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Infrared asphalt repair uses radiant heat to soften damaged asphalt in place, then blends in fresh mix and rolls it smooth. Because the patch fuses with the old pavement, there is no cold joint for water to enter. It works best on surface damage less than about 2 inches deep, while deeper pothole and patch repair needs a different fix.
Infrared is a smart tool, but it is not the answer for every crack or hole. This guide explains how the process works, the real limits shown in Texas testing, how it compares with traditional patching, and the signs that tell you which method your driveway or parking lot needs. If you want a repair assessment, call C. Brooks Paving at (210) 326-5707.
Key Takeaways
- Infrared repair heats existing asphalt so new and old material bond into one surface.
- It only treats the top layer, roughly the upper 2 inches of pavement.
- Base failure such as alligator cracking cannot be fixed with infrared heat alone.
- A San Antonio field study found good bonding but mixed long-term results and high costs.
- The right method depends on how deep the damage goes, not on what is trendy.
How Does Infrared Asphalt Repair Work?
An infrared heater is a large panel that sits a few inches above the pavement. It sends radiant heat down into the asphalt, the same way the sun warms a road, only much faster. After several minutes, the asphalt becomes soft and workable instead of brittle.
Once the area is soft, the crew loosens it with a rake, adds a rejuvenator to replace oils the old asphalt has lost, and mixes in fresh hot asphalt. Then the patch is leveled and compacted with a roller or plate tamp. The finished area bonds with the surrounding pavement because both were hot at the same time.
The Infrared Repair Process Step by Step
- Clean the area. Sweep or blow away water, dirt and loose stone. Debris blocks the heat.
- Heat the pavement. Position the infrared panel over the damage and heat until the asphalt is soft.
- Scarify the surface. Rake the softened asphalt to loosen it and square off the edges.
- Add rejuvenator. Spray a rejuvenating agent to restore flexibility to aged asphalt.
- Add new hot mix. Blend in fresh asphalt and level it slightly above grade.
- Compact. Roll or tamp the outer edges first, then the center, to lock in the bond.
What Texas Testing Shows About Infrared Patching
The Texas Transportation Institute studied an infrared patching process for TxDOT right here in the San Antonio District. In the TxDOT infrared patching study, researchers placed 83 patches, each 4 by 8 feet, mostly on cracked and raveled pavement rather than true potholes.
The findings are useful for any Texas property owner thinking about this method:
- Good bonding: the patches bonded well to the existing pavement and used little new material.
- Shallow reach: the treatment was effective only to a depth of under about 2 inches.
- Settling: at one site, some patches settled about 1/2 inch after roughly 12 months.
- Failures: at another site, many patches shoved and settled, likely from too much rejuvenator.
- High cost: the process cost about $190.88 per square yard in that study, far above a conventional overlay at about $10.80 per square yard.
The researchers saw promise for remote areas where hot mix is hard to get. For city work, they concluded traditional methods were more cost effective. The lesson for homeowners and business owners is simple. Infrared can do good work on the right damage, but the crew’s skill and the depth of the problem matter more than the machine.
Infrared Repair vs Traditional Patching
There are four common ways to fix damaged asphalt. Each one suits a different kind of damage. For a broader overview, see our guide to common asphalt repair techniques.
| Method | How It Works | Best For | Main Limitation |
|---|---|---|---|
| Infrared repair | Heats and reworks existing asphalt, adds new mix | Shallow potholes, raveling, low spots, utility trench seams | Only treats the top layer, about 2 inches |
| Saw cut and replace | Cuts out the damaged area and replaces it with new hot mix | Deep potholes, failed sections, base damage | Leaves cut joints that must be sealed |
| Cold patch | Pre-mixed asphalt packed into the hole cold | Temporary or emergency fixes | Often loosens within months |
| Full depth patch | Removes asphalt and base, rebuilds both | Alligator cracking, soft or sunken spots | More time and cost per square foot |
The FHWA pothole repair manual makes a similar point. The best patch method depends on the pavement, the weather and how long the repair needs to last, not on one universal rule.
When Should You Use Infrared Asphalt Repair?
Infrared repair earns its place when the damage is shallow and the base below is still strong. These are the jobs where it tends to perform well.
Good Fits for Infrared Repair
- Shallow potholes that have not broken through to the base layer.
- Raveling, where loose stones wear away from the surface.
- Trip hazards and small bumps that need to be leveled.
- Seams and joints between old and new paving that have opened up.
- Drainage low spots where water ponds in a shallow dip.
- Utility cuts where the trench edge has started to separate.
When Infrared Is the Wrong Choice
Some damage starts below the surface. Heating the top 2 inches will not fix it. Skip infrared and look at deeper repair if you see these signs:
- Alligator cracking, a web of connected cracks that looks like reptile skin.
- Soft or spongy pavement that flexes under a car tire.
- Potholes that keep coming back in the same spot after repair.
- Sunken areas where the base has washed out.
- Very old, gray, brittle asphalt that has lost most of its binder.
Alligator cracking almost always means base failure. Learn more in our guide on what alligator cracking means. Not sure which group your damage falls in? Call (210) 326-5707 and C. Brooks Paving will inspect it and recommend the method that fits, in writing.
Benefits and Drawbacks of Infrared Repair
Like every repair method, infrared has strong points and weak points. Knowing both helps you judge any quote you receive.
Benefits
The biggest benefit is the bond. Because the old asphalt is heated, the patch fuses into it instead of sitting in a cut hole. That removes the cold joint, which is where water usually enters a patch. The method also reuses much of the existing asphalt, which cuts down on waste and hauling. Repairs are fast, and traffic can often return the same day.
Drawbacks
The main drawback is depth. Infrared cannot reach a failing base. Results also depend heavily on the operator. Too much heat can burn the asphalt, and too much rejuvenator can make the patch soft, which is what caused failures in the Texas study. Price per square foot can also run higher than standard patching on small jobs.
How to Decide Which Asphalt Repair You Need
Use this simple check before you call anyone.
- Measure the depth. Push a screwdriver or ruler into the hole. Under 2 inches leans toward infrared or surface patching.
- Look at the pattern. A single hole or seam is a surface problem. A web of cracks is a base problem.
- Check for movement. Drive slowly over the area. Flexing means the base is soft.
- Note the history. If the same spot has been patched before, go deeper this time.
- Get a written recommendation. Ask the contractor to explain why they chose the method.
Small cracks around the damage should be sealed at the same time. Our asphalt crack repair service handles that so the repair is not undercut by water.
Questions to Ask Before You Approve an Asphalt Repair
Any repair quote should explain why a certain method was chosen. Ask the contractor how deep the damage goes and whether the base underneath is solid. If they recommend infrared, ask how they will control heat and rejuvenator so the patch does not stay soft. If they recommend saw cut or full depth patching, ask how they will seal the joints afterward.
You should also ask how long the repair is expected to last, how soon traffic can return, and whether nearby cracks will be sealed at the same visit. For parking lots, ask how the work will be phased so customers can still park. Clear answers in writing make it easy to compare quotes on the work itself, not just the price.
Frequently Asked Questions About Infrared Asphalt Repair
What is infrared asphalt?
Infrared asphalt is not a different type of asphalt. It refers to a repair method that uses infrared heat to soften existing asphalt so it can be reworked and blended with new hot mix. The result is a patch that bonds into the surrounding pavement.
How long does infrared asphalt repair last?
On shallow damage over a sound base, a well-done infrared patch can last for years. In the San Antonio field study, results ranged from patches performing well at five months to patches settling or failing within a year at one site. Base condition and crew skill make the difference.
Does cold patch asphalt ever get hard?
Cold patch firms up as it compacts and loses solvents, but it rarely gets as hard as hot mix. It is meant as a temporary fix. Most cold patches loosen within one season, especially under Texas heat and heavy traffic.
How does asphalt resurfacing work?
Resurfacing adds a new 1.5 to 2 inch layer of hot mix over the whole surface after cracks and holes are repaired. Infrared repair, by contrast, fixes individual spots. If damage is spread across the whole area, resurfacing is usually the better value.
Get the Right Asphalt Repair Method for Your Pavement
Call C. Brooks Paving at (210) 326-5707 to have your potholes, low spots or worn areas checked. We will tell you whether the damage is surface level or structural, then quote the repair that will actually last. Every estimate is in writing with no hidden charges.
We are open 7am to 6pm, Monday through Sunday, serving Bulverde, Spring Branch, Boerne and the Texas Hill Country. You can also reach us through our contact page online.
