Potholes form when water infiltrates existing cracks in asphalt, freezes, expands, and breaks the surface apart from beneath. In New England, the freeze-thaw cycle makes this a particularly aggressive problem from late fall through early spring.
How Potholes Form
The process starts with a crack in the surface — from age, load stress, or poor base preparation. Water enters the crack. When temperatures drop below freezing, that water expands as ice, forcing the crack wider and weakening the surrounding asphalt. When the ice thaws, the material contracts and a void is left beneath the surface. Vehicle traffic breaks through the weakened surface and a pothole forms.
The same pothole will keep forming in the same spot if only the surface is patched without addressing the underlying crack or drainage condition.
How Potholes Are Properly Repaired
Throw-and-Roll (Temporary)
Cold-mix asphalt is poured into the pothole and compacted by a vehicle driving over it. Fast and inexpensive, but not a permanent fix. Appropriate for emergency repairs in winter or as a short-term patch.
Full-Depth Patching (Permanent)
The damaged area is cut out to a clean edge, the base is inspected and repaired if needed, and new hot-mix asphalt is placed and compacted in lifts. This is the correct repair for a commercial property and the one that holds.
The key difference between a patch that lasts and one that fails within a season is edge preparation and base repair. Patching over a soft or compromised base produces a patch that sinks or separates.
Freequently Asked Questions
Why do potholes keep coming back in the same spots?
Because the surface was patched without addressing the crack or drainage condition that caused water to enter in the first place. Permanent repair requires cutting out the damaged area cleanly and verifying the base before new material is placed.
Can potholes be repaired in cold weather?
Temporary cold-mix repairs can be made in any weather. Permanent hot-mix repairs require temperatures above approximately 40 degrees Fahrenheit and a dry surface. Most commercial pothole repairs in New England are either temporary winter patches followed by permanent spring repairs, or full-depth permanent repairs during the paving season.
How many potholes before resurfacing makes more sense than patching?
There is no fixed number, but when patching costs accumulate to approach resurfacing costs, or when potholes are appearing across most of the lot rather than in isolated areas, resurfacing is typically the more cost-effective long-term answer.
Is a pothole a liability?
Yes. A pothole that damages a vehicle or injures a pedestrian creates liability exposure for the property owner. Documentation of known defects without prompt repair strengthens a negligence claim. Commercial properties should address potholes promptly.
US Asphalt provides commercial pothole repair and full-depth patching across the Boston metro. Call (855) 246-8867.
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