The kit list
- Cold mix asphalt — half a pallet of 7 Gauge as default stock
- 10 or 14 Gauge cold mix for deep holes
- Rubberised crack filler in carton lots
- Stiff broom
- Square-mouth shovel
- Wire brush
- Hand tamper
- Optional: small plate compactor
- Traffic cones, witches' hats and signage
- PPE — gloves, eye protection, hi-vis
Why pallet stock works
A pallet of cold mix in the depot means the next pothole call is a 10-minute deployment, not a half-day procurement exercise. Sealed bag shelf life of 12 months covers seasonal demand variability.
Vehicle setup
Most councils and contractors run a single-cab or dual-cab ute with the kit on a low-side tray. No specialist truck or trailer needed.
First-response workflow
- Drive to site, set out cones.
- Sweep the hole clean.
- Square edges with shovel.
- Fill with cold mix, slightly overfilled.
- Compact with tamper or vehicle wheel.
- Sweep, photograph for record, remove cones, leave site.
Cost comparison
A complete kit including a pallet of cold mix runs well under $5,000. The same response by a hot mix subcontractor on a single-pothole call-out is usually $400–$800 per visit.
Frequently asked questions
How many potholes does a pallet cover?
A pallet (typically 40 × 20 kg bags = 800 kg) handles 40–80 average potholes depending on depth.
Does the kit need a licensed operator?
No. Cold mix asphalt application requires no specific licence — standard PPE and traffic management are sufficient.
Can the kit handle wet-weather call-outs?
Yes. Cold mix can be applied in wet conditions, which is a major advantage over hot mix in tropical and winter response.
