How to repair potholes: a step-by-step guide

Potholes are depressions in the surface of roads or paths that pose a risk to both vehicles and pedestrians.

They can range from small divots to larger craters and will gradually become deeper and wider over time if they’re not attended to – particularly where heavy machinery is in use.

Potholes can cause damage to a vehicle’s tyres, suspension and steering system, and can even lead to crashes due to drivers losing control.

On footpaths, potholes are a trip hazard for pedestrians and can lead to nasty falls for cyclists.

Repairing potholes is therefore crucial to ensure the safety of road and path users. With the correct equipment and by following this step-by-step guide from Start Safety’s experts, the repair of potholes can be a straightforward task.

What is the cause of potholes?

Potholes are caused when water seeps into any small cracks that have formed on the surface of roads or paths due to damage or continued use.

Water, usually from rainfall, then seeps into these cracks. When this water freezes, it expands, putting pressure on the road or path surface. The repeated cycle of freezing and thawing weakens the surface and leads to a small hole developing. This hole then expands as more vehicles pass over it.

This is the reason the UK is particularly susceptible to potholes, as they’re exacerbated by cold and wet weather.

How long does it take to repair a pothole?

Repairing a pothole doesn’t take long – typically only between 30 minutes and an hour for a small to medium sized hole. Larger potholes may take a few hours to repair.

However, external factors such as sign-off for road closures and securing the site can mean that it takes a while for the project to begin.

Pothole repair equipment: what you’ll need

There is a range of pothole repair equipment and tools that you’ll require to effectively restore a road or path. Make sure you have the following to hand before beginning your repair work:

• Stiff brush
• Shovel
• Punner/rammer
• Overbanding tape/joint sealant
• Gas torch – depending on the product, this may not be required
• Cold lay tarmac

You will also need PPE, so be sure to check the requirements for your site and the products you’re using.

Step-by-step process for repairing potholes

Below is a straightforward process you can follow to restore a road or path to prime condition by repairing any potholes.

1. Remove debris from the hole

First thing’s first, you’ll need to remove any debris or loose material from the hole.

You might be able to remove larger rocks or chunks of tarmac by hand, while a stiff brush or shovel can be used to remove smaller fragments and dirt.

Depending on the size and shape of the pothole, you may also need to cut a square around the pothole area. This is to ensure that the bonding of the material has good depth and thickness. A shallow repair can easily break again.

Don’t worry about any standing water if you’re using instant cold lay tarmac solution like Viafix, as these actually perform better in wet conditions.

2. Clean the surface

The surface around the hole should also be clear, so use the stiff brush to sweep any debris away from the area directly around the hole.

Removing this debris will maximise the effectiveness and longevity of the repair.

3. Fill hole with cold lay tarmac

Deploy cold lay tarmac into the pothole, ensuring that the solution is slightly proud of the pre-existing surface.

4. Pack down the cold lay tarmac

You’ll then need to pack down the cold lay tarmac using a punner or rammer.

Properly compressing the tarmac will ensure that there are no cracks or air pockets within the repair that could cause future problems and hamper its longevity.

It also means that the repair is smoothed over and level with the pre-existing surface around it.

5. Use overbanding tape

As an optional extra step, you could apply skid-resistant overbanding tape on the border between the pothole repair and the pre-existing surface to seal and waterproof it.

Skid-resistant properties mean that roads can be opened almost immediately after the repair work is completed – and unlike other products, overbanding tape from InstaBand maintains this throughout its lifespan.

You’ll need to use a gas torch to melt the tape onto the surface and ensure there are no gaps.

Overbanding tape is ideal for potholes where the border features straight lines. If the border is more jagged, you can use joint sealant, which is normally deployed with a resin gun.

6. Identify other potential potholes

If you already have your joint sealant to hand, it might be worth checking around your completed pothole repair to identify other potential potholes.

Simply apply the sealant to any small cracks or holes in the surface, which will prevent water seeping in and eventually causing a pothole in the future.

If you need further information on pothole repairs and which products or tools you require, call our trained sales team on +44 (0)1905 794875. We can also discuss special delivery needs and discounts for bulk quantity requirements.