When is infrared repair the right option?

By Lori Helms

It’s an accepted industry standard that the infrared process for asphalt patching has its advantages. As a contractor, it’s imperative that not only do you understand the fundamentals of the process and its proper applications, but that you also recognize the extent of the capabilities as well as the limitations of your equipment to make a proper infrared patch.
For a little bit of a deeper dive into the infrared process for repairs, its advantages and drawbacks, and the importance of selecting the proper equipment, we reached out to several industry experts for their take on which projects are most likely to benefit from infrared repair, but more importantly, what equipment to look for and the reasonable expectations of how that equipment will perform.

The advantages to using the infrared process for repairs are many, as we learned from Jason Stepp, Vice President and National Sales Manager for VSS Macropaver, Stepp Mfg., and Kasi Infrared. He says the specialized application of modern heat technology to make repairs delivers results that are faster, more eco-friendly and more effective than conventional applications. Just a few of those advantages include:

• Faster repair: Most can be completed within about 25 minutes, as opposed to the lengthy surface closures required for most traditional methods. This means traffic and pedestrian use can be resumed after a fraction of the downtime typical of other repair processes. For your crews, Stepp says this means the ability to turn around multiple repair projects in a single day, maximizing productivity and reducing labor costs.

• Eco-friendly practice: By using the infrared process, existing asphalt is supplemented with a minimal amount of new material. This minimizes the amount of waste generated on a project.
• Moisture protection: Infrared asphalt repair minimizes the concern regarding cold joints, which are susceptible to water penetration. An infrared repair softens the old asphalt to allow it to blend with the new material and create a continuous, joint-free repair.

• Less equipment and reduced manpower: Stepp says infrared repair equipment is designed for maximum convenience and operational efficiency. Each unit is equipped with all the tools and materials needed on board, streamlining the process while reducing logistical obstacles and set-up time as well as needing only two- to three-person crews required to operate them.

As a contractor, however, it’s important to also understand the limitations of infrared repair technology when discussing this option with a customer. Things to consider include:

• Size of the compromised area: Infrared repair is not well-suited to large projects with highly potholed areas or other widespread failure, Stepp says.

• Heavy asphalt oxidation: Sunlight and age can take a toll on asphalt and cause it to turn brittle and less cohesive, which may require the removal and replacement of large portions or even the addition of new liquid asphalt for a more durable repair.

• Wet areas: Water reflects infrared heat, which Stepp says prevents it from penetrating and properly heating the blacktop.

• Extreme cold and windy conditions: Infrared repair efficiency drops rapidly in extreme cold (below 20 degrees Fahrenheit including wind chill). Wind can exacerbate cold weather challenges by accelerating heat loss.

• Quality of original material: Stepp says not all asphalt is created equal. Some repairs may not be suitable candidates for infrared patching depending on the original product and its changes over years of sun, weather and traffic.

Just as important as understanding which jobs will benefit from an infrared repair is choosing the right equipment and understanding its capabilities as well as its limitations. An infrared repair is only as good as the equipment, materials and its operator, so it’s important to do your research, according to Jarrod Filion, Owner and President of North American Infrared.
“Talk to someone that’s familiar with the brand of equipment you are looking at not related to the manufacturer,” he says.

“They are not all created equal, and some are definitely more efficient than others. If you are just starting out and you don’t want to take the leap into a truck-mounted system, then a trailer mount could be a good option.” He says that trailer mounted units have their maneuverability limitations, however, so a truck-mounted system may be the way to go, especially since they have room to carry the needed equipment and tools that include size options for the hotbox.

And it’s not just the equipment you should evaluate – the equipment you invest in is only as good as its operators. Barry McFadyen, Manager of Paving Products at Heat Design Equipment, Inc., believes that while finding the right equipment is key, just as critical is the training your crew receives to operate the equipment properly and at its maximum efficiency.

“You can’t get enough training,” McFadyen says. “Send your crews to factory training every year, or as often as possible. Constant reminders and learning should be taking place daily, regarding both the equipment capabilities and service intervals, but also about the pavements you are repairing and the hot mix asphalt you are using. … A tool is only as good as the person trained to use it.”

“When you are looking for an infrared (equipment) manufacturer, make sure you do your research,” says Filion. “This is a great industry, and you can make very good money. You need to be set up right – if not, you will struggle or potentially fail.”