What’s Inside an Instant Pothole Repair Kit? A Breakdown

In 2022, 4,446 pothole-related incidents killed 1,856 people in India (MoRTH data). That’s five deaths every day from something as avoidable as a road crater. With the fatality rate per accident rising significantly day by day in India, this is more than just an infrastructure issue; it’s a life-or-death emergency that calls for immediate pothole repair solutions rather than a choice.

India’s Needs Instant Pothole Repair Kit?

Potholes are more than mere blemishes that ruin the aesthetics of a road; they are an ever-present issue affecting road safety, vehicle performance, and overall driving comfort. Indian roads see the formation of these potholes overnight, subjected to adverse weather conditions, huge traffic loads, and frequent utility outages, posing serious safety threats to vehicles and pedestrians. Even tiny potholes in no time turn big, increasing repair costs and putting lives at risk.

Why Do We Even Need an Instant Solution?

Traditionally, pothole repairs were carried out by hot mix asphalt, which requires specialised and heavy equipment to first heat and mix and then lay. A long curing period and good weather pose unreasonable demands for an environment with ever-changing weather and busy roadways in India. 

Waiting seems a rather impractical option in such instances. An instant pothole repair system becomes paramount in offering a speedy antidote with a long life, reducing downtime, and preventing accidents while ensuring smooth rides in emergencies.

Developed for these needs is a modern technology-based cold mix product, namely, Durapave Emulsis Plus. It ensures quicker, easier, and more reliable repairs, assisting in making roads safer while leaving behind less waste.

What is an Instant Pothole Repair Kit?

An instant pothole repairing kit is a ready-to-use solution that serves the purpose of making quick, on-the-spot, effective pothole repairs without being heated. At its base is a special cold mix bitumen that can be used even at low temperature levels, which makes repairs possible in nearly any weather condition.

How Does Cold Mix Technology Work?

The cold mix technique, unlike conventional hot mix asphalt, which requires high temperatures and a speedy application, combines a modified bitumen, including CRMB, with an aggregate at ambient temperatures. This makes the mix usable at temperatures as low as -7°C; it is also highly water resistant, sticking to any surface even in moist situations.

Why Cold Mix Approach?

1. Speed: Ready to use; no heating or heavy equipment required
2. Convenience: Comes in easily stored 25 kg bags and can be applied straight on-site.
3. Cost-effectiveness: Saves time while lowering labour and machinery costs
4. Durability: The mix has a 5% binder concentration and a stability of 2.2 kN at 25°C, ensuring long-term performance.

Durapave Emulsis Plus facilitates repairing potholes at a far better pace with lower safety concerns.

Key Components Inside the Kit

The kit includes key components such as modified bitumen (CRMB) and bitumen emulsion. Provides flexibility, water resistance, and strong bonding to ensure the mix operates effectively under traffic and weather conditions.

• Cold Mix Aggregate: Specially graded aggregates improve workability even at low temperatures, making the mix suitable for use year-round.
• Adhesion Enhancers (Durapave Emulsis RS1): A tack coat that strengthens the binding between the repair mix and the existing road surface, resulting in longer-lasting repairs.
• Packaging and Quantity: Supplied in compact 25 kg bags for easy transportation, storage, and application with minimal equipment.

Technical Specifications – At a Glance

Durapave Emulsis Plus is engineered to offer long-lasting repairs even with the cold-mix approach. With 90% water resistance, it functions consistently even in moist conditions, ensuring that moisture does not harm the patch. Its workability at temperatures as low as -7°C makes it suitable for many different geographies in India and climates, while a 5% binder concentration ensures great adhesion and durability.

With a stability of 2.2 kN at 25°C, this product can resist the demands of busy roads and high traffic. These specifications made it suitable for not just less busy roads but also medium to early stages of heavy traffic roads, and also for the regions where the hot-mix technology is not suitable or reachable.

Where Can You Use It?

This is more than simply a pothole filler; it’s a whole road repair solution. Durapave Emulsis Plus manages urban and rural potholes, edge deformation, and utility cuts with ease. It works as well for alligator cracking, failed patches, heaves or swells, and even more difficult applications like rutting, trench work, and corrugation repairs. In brief, whenever the road surface is damaged, this mixture gives a reliable solution.

• Alligator cracking and failed patches
• Heaves or swells that disrupt road levels
• Rutting, trench work, or corrugation repairs

How to apply:

1. Clean the pothole thoroughly: To clean the pothole, use a strong wire brush to remove dust, grime, and loose debris, then a soft brush. A clean surface promotes strong adherence.
2. Apply the tack coat: For the tack coat, use Durapave Emulsis RS1. This improves the bonding between the existing road surface and the repair mix.
3. Fill with the ready-to-use mixture:
4. Place the cold mix in the pothole, filling it roughly 30 mm above the surrounding surface to facilitate compaction.
5. Compact carefully: To condense the patch, start at the edges and work your way towards the centre. Leave the finished patch slightly higher (3-5 mm) than the old road to allow for natural traffic compression.
6. For deeper potholes: For potholes deeper than 75 mm, apply the mix in layers and compact each layer for optimum strength.
7. Finish with sand: Finish with clean, dry sand over the repaired patch. This keeps the mixture from clinging to car tires before the route is reopened for traffic.

Precautions for a Long-Lasting Repair

To achieve the greatest results, avoid repairing during heavy rain or when water flows over the damaged region, since this can hinder adequate bonding. Do not fill the hole with loose earth before applying the mixture; a clean, stable basis is required. To ensure product integrity, keep Durapave Emulsis Plus in a cool, dry place until ready to use.

Conclusion

Potholes should be recognised as more than an inconvenience; they are inherently dangerous and an indicator of deteriorating road infrastructure. Durapave Emulsis Plus instant pothole repair kits present a new, reliable opportunity for road repair that utilises cold mix technology, ease of application, and longevity in a small 25 kg bag.

It’s the most efficient solution for immediate pothole repairs and annual maintenance, providing a smarter and faster mechanism for keeping roads safe and smooth. The combination of ITPL and Total Energies aims to integrate technology and innovate more road pavement products that address the current and most pressing road infrastructure issues in India, such as potholes. Our range of products addresses a specific issue on Indian roads.