All County Asphalt Creating More Opportunity with Falcon
Falcon’s durable, easy-to-use Hot Box has helped All County Asphalt save time, reduce waste, and improve performance on every job.
In Rockland and Orange counties in New York, as well as neighboring Northern New Jersey’s fast-paced pavement repair market, All County Asphalt faces constant pressure to deliver smooth, durable repairs on tight timelines. With multiple utility contracts and emergency repair work arising unpredictably, the company needed a more efficient way to keep asphalt hot and crews productive. That’s when they turned to Falcon’s Hot Box — and the results were immediate. Their goal was to have both patching and paving crews operating simultaneously, allowing them to take on more work and provide true year-round service. With the Falcon Hot Box added to their fleet, that goal quickly became a reality, enabling the company to maximize productivity, reduce waste, and respond to clients faster than ever before.
Why All County Asphalt Needed a Falcon Hot Box
All County Asphalt holds two ongoing contracts with local power and water utilities, performing asphalt restoration work after utility cuts. Originally, the crew completed most of these repairs using the back of a dump truck to transport asphalt— a setup that came with familiar challenges. The mix would cool quickly, forcing crews to race against time to place patches before the material became unusable. This often led to wasted asphalt, inconsistent repair quality, and increased frustration.
Seasonal limitations only made matters worse. During colder months, keeping hot mix at the proper temperature was nearly impossible, making it difficult for All County Asphalt to deliver permanent, high-quality repairs that met their standards. Cold material doesn’t adhere well and is much harder to work with, causing every job to take longer — and in this business, time is money. These challenges limited the amount of work All County Asphalt could take on during the winter, leaving valuable opportunities on the table. It was clear they needed a better solution — one that could keep material hot, crews productive, and work moving year-round. That’s when they turned to Falcon.
How did they land on choosing a Falcon Hot Box?
“I first reached out to Ray McGrath, (owner of McGrath Municipal Equipment), about three or four years ago about getting a trailer”, explained Kenny Lee from All County Asphalt. “At the time, our workload didn’t quite justify the investment. We only had one utility contract, and during the winter we could just go down to the plant whenever we needed mix. But as our utility work grew, we started hearing great things from local municipalities about Ray and Falcon. We reached out again, and Ray gave us a great price and built us a really solid unit. It’s been excellent for us ever since.”
They wanted a machine that would integrate seamlessly with their current operation — and specifically, their existing fleet of trucks. Since All County Asphalt was already using a hook-lift water system for its milling operation, adding a Falcon Hot Box was a logical choice. They purchased a 6-ton dual burner hot box that fit perfectly on their hook-lift truck. The new setup allowed them to get more value out of a hook-lift truck that had previously sat idle for several months each year. Ultimately, it created more opportunities for work and helped keep their 22 full-time employees busy year-round — something Robert ‘Chip’ Chiapperino, President of All County Asphalt, said was very important to him.
How have they used the Hot Box?
The primary use of All County Asphalt’s Falcon Hot Box is tied to the two utility contracts they hold with the local power and water companies. Whenever those utilities need to open up pavement to make repairs, All County Asphalt uses their Falcon Hot Box to place a permanent repair the same day. This approach keeps the utilities in compliance with city and county requirements and eliminates the need for temporary patches that leave a job technically unfinished.
Because All County Asphalt also produces its own asphalt using a Bagela high-speed recycler, pairing it with the Falcon Hot Box’s heating capabilities gives them the flexibility to supply hot mix on demand all year long. Together, these tools allow All County Asphalt to provide true 24/7 emergency service—responding quickly to critical issues like main line breaks, regardless of weather or time of day. It also gives them the flexibility to arrive at a job site and wait, if needed, without worrying about wasted material. If the utility company isn’t finished with its work, All County Asphalt can sit confidently knowing their mix is being held at the optimal temperature inside the Falcon Hot Box. No longer are they stuck in a dump truck watching their asphalt cool — and watching their profit evaporate.
Additionally, the Falcon Hot Box has allowed All County Asphalt to add patching work to their list of year-round services. Kenny Lee explained, “We can send crews out two to three days a week, mainly during the winter months, to patch potholes. When a property maintenance company calls and says their lot got damaged by a snowplow, we can quickly send a crew out to fix it.” This capability has opened a new revenue stream for the company, particularly during the slower winter season.
What type of return have they gotten from their Falcon Hot Box?
According to Mr. Lee, All County Asphalt has already begun to see substantial returns from their Falcon Hot Box, even after just one season of use. By using hot mix asphalt at the optimal temperature, rather than rapidly cooling asphalt out of or dump truck or cold mix out of a bag, the company has dramatically increased the amount of work they can complete each day. Wasted material from cooling during transport or on-site has been virtually eliminated, resulting in more efficient operations and lower costs per job. Looking ahead, they expect even greater returns over the next 12 months as more customers have become aware of their year-round patching services and 24/7 emergency repair capabilities.
The Falcon Hot Box has not only improved day-to-day productivity but also opened new revenue streams for All County Asphalt, particularly during the slower winter months. Crews can respond quickly to potholes, utility repairs, and emergency situations without worrying about cold material or wasted mix. For other contractors facing similar challenges, All County Asphalt’s experience demonstrates the tangible benefits of investing in the right equipment: faster turnaround times, reduced material waste, and the ability to take on more work with the same team. In an industry where efficiency and reliability directly impact the bottom line, a Falcon Hot Box can be a game-changer — keeping crews working smarter, clients satisfied, and opportunities flowing year-round.
For more information on any Falcon products, please visit falconrme.com, email sales@falconrme.com or call (989) 623-1699.
