.
Flex Patch Packs
Enhanced flexibility for surfaces with greater movement or thermal stress. The preferred material for bridge deck repairs, expansion joints, and areas subject to heavy dynamic loads and wide temperature swings.
How to Apply Patch Packs
No specialized equipment, heating, or mixing is required. A single person can complete a repair with basic hand tools:
- Clean the hole: Remove loose debris, standing water, and any deteriorated material from the pothole.
- Fill: Place Patch Packs material into the hole, overfilling slightly above the surrounding surface level to account for compaction.
- Compact: Tamp firmly with a hand tamper, or drive a vehicle tire over the repair. For potholes deeper than 4 inches, apply in 2-inch lifts, compacting each layer before adding the next.
- Open to traffic: The repair is immediately ready for vehicle traffic after compaction.
Applications
- Potholes and spalls on asphalt and concrete pavement (1 inch deep or greater)
- Bridge deck repairs — Flex variant handles dynamic loads and thermal movement
- Utility cut restoration — leveling around drains, manholes, and access points
- Parking lots and driveways — commercial and residential surfaces
- Highway and road maintenance — emergency and scheduled repairs
- Multi-use pathways — bike paths, trails, and shared-use surfaces
Why It Matters in Ohio
Northern Ohio's freeze-thaw cycle is brutal on pavement. Water enters cracks, freezes, expands, and breaks the pavement apart — creating potholes that grow worse with every cycle. Hot mix asphalt plants typically close from late fall through early spring, leaving municipalities and property managers without a repair option during the months when potholes are most severe.
Patch Packs fill that gap. They work in any temperature, require no special equipment, and produce a durable repair that holds through the rest of winter. For road crews, property managers, and contractors who can't wait until May to fix potholes, cold asphalt patch is the practical solution.
Key Specifications
- Aggregate: 100% recycled
- Binder: Non-volatile (zero VOCs)
- Application temperature: Any — including below freezing
- Minimum repair depth: 1 inch
- Traffic ready: Immediately after compaction
- Equipment required: None — hand tamper or vehicle tire for compaction
- Variants: Standard and Flex
Order Patch Packs
We stock Patch Packs at our Solon, Ohio warehouse with delivery throughout Northern Ohio. Most orders ship or are available for pickup within 24-48 hours.