For municipal road crews, pothole repair is a constant battle. Whether caused by freeze-thaw cycles, heavy traffic, sub-base failures or aging pavement, these road hazards demand quick attention to maintain safety and avoid costly vehicle damage claims. But fixing potholes is more than just dumping asphalt into a hole—it’s a multi-step process requiring specialized tools and consistent heat retention to ensure repairs are permanent.
Falcon Patch Trucks were designed with one mission in mind: to make every stage of pothole repair possible from a single truck. By combining heating, delivery, tack application, compaction, and debris management in one integrated platform, Falcon eliminates the inefficiencies of juggling multiple vehicles and tools. The result is faster, cleaner, and longer-lasting repairs without sacrificing crew safety or municipal budgets.
All-in-One Capability for Complete Pothole Repair
Traditional methods often require multiple vehicles: one to haul asphalt, another for tack application, and another for compaction. Falcon Patch Trucks streamline this into a single, compact solution.
At the heart of each truck is Falcon’s proven hot mix delivery system. The 105,000 BTU Beckett diesel burner maintains up to 8,000 lbs of material at ideal working temperature for an entire shift, and even up to 48 hours overnight, so your crew can start patching first thing in the morning without a trip to the plant. With this capacity, crews can repair up to 80 potholes at a standard 1’x1’x4” depth before needing a reload.
Built-In Tools for Every Step
What sets Falcon apart is how the truck is equipped to handle every phase of repair:
- Tack tack: Ensures a consistent bonding layer between the existing pavement and new asphalt, essential for preventing premature patch failure.
- Onboard compaction: Delivers the density needed for a smooth, level surface that resists water infiltration and rutting.
- Spoil bin: Keeps broken pavement, debris, and removed material contained, making cleanup quick and preventing scattered hazards on the job site.
Combined with the largest gravity-assisted delivery doors in the industry, operators have unmatched control over the amount and speed of asphalt placement, whether repairing a small seam or a large utility cut.
Efficiency That Pays Off
By integrating all repair functions into one vehicle, Falcon Patch Trucks slashes downtime. Crews avoid the constant back-and-forth to the asphalt plant, reducing fuel costs and non-productive travel time. The ability to store hot mix overnight means repairs can start immediately in the morning rush, an advantage for municipalities balancing limited manpower with high repair volumes.
And because Falcon trucks use a gravity dump design instead of augers or hydraulic systems, there are fewer moving parts to maintain. That translates to more uptime, lower maintenance costs, and reduced fuel consumption over an 8-hour shift.
Designed for the Realities of Public Works
One of Falcon’s most impactful design choices is eliminating the need for a CDL driver to operate the truck. Any crew member with a standard driver’s license can step in, giving departments flexibility when a primary operator is unavailable. For many municipalities, this alone provides significant labor cost savings.
The trucks are also ergonomically designed to minimize worker strain. The gravity-fed material delivery reduces shoveling at awkward heights, a common cause of repetitive motion injuries and workers’ compensation claims.
Versatility Across Job Types
Falcon Patch Trucks are built to go beyond just filling potholes. Their combination of onboard heating, gravity-fed material delivery, and optional recycling capabilities gives public works crews and contractors the flexibility to respond to a wide range of pavement issues, quickly, efficiently, and in any season. Whether it’s emergency repairs, planned maintenance, or specialized road work, a Falcon Patch Truck is ready to go.
Falcon Patch Trucks can be used for:
- Utility cut repairs after water or sewer work\
- Full-depth patches for structural failures
- Cold weather repairs with reclaimed asphalt, using the truck’s recycling capabilities to reheat millings or chunks for reuse
This adaptability means your investment isn’t just for seasonal pothole work. It’s a year-round road maintenance asset.
Why the Right Patch Truck Matters
When crews ask, do patch trucks offer complete pothole repair?—The answer depends on the truck. A truly complete solution must heat, store, deliver, bond, compact, and clean up, all in one trip. Falcon Patch Trucks check every box.
They’re more than a hauling vehicle; they’re a mobile asphalt repair station engineered to maximize productivity, extend repair life, and reduce the total cost of ownership. For municipalities tasked with doing more with less, that’s a difference you can measure in both road quality and budget impact.
Falcon Asphalt Repair Equipment is the expert in designing patch trucks that deliver complete pothole repair, fast, durable, and cost-effective. Whether you manage a small-town crew or a metro-area fleet, Falcon offers a proven, fully integrated solution built for the demands of real-world road work.
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