Pothole Repair

First, clear the area of dirt and debris, then cut a neat vertical “picture frame” around the pothole using a circular saw. Remove any loose tarmac and seal the edges with a cold jointing spray to improve adhesion. Pour the pothole repair material into the hole and tamp it down firmly. For deeper repairs, apply additional cold joint spray and add another layer of repair material before thoroughly compacting the final surface. Once fully compacted, the repaired pothole is ready for immediate foot or vehicle traffic, providing a fast, durable, and professional finish.

Ultracrete offers three main types of cold-lay tarmac for fast, durable pothole repair: Instant Road Repair (IRR), Permanent Pothole Repair (PPR), and Tough Patch. IRR and PPR are bitumen and solvent-based materials that harden after compaction as the solvent evaporates, gaining strength through stone interlock and curing over time—making them cost-effective options for general repairs. Tough Patch uses a reactive binder activated by water, enabling rapid curing (around one hour) and delivering high skid resistance, scuff resistance, and durability in heavily trafficked or turning areas. Aggregate size determines suitability, with PPR 3 mm and IRR 6 mm ideal for paths, driveways, and light-traffic areas, while IRR 10 mm is better for busy roads and carriageways. For wet weather repairs, specialist wet-grade products like Tough Patch provide reliable performance, helping ensure long-lasting pothole repairs in all conditions.

Typically black or red, in 25kg bags or tubs. Coverage is approx. 1 m² at 12–15mm depth per 25kg unit.

A 25kg tub or bag of Ultracrete Instant Road Repair (IRR), Permanent Pothole Repair (PPR) or Tough Patch will cover an area of approximately 1 metre square, filled at a depth of 12–15mm when fully compacted. This estimate does depend on the surface of the repair and the product - use the calculators on each individual page for an accurate guide.

Generally safe in all weathers, but avoid freezing or extreme heat above 20°C. Use Permanent Pothole Repair or Tough Patch for wet conditions.

If your bag or tub of pothole repair such as IRR 6mm, IRR 10mm, PPR, or Tough Patch has hardened in the bag during storage, it is still good to use. Pothole repair can be softened by applying gentle pressure. Rolling your knee or hand over the edge of the bag works well to loosen the material without tearing the bag. Once softened, the tarmac is ready to use for filling potholes or defects. To help prevent hardening, store bags off the bottom of pallets in a cool, dry environment.

Yes. For a complete, long-lasting repair, it’s recommended to use SCJ Cold Joint Bitumen Spray to prevent water ingress between the old and new surfaces, and Instaband ECO overbanding tape to seal the repair and protect against further damage. These products, when used with Instarmac UltraCrete pothole repair materials like IRR, PPR, or Tough Patch, ensure a durable, professional reinstatement suitable for both light and heavy traffic.

Ultracrete Permanent Pothole Repair and Tough Patch are specially formulated to be applied during wet weather, as they cure through water activation rather than compaction.

When used correctly, cold-lay tarmac products will cure and harden instantly. The benefit of using the HAPAS approved Ultracrete range of products – including Instant Road Repair (IRR), Permanent Pothole Repair (PPR) and Tough Patch – are an instant, first time permanent reinstatement to potholes. When compacted with a tamp or wacker plate, these areas can be trafficked by vehicles and pedestrians immediately.

Different cold-lay tarmac products are available for different sized holes. For example, Instant Road Repair 6mm contains smaller aggregates that can fill holes up to 60mm deep. Typically used on roads and carriageways, Instant Road Repair 10mm includes asphalt repair material with larger aggregates that can fill potholes up to 100mm deep.