Ultracrete Tough Patch Rapid 6mm 25KG Bag: High Skid & Rut Resistance
About the product
UltraCrete Tough Patch Rapid 6mm (25kg Bag) is a PAS-certified, water-cured permanent cold-lay surfacing material (PCSM) for defect repairs, trench reinstatement, utility installations, car parks, driveways and other local repairs. Unlike standard cold-lay asphalt, Tough Patch cures via a water-activated reactive binder — making it suitable for use in all weather conditions, including heavy and persistent rain, and delivering high deformation and rut resistance (PSV 65 min; mean PTV 82) in turning circles, lorry parks and heavily stressed locations.
Instantly trafficable once compacted. Can be cored after 24 hours. Application temperature 5°C to 40°C. Ready to use directly from the bag — no mixing or heating required.
Got a question about Tough Patch? Download the technical datasheet (PDF) or see the pothole repair FAQs. Otherwise get in touch or call 0330 122 1025 — we’re a small, family-run team and always happy to help.
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Ultracrete Tough Patch Rapid 6mm 25KG Bag: High Skid & Rut Resistance
See full delivery info →
For Highlands, Guernsey, Jersey, Isle of Man, and Isle of Wight – call 0330 122 1025.
See full delivery info →
For Highlands, Guernsey, Jersey, Isle of Man, and Isle of Wight – call 0330 122 1025.
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UltraCrete Tough Patch Rapid 6mm — Technical Information
Tough Patch 6mm is a rapid-curing, permanent cold-lay surfacing material (PCSM) using an innovative reactive binder based on renewable materials. The binder contains no solvents and is activated by water prior to compaction. It complies with all test requirements of the revised Specification for Highway Works (SHW) Clause 946 and SROH Fourth Edition 2020. PAS certification reference PA 946 0005, issued by Pavement Testing Services Ltd (PTS Ltd).
In light of the SROH clarification issued 30th May 2025 (NGA2.4), Tough Patch is confirmed as a permitted PCSM for reinstatements within equivalent materials in terms of performance, such as HRA and other bituminous surfaces. The PAS certificate and independent test certificates are available on request — contact us for details.
• Grade: 6mm nominal aggregate
• Curing mechanism: Water-activated reactive binder (not compaction-cured)
• Application: Permanent repairs to footways, footpaths and cycle tracks as a PCSM; temporary/emergency repairs on same surfaces and Class 3 & 4 carriageways
• Depth range: Up to 60mm (layer method)
• Packaging: 25kg foil bag
• Coverage: Approximately 1m² at 12–15mm compacted depth, depending on surface regularity
• Application temperature: 5°C to 40°C
• Weather conditions: All weather, including heavy and persistent rain
• Set time: Instantly trafficable once compacted
• Coring: Can be cored for assessment after 24 hours
• Skid resistance: Minimum PSV 65; mean Corrected Pendulum Test Value (PTV) 82
• Deformation resistance: High deformation and rut resistance; assessed for wheel tracking and permanent deformation; enhanced performance in heavily stressed locations
• Ready to use: No mixing or heating required
• Binder: Innovative reactive binder; renewable materials; solvent free
• Certification: PAS PA 946 0005 — Pavement Testing Services Ltd (PTS Ltd)
• Conformance: SHW Clause 946; SROH Fourth Edition, May 2020
• NBS Source-registered for ease of specification
• UCARS product — UltraCrete Accredited Reinstatement Specification
• Storage: Dry, well-ventilated place; 5°C to 30°C
• Shelf life: 6 months from date of manufacture in sealed units; once opened, use all material
• PPE: Appropriate PPE required during preparation and application. Wash hands before consuming food. Keep out of reach of children and animals. Dispose of packaging responsibly.
• Download the UltraCrete Tough Patch 6mm technical datasheet (PDF)
Technical information courtesy of Instarmac.
How to Apply UltraCrete Tough Patch Rapid 6mm
Tough Patch is ready to use directly from the bag — no mixing or heating required. The curing reaction is activated by water, not compaction alone. Follow the steps below for a permanent, compliant reinstatement.
Permanent Repair
- Saw cut a ‘picture frame’ around the defect or opening to ensure straight, vertical edges that support compaction when material is installed.
- Remove all debris, mud, silt or ice from within the defect.
- Seal the vertical cut edges and base of the defect with UltraCrete SCJ Seal & Tack. This is essential when the substrate is concrete.
- Apply Tough Patch using the layer method (see below), spreading each layer loosely and uniformly using a shovel or rake.
- Before compacting each layer, sprinkle water over the complete surface at approximately 1 litre per 25kg bag — this activates the curing process.
- Mechanically compact the material in accordance with Appendix 8 of the SROH. Ensure the final layer is slightly proud of the surrounding surface before fully compacting.
- Repeat for all layers. If overbanding is required, apply UltraCrete Instaband ECO after compaction.
Layer Installation Method
Tough Patch 6mm is generally installed to a maximum depth of 60mm in accordance with SROH, using the following layer method:
- Apply product to a depth of approximately 45mm and compact to 30mm for the first layer.
- Repeat the process to achieve a total 60mm finished depth.
Emergency and Temporary Repair
For emergency repairs where saw cutting and full preparation cannot be undertaken due to traffic management requirements, Tough Patch can be applied directly to prevent risk to operatives, pedestrians, cyclists and motorists. In such cases the repair may be filled in one application and compacted using a suitable tamping device, or in areas with limited traffic management, traffic can be used to compact. A more permanent solution should be carried out at the earliest opportunity. It is the responsibility of the user to satisfy themselves on the effectiveness of the application.
Storage & Handling
Store in a dry, well-ventilated place at temperatures above 5°C and below 30°C. Shelf life is 6 months from date of manufacture in sealed units. Once opened, all material should be used.
About the product
UltraCrete Tough Patch Rapid 6mm (25kg Bag) is a PAS-certified, water-cured permanent cold-lay surfacing material (PCSM) for defect repairs, trench reinstatement, utility installations, car parks, driveways and other local repairs. Unlike standard cold-lay asphalt, Tough Patch cures via a water-activated reactive binder — making it suitable for use in all weather conditions, including heavy and persistent rain, and delivering high deformation and rut resistance (PSV 65 min; mean PTV 82) in turning circles, lorry parks and heavily stressed locations.
Instantly trafficable once compacted. Can be cored after 24 hours. Application temperature 5°C to 40°C. Ready to use directly from the bag — no mixing or heating required.
Got a question about Tough Patch? Download the technical datasheet (PDF) or see the pothole repair FAQs. Otherwise get in touch or call 0330 122 1025 — we’re a small, family-run team and always happy to help.
UltraCrete Tough Patch® Rapid 6mm is one of the most durable permanent cold-lay surfacing materials available in the UK — and it’s the product contractors consistently reach for when standard cold-lay asphalt isn’t enough. Where other materials require dry conditions or struggle with turning circles, lorry parks and heavy braking zones, Tough Patch delivers a first-time permanent repair that’s instantly trafficable, fully water-cured, and built for the most demanding applications on the network.
PAS certified (PA 946 0005). Water-cured — not compaction-cured. Depth range up to 60mm (layer method). Instantly trafficable once compacted. Use in all weather conditions including heavy rain. Application temperature: 5°C to 40°C. SROH Fourth Edition 2020 compliant. NBS Source-registered. UCARS product.
We’re a small, family-run business — I’m Cleo, the owner, with over 25 years in the construction industry working with businesses including Tarmac and Instarmac. I work alongside a team of incredibly knowledgeable and caring individuals, and we’ve supplied UltraCrete products to local authorities, civil contractors and highways teams across the UK. If you need technical support or help with specification, we’re always happy to help.
Need standard black cold-lay for footways or cycle tracks? See IRR 6mm or IRR 6mm bag. Need the 10mm grade for Type 3 & 4 carriageways? Contact us or call 0330 122 1025. Prefer a tub format? See Tough Patch Rapid 25kg Tub. Buying a full pallet? See our 56-bag pallet deal with free delivery.
What is UltraCrete Tough Patch Rapid 6mm?
Tough Patch 6mm is a rapid-curing, permanent cold-lay surfacing material (PCSM) suitable for defect repairs, trench reinstatement, utility installations, patching in car parks, driveways and other local repairs. It is ideally suited for use on bituminous/asphalt and cementitious paving and road substrates.
Unlike standard cold-lay asphalt which is compaction-cured, Tough Patch uses an innovative reactive binder that is activated by sprinkling water over the product before compacting. This water-activated curing reaction rapidly produces a first-time permanent repair that is instantly trafficable, can be used in all weather conditions — including heavy rain — and can be cored for assessment after 24 hours. The binder is based on renewable materials and contains no solvents.
Tough Patch 6mm can also be used for emergency or temporary repairs where a rapid response is required to prevent risk to operatives, pedestrians, cyclists and motorists.
Technical information courtesy of Instarmac.
Proven Results: Kier Records 82% Reduction in Repeat Visits
Leading UK construction and infrastructure services company Kier had identified a problem: data from April 2019 to January 2020 showed 98 instances across 17 routes where a repeat visit had been made to repair the same site. After working closely with UltraCrete and standardising their repair process around Tough Patch®, Kier recorded an 82% reduction in repeat visits to the same repair site.
Of the original 98 instances requiring a return visit, only 21 sites were revisited after switching to Tough Patch between February and April 2020. UltraCrete’s technical team worked directly with Kier’s crews across multiple depots — reviewing processes, addressing inconsistencies, and demonstrating correct application technique — to maximise the effectiveness of the material.
Having one superior cold-lay surfacing material and a standardised application process delivered a significant, measurable reduction in network interventions.
“Tough Patch flows easily, doesn’t go hard in the bags and is not weather dependent. It appears to compact better and cures harder.”
— Stuart, Rowan Ashworth Ltd
SROH Clarification — May 2025
In light of the SROH clarification issued 30th May 2025 (NGA2.4 Cold Lay Surfacing Material), Instarmac are proud to confirm that Tough Patch remains a permitted PCSM for all reinstatements within equivalent materials in terms of performance, such as HRA and other bituminous surfaces. Detailed evidence demonstrating Tough Patch’s in-life durability as equivalent to HRA and other bituminous surfaces can be found on the PAS certificate, which is available to download. Independent test certificates are also available upon request — contact our team or call 0330 122 1025.
When Should I Use Tough Patch Instead of Standard IRR?
Tough Patch and the standard IRR range are both permanent cold-lay materials, but they are designed for different conditions and applications. The key distinction is the curing mechanism and performance specification.
| Tough Patch 6mm | IRR 6mm | |
|---|---|---|
| Curing mechanism | Water-activated reactive binder | Compaction-cured |
| Heavy/persistent rain | Yes — designed for wet conditions | Light rain only |
| Skid resistance | PSV 65 min; mean PTV 82 | PSV 65 |
| Turning circles & lorry parks | Recommended | Not recommended |
| Application temperature | 5°C to 40°C | All weathers (standard) |
| Max depth (layer method) | 60mm | 100mm |
| Coring | After 24 hours | N/A |
| Certification | PAS (PA 946 0005) | BBA/HAPAS since 2002 |
| Primary application | High-stress, wet weather, turning zones | Footways, cycle tracks, car parks |
Choose Tough Patch if: you’re working in heavy or persistent rain, the surface is a turning circle, lorry park or bus lane subject to braking loads, or you need the highest available deformation and rut resistance.
Choose IRR 6mm if: you’re repairing a footway, footpath or cycle track in normal conditions and the surface is not subject to extreme trafficking loads.
Not sure? Call us on 0330 122 1025 and we’ll advise on the right product for your specification.
What Surfaces is Tough Patch 6mm Designed For?
The 6mm grade is certified as a permanent repair to footways, footpaths and cycle tracks as a PCSM. It can also be used as a temporary or emergency repair on the same applications, and as a temporary or emergency repair on Class 3 and 4 carriageways.
Typical applications include:
- Defect repairs and patching in footways, footpaths and cycle tracks
- Trench reinstatement and utility installations
- Car parks and driveways, including turning circles and lorry parks
- Bus lanes and high-braking zones
- Emergency and reactive repairs on Class 3 & 4 carriageways
- Any application where wet weather working or maximum rut resistance is required
The 10mm grade is available for first-time permanent repairs in Type 3 & 4 carriageways — contact us or call 0330 122 1025 to order.
Complete Reinstatement System
- UltraCrete SCJ Seal and Tack Spray — applied to vertical cut edges and base of defect before applying Tough Patch; essential when substrate is concrete
- UltraCrete Tough Patch Rapid 6mm — applied in layers with water activation before each compaction pass
- UltraCrete Instaband ECO — overbanding sealant applied if required after compaction
Key Features
- Water-cured reactive binder — activated by sprinkling water before compaction; performs in all weather including heavy rain
- PAS certified — PA 946 0005, Pavement Testing Services Ltd; complies with SHW Clause 946 and SROH Fourth Edition 2020
- Instantly trafficable — open to all traffic immediately once compacted
- High deformation and rut resistance — PSV 65 minimum, mean PTV 82; designed for turning circles, lorry parks, bus lanes and high-stress braking zones
- Application temperature 5°C to 40°C — wider range than standard cold-lay materials
- Can be cored after 24 hours — for assessment and compliance purposes
- Renewable binder materials — solvent free, no dangerous fumes
- Ready to use — no mixing or heating; apply direct from the bag
- Emergency repair capable — can be applied without saw cutting in reactive maintenance situations
- SROH 2020 compliant — satisfactory for use as a PCSM in accordance with SROH Fourth Edition, May 2020
- NBS Source-registered — for ease of specification
- UCARS product — UltraCrete Accredited Reinstatement Specification
For technical support, bulk pricing, PAS certificates, or help with specification, contact our team or call 0330 122 1025 — we’re a small, family-run business and always happy to help.
UltraCrete Tough Patch Rapid 6mm FAQs
I’m Cleo, owner of The Paving Experts, with over 25 years in the construction industry working with businesses including Tarmac and Instarmac. I work alongside a small team of incredibly knowledgeable and caring individuals who share the same passion for getting it right. The FAQ answers below come from the questions we’re asked every single day.
What is UltraCrete Tough Patch 6mm?
UltraCrete Tough Patch 6mm is a rapid-curing, permanent cold-lay surfacing material (PCSM) designed for defect repairs, potholes, trench reinstatement, utility installations, car parks, driveways and other local repairs.
What can Tough Patch 6mm be used for?
Tough Patch 6mm is suitable for repairs to bituminous/asphalt and cementitious paving and road substrates. It can be used for footpaths, footways, cycle tracks, driveways, car parks and localised surface repairs.
Is Tough Patch 6mm a permanent repair material?
Yes. Tough Patch 6mm is designed to provide first-time permanent repairs, as well as emergency and temporary repairs where required.
Can Tough Patch 6mm be used in wet weather?
Yes. Tough Patch 6mm can be used in all weather conditions, making it suitable for repairs where conventional weather restrictions can be a problem. Because the curing reaction is water-activated, wet conditions assist rather than hinder the cure.
How quickly does Tough Patch 6mm cure?
Tough Patch uses an innovative reactive binder that rapidly cures on contact with water. The repaired area is instantly trafficable after installation, and the material can be cored after 24 hours.
Can traffic use Tough Patch 6mm immediately after installation?
Yes. Tough Patch 6mm is instantly trafficable once the repair has been correctly installed and compacted.
Is Tough Patch 6mm suitable for pothole repairs?
Yes — it is specifically designed for defect repairs and potholes, as well as trench reinstatements and other local repairs. Its water-cured binder and high rut resistance make it particularly well suited to high-stress locations such as junctions, turning circles and bus lanes.
Is Tough Patch 6mm resistant to rutting?
Yes. Tough Patch 6mm has high deformation and rut resistance. It has been assessed for wheel tracking and permanent deformation, and has demonstrated enhanced performance in heavily stressed locations requiring high rut resistance.
Is Tough Patch 6mm suitable for areas with heavy traffic?
Yes. Tough Patch has been assessed for wheel tracking and permanent deformation and has demonstrated enhanced performance in heavily stressed locations requiring high rut resistance — including turning circles, lorry parks and bus lanes.
Is Tough Patch 6mm skid resistant?
Yes. Tough Patch 6mm is skid resistant, with a minimum Polished Stone Value (PSV) of 65 and a mean Corrected Pendulum Test Value (PTV) of 82.
What size aggregate does Tough Patch 6mm contain?
Tough Patch 6mm uses a nominal 6mm aggregate grade.
How deep can Tough Patch 6mm be installed?
For paving applications, Tough Patch 6mm is generally installed to a maximum finished depth of 60mm in accordance with SROH, using a layered installation method: apply to 45mm and compact to 30mm for the first layer, then repeat to achieve the 60mm finished depth.
How is Tough Patch 6mm supplied?
Tough Patch 6mm is supplied in 25kg foil bags and 25kg buckets. This page is for the 25kg bag. See the 25kg tub if you prefer the bucket format.
Does Tough Patch 6mm require a special binder or heating?
No heating is required. Tough Patch uses an innovative reactive binder that allows the material to rapidly cure as a cold-lay surfacing material. Simply sprinkle approximately 1 litre of water per 25kg bag over each layer before compacting.
Is Tough Patch 6mm PAS certified?
Yes. Tough Patch 6mm is certified through the Product Assessment Scheme (PAS), reference PA 946 0005, issued by Pavement Testing Services Ltd. It is also a UCARS (UltraCrete Accredited Reinstatement Specification) product.
What makes Tough Patch different from standard IRR cold-lay?
The key difference is the curing mechanism. Standard IRR is compaction-cured. Tough Patch uses a water-activated reactive binder — you sprinkle water over each layer before compacting, which triggers the curing reaction. This means Tough Patch performs in heavy rain, and delivers higher deformation and rut resistance, making it the right choice for turning circles, lorry parks and high-stress braking zones.
What is the SROH May 2025 clarification and does it affect Tough Patch?
The SROH clarification issued 30th May 2025 (NGA2.4) confirmed requirements for cold-lay surfacing materials used as equivalent to HRA and other bituminous surfaces. Instarmac confirm that Tough Patch remains a permitted PCSM for these reinstatements. Detailed evidence of in-life durability equivalent to HRA is available on the PAS certificate. Independent test certificates are also available — contact us to request them.
Is Tough Patch certified — does it have HAPAS approval?
Tough Patch is certified through the Product Assessment Scheme (PAS), not HAPAS. PAS certification reference PA 946 0005, issued by Pavement Testing Services Ltd (PTS Ltd). It complies with all test requirements of the revised Specification for Highway Works (SHW) Clause 946 and SROH Fourth Edition 2020.
What surfaces is Tough Patch 6mm certified for?
The 6mm grade is certified as a permanent repair to footways, footpaths and cycle tracks as a PCSM. It can also be used as a temporary or emergency repair on the same surfaces and on Class 3 & 4 carriageways. For first-time permanent repairs on Type 3 & 4 carriageways, the 10mm grade is required — contact us to order.
Can I use Tough Patch for an emergency repair without saw cutting?
Yes — in emergency or reactive maintenance situations where saw cutting and full preparation are not possible, Tough Patch can be applied directly. The repair may be filled in one application and compacted using a tamping device, or traffic can be used to compact in areas with limited traffic management. The user is responsible for satisfying themselves on the effectiveness of the application, with a more permanent solution to follow.
Is a 10mm grade available?
Yes — Tough Patch 10mm is available to order for first-time permanent repairs in Type 3 & 4 carriageways. Contact us or call 0330 122 1025.
Is a pallet deal available?
Yes — see our 56-bag pallet deal with free standard delivery. Bulk pricing on 32+ bags (5% off) and 56+ bags (10% off) — call 0330 122 1025.
Technical information courtesy of Instarmac.
For technical support, PAS certificates, specification help, or further information, contact our team or call 0330 122 1025.
- Brand: Instarmac
- Product Type: Pothole Repair
- SKU: TPE-TOUPATBAG
- Weight: 25.0 kg / 55.12 lb
Delivery & Returns Info
Our delivery charges are calculated based on the size and weight of your order. When you add items to your basket, the delivery charges are displayed. Small orders are distributed via courier; larger orders via Pallet Network. Collection is available from our Tamworth depot by request (contact us first to arrange on 0330 122 1025).
Please note, there is a slight surcharge for areas that are outside of our locality, charges calculated at checkout.
| Weight and size | Next Working Day* Order before 1PM (excl. VAT) |
Standard 3-5 Working Day (excl. VAT) |
|---|---|---|
| 0-13KG (1 small bag/tub) |
£14.00 | £9.00 |
| 13.01-25KG (1 large bag/tub) |
£16.00 | £10.00 |
| 25.01-50KG (2 bags/tubs) |
£26.00 | £19.00 |
| 50.01-75KG (3 bags/tubs) |
£36.00 | £28.00 |
| 75.01-100KG (4-5 bags/tubs) |
£46.00 | £37.00 |
| 100.01-249KG (6-9 bags/tubs) |
£60.00 | £45.00 |
| 249.01-750KG (10 bags plus) |
£68.00 | £48.00 |
| 750.01KG plus (30 bags plus) |
£75.00 | £55.00 |
| Full Pallets (56 bags/52 tubs) |
£88.00 | Free of charge |
| Next Working Day delivery (Premium 1-2 Working Day Service) | +avg. £5-10 Extra. Click here for prices |
|---|---|
| Scotland Delivery Service (Deliveries into some parts of Scotland can take 8-10 working days) | Click here for prices |
| Local Delivery & Click & Collect: | Email: orders@thepavingexperts.co.uk |
Delivery Information
- Prices apply to mainland England and Wales. Scottish delivery slight surcharge.
- Orders are packed and dispatched Monday–Friday (excluding weekends & public holidays).
Next Working Day Delivery
- Order before 1PM → same-day dispatch.
- Order after 1PM or on weekends/bank holidays → next working day dispatch.
- You'll receive tracking updates via email/SMS if you provide your details.
Delivery Examples
- Mon before 1PM → Packed Mon, delivered Tue.
- Mon after 1PM → Packed Tues delivered Wed.
- Fri before 1PM → Packed Fri, delivered Mon.
- Fri after 1PM/weekend → Packed Mon, delivered Tues (or Wed after a bank holiday).
- Standard Service: 3–5 working days.
Notes
- Occasional delays due to manufacturing, supply, or courier issues may happen, but we'll keep you informed.
Returns, cancel up to 14 days from date of delivery. Product to be returned in the same condition & packaging. No returns for cementitious & perishable products. You are responsible for the cost of returning goods to The Paving Experts, 20% admin restock fee applies. Need further info, click here.
For further detailed delivery information click here →
For any advice; technical, product, stock or quantity needed, call our team on 0330 122 1025.
Please see our FAQs for more information.
UltraCrete Tough Patch® Rapid 6mm is one of the most durable permanent cold-lay surfacing materials available in the UK — and it’s the product contractors consistently reach for when standard cold-lay asphalt isn’t enough. Where other materials require dry conditions or struggle with turning circles, lorry parks and heavy braking zones, Tough Patch delivers a first-time permanent repair that’s instantly trafficable, fully water-cured, and built for the most demanding applications on the network.
PAS certified (PA 946 0005). Water-cured — not compaction-cured. Depth range up to 60mm (layer method). Instantly trafficable once compacted. Use in all weather conditions including heavy rain. Application temperature: 5°C to 40°C. SROH Fourth Edition 2020 compliant. NBS Source-registered. UCARS product.
We’re a small, family-run business — I’m Cleo, the owner, with over 25 years in the construction industry working with businesses including Tarmac and Instarmac. I work alongside a team of incredibly knowledgeable and caring individuals, and we’ve supplied UltraCrete products to local authorities, civil contractors and highways teams across the UK. If you need technical support or help with specification, we’re always happy to help.
Need standard black cold-lay for footways or cycle tracks? See IRR 6mm or IRR 6mm bag. Need the 10mm grade for Type 3 & 4 carriageways? Contact us or call 0330 122 1025. Prefer a tub format? See Tough Patch Rapid 25kg Tub. Buying a full pallet? See our 56-bag pallet deal with free delivery.
What is UltraCrete Tough Patch Rapid 6mm?
Tough Patch 6mm is a rapid-curing, permanent cold-lay surfacing material (PCSM) suitable for defect repairs, trench reinstatement, utility installations, patching in car parks, driveways and other local repairs. It is ideally suited for use on bituminous/asphalt and cementitious paving and road substrates.
Unlike standard cold-lay asphalt which is compaction-cured, Tough Patch uses an innovative reactive binder that is activated by sprinkling water over the product before compacting. This water-activated curing reaction rapidly produces a first-time permanent repair that is instantly trafficable, can be used in all weather conditions — including heavy rain — and can be cored for assessment after 24 hours. The binder is based on renewable materials and contains no solvents.
Tough Patch 6mm can also be used for emergency or temporary repairs where a rapid response is required to prevent risk to operatives, pedestrians, cyclists and motorists.
Technical information courtesy of Instarmac.
Proven Results: Kier Records 82% Reduction in Repeat Visits
Leading UK construction and infrastructure services company Kier had identified a problem: data from April 2019 to January 2020 showed 98 instances across 17 routes where a repeat visit had been made to repair the same site. After working closely with UltraCrete and standardising their repair process around Tough Patch®, Kier recorded an 82% reduction in repeat visits to the same repair site.
Of the original 98 instances requiring a return visit, only 21 sites were revisited after switching to Tough Patch between February and April 2020. UltraCrete’s technical team worked directly with Kier’s crews across multiple depots — reviewing processes, addressing inconsistencies, and demonstrating correct application technique — to maximise the effectiveness of the material.
Having one superior cold-lay surfacing material and a standardised application process delivered a significant, measurable reduction in network interventions.
“Tough Patch flows easily, doesn’t go hard in the bags and is not weather dependent. It appears to compact better and cures harder.”
— Stuart, Rowan Ashworth Ltd
SROH Clarification — May 2025
In light of the SROH clarification issued 30th May 2025 (NGA2.4 Cold Lay Surfacing Material), Instarmac are proud to confirm that Tough Patch remains a permitted PCSM for all reinstatements within equivalent materials in terms of performance, such as HRA and other bituminous surfaces. Detailed evidence demonstrating Tough Patch’s in-life durability as equivalent to HRA and other bituminous surfaces can be found on the PAS certificate, which is available to download. Independent test certificates are also available upon request — contact our team or call 0330 122 1025.
When Should I Use Tough Patch Instead of Standard IRR?
Tough Patch and the standard IRR range are both permanent cold-lay materials, but they are designed for different conditions and applications. The key distinction is the curing mechanism and performance specification.
| Tough Patch 6mm | IRR 6mm | |
|---|---|---|
| Curing mechanism | Water-activated reactive binder | Compaction-cured |
| Heavy/persistent rain | Yes — designed for wet conditions | Light rain only |
| Skid resistance | PSV 65 min; mean PTV 82 | PSV 65 |
| Turning circles & lorry parks | Recommended | Not recommended |
| Application temperature | 5°C to 40°C | All weathers (standard) |
| Max depth (layer method) | 60mm | 100mm |
| Coring | After 24 hours | N/A |
| Certification | PAS (PA 946 0005) | BBA/HAPAS since 2002 |
| Primary application | High-stress, wet weather, turning zones | Footways, cycle tracks, car parks |
Choose Tough Patch if: you’re working in heavy or persistent rain, the surface is a turning circle, lorry park or bus lane subject to braking loads, or you need the highest available deformation and rut resistance.
Choose IRR 6mm if: you’re repairing a footway, footpath or cycle track in normal conditions and the surface is not subject to extreme trafficking loads.
Not sure? Call us on 0330 122 1025 and we’ll advise on the right product for your specification.
What Surfaces is Tough Patch 6mm Designed For?
The 6mm grade is certified as a permanent repair to footways, footpaths and cycle tracks as a PCSM. It can also be used as a temporary or emergency repair on the same applications, and as a temporary or emergency repair on Class 3 and 4 carriageways.
Typical applications include:
- Defect repairs and patching in footways, footpaths and cycle tracks
- Trench reinstatement and utility installations
- Car parks and driveways, including turning circles and lorry parks
- Bus lanes and high-braking zones
- Emergency and reactive repairs on Class 3 & 4 carriageways
- Any application where wet weather working or maximum rut resistance is required
The 10mm grade is available for first-time permanent repairs in Type 3 & 4 carriageways — contact us or call 0330 122 1025 to order.
Complete Reinstatement System
- UltraCrete SCJ Seal and Tack Spray — applied to vertical cut edges and base of defect before applying Tough Patch; essential when substrate is concrete
- UltraCrete Tough Patch Rapid 6mm — applied in layers with water activation before each compaction pass
- UltraCrete Instaband ECO — overbanding sealant applied if required after compaction
Key Features
- Water-cured reactive binder — activated by sprinkling water before compaction; performs in all weather including heavy rain
- PAS certified — PA 946 0005, Pavement Testing Services Ltd; complies with SHW Clause 946 and SROH Fourth Edition 2020
- Instantly trafficable — open to all traffic immediately once compacted
- High deformation and rut resistance — PSV 65 minimum, mean PTV 82; designed for turning circles, lorry parks, bus lanes and high-stress braking zones
- Application temperature 5°C to 40°C — wider range than standard cold-lay materials
- Can be cored after 24 hours — for assessment and compliance purposes
- Renewable binder materials — solvent free, no dangerous fumes
- Ready to use — no mixing or heating; apply direct from the bag
- Emergency repair capable — can be applied without saw cutting in reactive maintenance situations
- SROH 2020 compliant — satisfactory for use as a PCSM in accordance with SROH Fourth Edition, May 2020
- NBS Source-registered — for ease of specification
- UCARS product — UltraCrete Accredited Reinstatement Specification
For technical support, bulk pricing, PAS certificates, or help with specification, contact our team or call 0330 122 1025 — we’re a small, family-run business and always happy to help.
UltraCrete Tough Patch Rapid 6mm FAQs
I’m Cleo, owner of The Paving Experts, with over 25 years in the construction industry working with businesses including Tarmac and Instarmac. I work alongside a small team of incredibly knowledgeable and caring individuals who share the same passion for getting it right. The FAQ answers below come from the questions we’re asked every single day.
What is UltraCrete Tough Patch 6mm?
UltraCrete Tough Patch 6mm is a rapid-curing, permanent cold-lay surfacing material (PCSM) designed for defect repairs, potholes, trench reinstatement, utility installations, car parks, driveways and other local repairs.
What can Tough Patch 6mm be used for?
Tough Patch 6mm is suitable for repairs to bituminous/asphalt and cementitious paving and road substrates. It can be used for footpaths, footways, cycle tracks, driveways, car parks and localised surface repairs.
Is Tough Patch 6mm a permanent repair material?
Yes. Tough Patch 6mm is designed to provide first-time permanent repairs, as well as emergency and temporary repairs where required.
Can Tough Patch 6mm be used in wet weather?
Yes. Tough Patch 6mm can be used in all weather conditions, making it suitable for repairs where conventional weather restrictions can be a problem. Because the curing reaction is water-activated, wet conditions assist rather than hinder the cure.
How quickly does Tough Patch 6mm cure?
Tough Patch uses an innovative reactive binder that rapidly cures on contact with water. The repaired area is instantly trafficable after installation, and the material can be cored after 24 hours.
Can traffic use Tough Patch 6mm immediately after installation?
Yes. Tough Patch 6mm is instantly trafficable once the repair has been correctly installed and compacted.
Is Tough Patch 6mm suitable for pothole repairs?
Yes — it is specifically designed for defect repairs and potholes, as well as trench reinstatements and other local repairs. Its water-cured binder and high rut resistance make it particularly well suited to high-stress locations such as junctions, turning circles and bus lanes.
Is Tough Patch 6mm resistant to rutting?
Yes. Tough Patch 6mm has high deformation and rut resistance. It has been assessed for wheel tracking and permanent deformation, and has demonstrated enhanced performance in heavily stressed locations requiring high rut resistance.
Is Tough Patch 6mm suitable for areas with heavy traffic?
Yes. Tough Patch has been assessed for wheel tracking and permanent deformation and has demonstrated enhanced performance in heavily stressed locations requiring high rut resistance — including turning circles, lorry parks and bus lanes.
Is Tough Patch 6mm skid resistant?
Yes. Tough Patch 6mm is skid resistant, with a minimum Polished Stone Value (PSV) of 65 and a mean Corrected Pendulum Test Value (PTV) of 82.
What size aggregate does Tough Patch 6mm contain?
Tough Patch 6mm uses a nominal 6mm aggregate grade.
How deep can Tough Patch 6mm be installed?
For paving applications, Tough Patch 6mm is generally installed to a maximum finished depth of 60mm in accordance with SROH, using a layered installation method: apply to 45mm and compact to 30mm for the first layer, then repeat to achieve the 60mm finished depth.
How is Tough Patch 6mm supplied?
Tough Patch 6mm is supplied in 25kg foil bags and 25kg buckets. This page is for the 25kg bag. See the 25kg tub if you prefer the bucket format.
Does Tough Patch 6mm require a special binder or heating?
No heating is required. Tough Patch uses an innovative reactive binder that allows the material to rapidly cure as a cold-lay surfacing material. Simply sprinkle approximately 1 litre of water per 25kg bag over each layer before compacting.
Is Tough Patch 6mm PAS certified?
Yes. Tough Patch 6mm is certified through the Product Assessment Scheme (PAS), reference PA 946 0005, issued by Pavement Testing Services Ltd. It is also a UCARS (UltraCrete Accredited Reinstatement Specification) product.
What makes Tough Patch different from standard IRR cold-lay?
The key difference is the curing mechanism. Standard IRR is compaction-cured. Tough Patch uses a water-activated reactive binder — you sprinkle water over each layer before compacting, which triggers the curing reaction. This means Tough Patch performs in heavy rain, and delivers higher deformation and rut resistance, making it the right choice for turning circles, lorry parks and high-stress braking zones.
What is the SROH May 2025 clarification and does it affect Tough Patch?
The SROH clarification issued 30th May 2025 (NGA2.4) confirmed requirements for cold-lay surfacing materials used as equivalent to HRA and other bituminous surfaces. Instarmac confirm that Tough Patch remains a permitted PCSM for these reinstatements. Detailed evidence of in-life durability equivalent to HRA is available on the PAS certificate. Independent test certificates are also available — contact us to request them.
Is Tough Patch certified — does it have HAPAS approval?
Tough Patch is certified through the Product Assessment Scheme (PAS), not HAPAS. PAS certification reference PA 946 0005, issued by Pavement Testing Services Ltd (PTS Ltd). It complies with all test requirements of the revised Specification for Highway Works (SHW) Clause 946 and SROH Fourth Edition 2020.
What surfaces is Tough Patch 6mm certified for?
The 6mm grade is certified as a permanent repair to footways, footpaths and cycle tracks as a PCSM. It can also be used as a temporary or emergency repair on the same surfaces and on Class 3 & 4 carriageways. For first-time permanent repairs on Type 3 & 4 carriageways, the 10mm grade is required — contact us to order.
Can I use Tough Patch for an emergency repair without saw cutting?
Yes — in emergency or reactive maintenance situations where saw cutting and full preparation are not possible, Tough Patch can be applied directly. The repair may be filled in one application and compacted using a tamping device, or traffic can be used to compact in areas with limited traffic management. The user is responsible for satisfying themselves on the effectiveness of the application, with a more permanent solution to follow.
Is a 10mm grade available?
Yes — Tough Patch 10mm is available to order for first-time permanent repairs in Type 3 & 4 carriageways. Contact us or call 0330 122 1025.
Is a pallet deal available?
Yes — see our 56-bag pallet deal with free standard delivery. Bulk pricing on 32+ bags (5% off) and 56+ bags (10% off) — call 0330 122 1025.
Technical information courtesy of Instarmac.
For technical support, PAS certificates, specification help, or further information, contact our team or call 0330 122 1025.
UltraCrete Tough Patch Rapid 6mm — Technical Information
Tough Patch 6mm is a rapid-curing, permanent cold-lay surfacing material (PCSM) using an innovative reactive binder based on renewable materials. The binder contains no solvents and is activated by water prior to compaction. It complies with all test requirements of the revised Specification for Highway Works (SHW) Clause 946 and SROH Fourth Edition 2020. PAS certification reference PA 946 0005, issued by Pavement Testing Services Ltd (PTS Ltd).
In light of the SROH clarification issued 30th May 2025 (NGA2.4), Tough Patch is confirmed as a permitted PCSM for reinstatements within equivalent materials in terms of performance, such as HRA and other bituminous surfaces. The PAS certificate and independent test certificates are available on request — contact us for details.
• Grade: 6mm nominal aggregate
• Curing mechanism: Water-activated reactive binder (not compaction-cured)
• Application: Permanent repairs to footways, footpaths and cycle tracks as a PCSM; temporary/emergency repairs on same surfaces and Class 3 & 4 carriageways
• Depth range: Up to 60mm (layer method)
• Packaging: 25kg foil bag
• Coverage: Approximately 1m² at 12–15mm compacted depth, depending on surface regularity
• Application temperature: 5°C to 40°C
• Weather conditions: All weather, including heavy and persistent rain
• Set time: Instantly trafficable once compacted
• Coring: Can be cored for assessment after 24 hours
• Skid resistance: Minimum PSV 65; mean Corrected Pendulum Test Value (PTV) 82
• Deformation resistance: High deformation and rut resistance; assessed for wheel tracking and permanent deformation; enhanced performance in heavily stressed locations
• Ready to use: No mixing or heating required
• Binder: Innovative reactive binder; renewable materials; solvent free
• Certification: PAS PA 946 0005 — Pavement Testing Services Ltd (PTS Ltd)
• Conformance: SHW Clause 946; SROH Fourth Edition, May 2020
• NBS Source-registered for ease of specification
• UCARS product — UltraCrete Accredited Reinstatement Specification
• Storage: Dry, well-ventilated place; 5°C to 30°C
• Shelf life: 6 months from date of manufacture in sealed units; once opened, use all material
• PPE: Appropriate PPE required during preparation and application. Wash hands before consuming food. Keep out of reach of children and animals. Dispose of packaging responsibly.
• Download the UltraCrete Tough Patch 6mm technical datasheet (PDF)
Technical information courtesy of Instarmac.
How to Apply UltraCrete Tough Patch Rapid 6mm
Tough Patch is ready to use directly from the bag — no mixing or heating required. The curing reaction is activated by water, not compaction alone. Follow the steps below for a permanent, compliant reinstatement.
Permanent Repair
- Saw cut a ‘picture frame’ around the defect or opening to ensure straight, vertical edges that support compaction when material is installed.
- Remove all debris, mud, silt or ice from within the defect.
- Seal the vertical cut edges and base of the defect with UltraCrete SCJ Seal & Tack. This is essential when the substrate is concrete.
- Apply Tough Patch using the layer method (see below), spreading each layer loosely and uniformly using a shovel or rake.
- Before compacting each layer, sprinkle water over the complete surface at approximately 1 litre per 25kg bag — this activates the curing process.
- Mechanically compact the material in accordance with Appendix 8 of the SROH. Ensure the final layer is slightly proud of the surrounding surface before fully compacting.
- Repeat for all layers. If overbanding is required, apply UltraCrete Instaband ECO after compaction.
Layer Installation Method
Tough Patch 6mm is generally installed to a maximum depth of 60mm in accordance with SROH, using the following layer method:
- Apply product to a depth of approximately 45mm and compact to 30mm for the first layer.
- Repeat the process to achieve a total 60mm finished depth.
Emergency and Temporary Repair
For emergency repairs where saw cutting and full preparation cannot be undertaken due to traffic management requirements, Tough Patch can be applied directly to prevent risk to operatives, pedestrians, cyclists and motorists. In such cases the repair may be filled in one application and compacted using a suitable tamping device, or in areas with limited traffic management, traffic can be used to compact. A more permanent solution should be carried out at the earliest opportunity. It is the responsibility of the user to satisfy themselves on the effectiveness of the application.
Storage & Handling
Store in a dry, well-ventilated place at temperatures above 5°C and below 30°C. Shelf life is 6 months from date of manufacture in sealed units. Once opened, all material should be used.
Delivery & Returns Info
Our delivery charges are calculated based on the size and weight of your order. When you add items to your basket, the delivery charges are displayed. Small orders are distributed via courier; larger orders via Pallet Network. Collection is available from our Tamworth depot by request (contact us first to arrange on 0330 122 1025).
Please note, there is a slight surcharge for areas that are outside of our locality, charges calculated at checkout.
| Weight and size | Next Working Day* Order before 1PM (excl. VAT) |
Standard 3-5 Working Day (excl. VAT) |
|---|---|---|
| 0-13KG (1 small bag/tub) |
£14.00 | £9.00 |
| 13.01-25KG (1 large bag/tub) |
£16.00 | £10.00 |
| 25.01-50KG (2 bags/tubs) |
£26.00 | £19.00 |
| 50.01-75KG (3 bags/tubs) |
£36.00 | £28.00 |
| 75.01-100KG (4-5 bags/tubs) |
£46.00 | £37.00 |
| 100.01-249KG (6-9 bags/tubs) |
£60.00 | £45.00 |
| 249.01-750KG (10 bags plus) |
£68.00 | £48.00 |
| 750.01KG plus (30 bags plus) |
£75.00 | £55.00 |
| Full Pallets (56 bags/52 tubs) |
£88.00 | Free of charge |
| Next Working Day delivery (Premium 1-2 Working Day Service) | +avg. £5-10 Extra. Click here for prices |
|---|---|
| Scotland Delivery Service (Deliveries into some parts of Scotland can take 8-10 working days) | Click here for prices |
| Local Delivery & Click & Collect: | Email: orders@thepavingexperts.co.uk |
Delivery Information
- Prices apply to mainland England and Wales. Scottish delivery slight surcharge.
- Orders are packed and dispatched Monday–Friday (excluding weekends & public holidays).
Next Working Day Delivery
- Order before 1PM → same-day dispatch.
- Order after 1PM or on weekends/bank holidays → next working day dispatch.
- You'll receive tracking updates via email/SMS if you provide your details.
Delivery Examples
- Mon before 1PM → Packed Mon, delivered Tue.
- Mon after 1PM → Packed Tues delivered Wed.
- Fri before 1PM → Packed Fri, delivered Mon.
- Fri after 1PM/weekend → Packed Mon, delivered Tues (or Wed after a bank holiday).
- Standard Service: 3–5 working days.
Notes
- Occasional delays due to manufacturing, supply, or courier issues may happen, but we'll keep you informed.
Returns, cancel up to 14 days from date of delivery. Product to be returned in the same condition & packaging. No returns for cementitious & perishable products. You are responsible for the cost of returning goods to The Paving Experts, 20% admin restock fee applies. Need further info, click here.
For further detailed delivery information click here →
UltraCrete Tough Patch® Rapid 6mm is one of the most durable permanent cold-lay surfacing materials available in the UK — and it’s the product contractors consistently reach for when standard cold-lay asphalt isn’t enough. Where other materials require dry conditions or struggle with turning circles, lorry parks and heavy braking zones, Tough Patch delivers a first-time permanent repair that’s instantly trafficable, fully water-cured, and built for the most demanding applications on the network.
PAS certified (PA 946 0005). Water-cured — not compaction-cured. Depth range up to 60mm (layer method). Instantly trafficable once compacted. Use in all weather conditions including heavy rain. Application temperature: 5°C to 40°C. SROH Fourth Edition 2020 compliant. NBS Source-registered. UCARS product.
We’re a small, family-run business — I’m Cleo, the owner, with over 25 years in the construction industry working with businesses including Tarmac and Instarmac. I work alongside a team of incredibly knowledgeable and caring individuals, and we’ve supplied UltraCrete products to local authorities, civil contractors and highways teams across the UK. If you need technical support or help with specification, we’re always happy to help.
Need standard black cold-lay for footways or cycle tracks? See IRR 6mm or IRR 6mm bag. Need the 10mm grade for Type 3 & 4 carriageways? Contact us or call 0330 122 1025. Prefer a tub format? See Tough Patch Rapid 25kg Tub. Buying a full pallet? See our 56-bag pallet deal with free delivery.
What is UltraCrete Tough Patch Rapid 6mm?
Tough Patch 6mm is a rapid-curing, permanent cold-lay surfacing material (PCSM) suitable for defect repairs, trench reinstatement, utility installations, patching in car parks, driveways and other local repairs. It is ideally suited for use on bituminous/asphalt and cementitious paving and road substrates.
Unlike standard cold-lay asphalt which is compaction-cured, Tough Patch uses an innovative reactive binder that is activated by sprinkling water over the product before compacting. This water-activated curing reaction rapidly produces a first-time permanent repair that is instantly trafficable, can be used in all weather conditions — including heavy rain — and can be cored for assessment after 24 hours. The binder is based on renewable materials and contains no solvents.
Tough Patch 6mm can also be used for emergency or temporary repairs where a rapid response is required to prevent risk to operatives, pedestrians, cyclists and motorists.
Technical information courtesy of Instarmac.
Proven Results: Kier Records 82% Reduction in Repeat Visits
Leading UK construction and infrastructure services company Kier had identified a problem: data from April 2019 to January 2020 showed 98 instances across 17 routes where a repeat visit had been made to repair the same site. After working closely with UltraCrete and standardising their repair process around Tough Patch®, Kier recorded an 82% reduction in repeat visits to the same repair site.
Of the original 98 instances requiring a return visit, only 21 sites were revisited after switching to Tough Patch between February and April 2020. UltraCrete’s technical team worked directly with Kier’s crews across multiple depots — reviewing processes, addressing inconsistencies, and demonstrating correct application technique — to maximise the effectiveness of the material.
Having one superior cold-lay surfacing material and a standardised application process delivered a significant, measurable reduction in network interventions.
“Tough Patch flows easily, doesn’t go hard in the bags and is not weather dependent. It appears to compact better and cures harder.”
— Stuart, Rowan Ashworth Ltd
SROH Clarification — May 2025
In light of the SROH clarification issued 30th May 2025 (NGA2.4 Cold Lay Surfacing Material), Instarmac are proud to confirm that Tough Patch remains a permitted PCSM for all reinstatements within equivalent materials in terms of performance, such as HRA and other bituminous surfaces. Detailed evidence demonstrating Tough Patch’s in-life durability as equivalent to HRA and other bituminous surfaces can be found on the PAS certificate, which is available to download. Independent test certificates are also available upon request — contact our team or call 0330 122 1025.
When Should I Use Tough Patch Instead of Standard IRR?
Tough Patch and the standard IRR range are both permanent cold-lay materials, but they are designed for different conditions and applications. The key distinction is the curing mechanism and performance specification.
| Tough Patch 6mm | IRR 6mm | |
|---|---|---|
| Curing mechanism | Water-activated reactive binder | Compaction-cured |
| Heavy/persistent rain | Yes — designed for wet conditions | Light rain only |
| Skid resistance | PSV 65 min; mean PTV 82 | PSV 65 |
| Turning circles & lorry parks | Recommended | Not recommended |
| Application temperature | 5°C to 40°C | All weathers (standard) |
| Max depth (layer method) | 60mm | 100mm |
| Coring | After 24 hours | N/A |
| Certification | PAS (PA 946 0005) | BBA/HAPAS since 2002 |
| Primary application | High-stress, wet weather, turning zones | Footways, cycle tracks, car parks |
Choose Tough Patch if: you’re working in heavy or persistent rain, the surface is a turning circle, lorry park or bus lane subject to braking loads, or you need the highest available deformation and rut resistance.
Choose IRR 6mm if: you’re repairing a footway, footpath or cycle track in normal conditions and the surface is not subject to extreme trafficking loads.
Not sure? Call us on 0330 122 1025 and we’ll advise on the right product for your specification.
What Surfaces is Tough Patch 6mm Designed For?
The 6mm grade is certified as a permanent repair to footways, footpaths and cycle tracks as a PCSM. It can also be used as a temporary or emergency repair on the same applications, and as a temporary or emergency repair on Class 3 and 4 carriageways.
Typical applications include:
- Defect repairs and patching in footways, footpaths and cycle tracks
- Trench reinstatement and utility installations
- Car parks and driveways, including turning circles and lorry parks
- Bus lanes and high-braking zones
- Emergency and reactive repairs on Class 3 & 4 carriageways
- Any application where wet weather working or maximum rut resistance is required
The 10mm grade is available for first-time permanent repairs in Type 3 & 4 carriageways — contact us or call 0330 122 1025 to order.
Complete Reinstatement System
- UltraCrete SCJ Seal and Tack Spray — applied to vertical cut edges and base of defect before applying Tough Patch; essential when substrate is concrete
- UltraCrete Tough Patch Rapid 6mm — applied in layers with water activation before each compaction pass
- UltraCrete Instaband ECO — overbanding sealant applied if required after compaction
Key Features
- Water-cured reactive binder — activated by sprinkling water before compaction; performs in all weather including heavy rain
- PAS certified — PA 946 0005, Pavement Testing Services Ltd; complies with SHW Clause 946 and SROH Fourth Edition 2020
- Instantly trafficable — open to all traffic immediately once compacted
- High deformation and rut resistance — PSV 65 minimum, mean PTV 82; designed for turning circles, lorry parks, bus lanes and high-stress braking zones
- Application temperature 5°C to 40°C — wider range than standard cold-lay materials
- Can be cored after 24 hours — for assessment and compliance purposes
- Renewable binder materials — solvent free, no dangerous fumes
- Ready to use — no mixing or heating; apply direct from the bag
- Emergency repair capable — can be applied without saw cutting in reactive maintenance situations
- SROH 2020 compliant — satisfactory for use as a PCSM in accordance with SROH Fourth Edition, May 2020
- NBS Source-registered — for ease of specification
- UCARS product — UltraCrete Accredited Reinstatement Specification
For technical support, bulk pricing, PAS certificates, or help with specification, contact our team or call 0330 122 1025 — we’re a small, family-run business and always happy to help.
UltraCrete Tough Patch Rapid 6mm FAQs
I’m Cleo, owner of The Paving Experts, with over 25 years in the construction industry working with businesses including Tarmac and Instarmac. I work alongside a small team of incredibly knowledgeable and caring individuals who share the same passion for getting it right. The FAQ answers below come from the questions we’re asked every single day.
What is UltraCrete Tough Patch 6mm?
UltraCrete Tough Patch 6mm is a rapid-curing, permanent cold-lay surfacing material (PCSM) designed for defect repairs, potholes, trench reinstatement, utility installations, car parks, driveways and other local repairs.
What can Tough Patch 6mm be used for?
Tough Patch 6mm is suitable for repairs to bituminous/asphalt and cementitious paving and road substrates. It can be used for footpaths, footways, cycle tracks, driveways, car parks and localised surface repairs.
Is Tough Patch 6mm a permanent repair material?
Yes. Tough Patch 6mm is designed to provide first-time permanent repairs, as well as emergency and temporary repairs where required.
Can Tough Patch 6mm be used in wet weather?
Yes. Tough Patch 6mm can be used in all weather conditions, making it suitable for repairs where conventional weather restrictions can be a problem. Because the curing reaction is water-activated, wet conditions assist rather than hinder the cure.
How quickly does Tough Patch 6mm cure?
Tough Patch uses an innovative reactive binder that rapidly cures on contact with water. The repaired area is instantly trafficable after installation, and the material can be cored after 24 hours.
Can traffic use Tough Patch 6mm immediately after installation?
Yes. Tough Patch 6mm is instantly trafficable once the repair has been correctly installed and compacted.
Is Tough Patch 6mm suitable for pothole repairs?
Yes — it is specifically designed for defect repairs and potholes, as well as trench reinstatements and other local repairs. Its water-cured binder and high rut resistance make it particularly well suited to high-stress locations such as junctions, turning circles and bus lanes.
Is Tough Patch 6mm resistant to rutting?
Yes. Tough Patch 6mm has high deformation and rut resistance. It has been assessed for wheel tracking and permanent deformation, and has demonstrated enhanced performance in heavily stressed locations requiring high rut resistance.
Is Tough Patch 6mm suitable for areas with heavy traffic?
Yes. Tough Patch has been assessed for wheel tracking and permanent deformation and has demonstrated enhanced performance in heavily stressed locations requiring high rut resistance — including turning circles, lorry parks and bus lanes.
Is Tough Patch 6mm skid resistant?
Yes. Tough Patch 6mm is skid resistant, with a minimum Polished Stone Value (PSV) of 65 and a mean Corrected Pendulum Test Value (PTV) of 82.
What size aggregate does Tough Patch 6mm contain?
Tough Patch 6mm uses a nominal 6mm aggregate grade.
How deep can Tough Patch 6mm be installed?
For paving applications, Tough Patch 6mm is generally installed to a maximum finished depth of 60mm in accordance with SROH, using a layered installation method: apply to 45mm and compact to 30mm for the first layer, then repeat to achieve the 60mm finished depth.
How is Tough Patch 6mm supplied?
Tough Patch 6mm is supplied in 25kg foil bags and 25kg buckets. This page is for the 25kg bag. See the 25kg tub if you prefer the bucket format.
Does Tough Patch 6mm require a special binder or heating?
No heating is required. Tough Patch uses an innovative reactive binder that allows the material to rapidly cure as a cold-lay surfacing material. Simply sprinkle approximately 1 litre of water per 25kg bag over each layer before compacting.
Is Tough Patch 6mm PAS certified?
Yes. Tough Patch 6mm is certified through the Product Assessment Scheme (PAS), reference PA 946 0005, issued by Pavement Testing Services Ltd. It is also a UCARS (UltraCrete Accredited Reinstatement Specification) product.
What makes Tough Patch different from standard IRR cold-lay?
The key difference is the curing mechanism. Standard IRR is compaction-cured. Tough Patch uses a water-activated reactive binder — you sprinkle water over each layer before compacting, which triggers the curing reaction. This means Tough Patch performs in heavy rain, and delivers higher deformation and rut resistance, making it the right choice for turning circles, lorry parks and high-stress braking zones.
What is the SROH May 2025 clarification and does it affect Tough Patch?
The SROH clarification issued 30th May 2025 (NGA2.4) confirmed requirements for cold-lay surfacing materials used as equivalent to HRA and other bituminous surfaces. Instarmac confirm that Tough Patch remains a permitted PCSM for these reinstatements. Detailed evidence of in-life durability equivalent to HRA is available on the PAS certificate. Independent test certificates are also available — contact us to request them.
Is Tough Patch certified — does it have HAPAS approval?
Tough Patch is certified through the Product Assessment Scheme (PAS), not HAPAS. PAS certification reference PA 946 0005, issued by Pavement Testing Services Ltd (PTS Ltd). It complies with all test requirements of the revised Specification for Highway Works (SHW) Clause 946 and SROH Fourth Edition 2020.
What surfaces is Tough Patch 6mm certified for?
The 6mm grade is certified as a permanent repair to footways, footpaths and cycle tracks as a PCSM. It can also be used as a temporary or emergency repair on the same surfaces and on Class 3 & 4 carriageways. For first-time permanent repairs on Type 3 & 4 carriageways, the 10mm grade is required — contact us to order.
Can I use Tough Patch for an emergency repair without saw cutting?
Yes — in emergency or reactive maintenance situations where saw cutting and full preparation are not possible, Tough Patch can be applied directly. The repair may be filled in one application and compacted using a tamping device, or traffic can be used to compact in areas with limited traffic management. The user is responsible for satisfying themselves on the effectiveness of the application, with a more permanent solution to follow.
Is a 10mm grade available?
Yes — Tough Patch 10mm is available to order for first-time permanent repairs in Type 3 & 4 carriageways. Contact us or call 0330 122 1025.
Is a pallet deal available?
Yes — see our 56-bag pallet deal with free standard delivery. Bulk pricing on 32+ bags (5% off) and 56+ bags (10% off) — call 0330 122 1025.
Technical information courtesy of Instarmac.
For technical support, PAS certificates, specification help, or further information, contact our team or call 0330 122 1025.
UltraCrete Tough Patch Rapid 6mm — Technical Information
Tough Patch 6mm is a rapid-curing, permanent cold-lay surfacing material (PCSM) using an innovative reactive binder based on renewable materials. The binder contains no solvents and is activated by water prior to compaction. It complies with all test requirements of the revised Specification for Highway Works (SHW) Clause 946 and SROH Fourth Edition 2020. PAS certification reference PA 946 0005, issued by Pavement Testing Services Ltd (PTS Ltd).
In light of the SROH clarification issued 30th May 2025 (NGA2.4), Tough Patch is confirmed as a permitted PCSM for reinstatements within equivalent materials in terms of performance, such as HRA and other bituminous surfaces. The PAS certificate and independent test certificates are available on request — contact us for details.
• Grade: 6mm nominal aggregate
• Curing mechanism: Water-activated reactive binder (not compaction-cured)
• Application: Permanent repairs to footways, footpaths and cycle tracks as a PCSM; temporary/emergency repairs on same surfaces and Class 3 & 4 carriageways
• Depth range: Up to 60mm (layer method)
• Packaging: 25kg foil bag
• Coverage: Approximately 1m² at 12–15mm compacted depth, depending on surface regularity
• Application temperature: 5°C to 40°C
• Weather conditions: All weather, including heavy and persistent rain
• Set time: Instantly trafficable once compacted
• Coring: Can be cored for assessment after 24 hours
• Skid resistance: Minimum PSV 65; mean Corrected Pendulum Test Value (PTV) 82
• Deformation resistance: High deformation and rut resistance; assessed for wheel tracking and permanent deformation; enhanced performance in heavily stressed locations
• Ready to use: No mixing or heating required
• Binder: Innovative reactive binder; renewable materials; solvent free
• Certification: PAS PA 946 0005 — Pavement Testing Services Ltd (PTS Ltd)
• Conformance: SHW Clause 946; SROH Fourth Edition, May 2020
• NBS Source-registered for ease of specification
• UCARS product — UltraCrete Accredited Reinstatement Specification
• Storage: Dry, well-ventilated place; 5°C to 30°C
• Shelf life: 6 months from date of manufacture in sealed units; once opened, use all material
• PPE: Appropriate PPE required during preparation and application. Wash hands before consuming food. Keep out of reach of children and animals. Dispose of packaging responsibly.
• Download the UltraCrete Tough Patch 6mm technical datasheet (PDF)
Technical information courtesy of Instarmac.
Delivery & Returns Info
Our delivery charges are calculated based on the size and weight of your order. When you add items to your basket, the delivery charges are displayed. Small orders are distributed via courier; larger orders via Pallet Network. Collection is available from our Tamworth depot by request (contact us first to arrange on 0330 122 1025).
Please note, there is a slight surcharge for areas that are outside of our locality, charges calculated at checkout.
| Weight and size | Next Working Day* Order before 1PM (excl. VAT) |
Standard 3-5 Working Day (excl. VAT) |
|---|---|---|
| 0-13KG (1 small bag/tub) |
£14.00 | £9.00 |
| 13.01-25KG (1 large bag/tub) |
£16.00 | £10.00 |
| 25.01-50KG (2 bags/tubs) |
£26.00 | £19.00 |
| 50.01-75KG (3 bags/tubs) |
£36.00 | £28.00 |
| 75.01-100KG (4-5 bags/tubs) |
£46.00 | £37.00 |
| 100.01-249KG (6-9 bags/tubs) |
£60.00 | £45.00 |
| 249.01-750KG (10 bags plus) |
£68.00 | £48.00 |
| 750.01KG plus (30 bags plus) |
£75.00 | £55.00 |
| Full Pallets (56 bags/52 tubs) |
£88.00 | Free of charge |
| Next Working Day delivery (Premium 1-2 Working Day Service) | +avg. £5-10 Extra. Click here for prices |
|---|---|
| Scotland Delivery Service (Deliveries into some parts of Scotland can take 8-10 working days) | Click here for prices |
| Local Delivery & Click & Collect: | Email: orders@thepavingexperts.co.uk |
Delivery Information
- Prices apply to mainland England and Wales. Scottish delivery slight surcharge.
- Orders are packed and dispatched Monday–Friday (excluding weekends & public holidays).
Next Working Day Delivery
- Order before 1PM → same-day dispatch.
- Order after 1PM or on weekends/bank holidays → next working day dispatch.
- You'll receive tracking updates via email/SMS if you provide your details.
Delivery Examples
- Mon before 1PM → Packed Mon, delivered Tue.
- Mon after 1PM → Packed Tues delivered Wed.
- Fri before 1PM → Packed Fri, delivered Mon.
- Fri after 1PM/weekend → Packed Mon, delivered Tues (or Wed after a bank holiday).
- Standard Service: 3–5 working days.
Notes
- Occasional delays due to manufacturing, supply, or courier issues may happen, but we'll keep you informed.
Returns, cancel up to 14 days from date of delivery. Product to be returned in the same condition & packaging. No returns for cementitious & perishable products. You are responsible for the cost of returning goods to The Paving Experts, 20% admin restock fee applies. Need further info, click here.
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How to Apply UltraCrete Tough Patch Rapid 6mm
Tough Patch is ready to use directly from the bag — no mixing or heating required. The curing reaction is activated by water, not compaction alone. Follow the steps below for a permanent, compliant reinstatement.
Permanent Repair
- Saw cut a ‘picture frame’ around the defect or opening to ensure straight, vertical edges that support compaction when material is installed.
- Remove all debris, mud, silt or ice from within the defect.
- Seal the vertical cut edges and base of the defect with UltraCrete SCJ Seal & Tack. This is essential when the substrate is concrete.
- Apply Tough Patch using the layer method (see below), spreading each layer loosely and uniformly using a shovel or rake.
- Before compacting each layer, sprinkle water over the complete surface at approximately 1 litre per 25kg bag — this activates the curing process.
- Mechanically compact the material in accordance with Appendix 8 of the SROH. Ensure the final layer is slightly proud of the surrounding surface before fully compacting.
- Repeat for all layers. If overbanding is required, apply UltraCrete Instaband ECO after compaction.
Layer Installation Method
Tough Patch 6mm is generally installed to a maximum depth of 60mm in accordance with SROH, using the following layer method:
- Apply product to a depth of approximately 45mm and compact to 30mm for the first layer.
- Repeat the process to achieve a total 60mm finished depth.
Emergency and Temporary Repair
For emergency repairs where saw cutting and full preparation cannot be undertaken due to traffic management requirements, Tough Patch can be applied directly to prevent risk to operatives, pedestrians, cyclists and motorists. In such cases the repair may be filled in one application and compacted using a suitable tamping device, or in areas with limited traffic management, traffic can be used to compact. A more permanent solution should be carried out at the earliest opportunity. It is the responsibility of the user to satisfy themselves on the effectiveness of the application.
Storage & Handling
Store in a dry, well-ventilated place at temperatures above 5°C and below 30°C. Shelf life is 6 months from date of manufacture in sealed units. Once opened, all material should be used.