Pacopatch®

Over 100,000 drainage gullies and public utility ironworks have been successfully reinstated with Pacopatch!

Pacopatch is a revolutionary polymer based bituminous reinstatment system developed specifically for the single reinstatement of manholes and gullies.

Pacopatch comes with a 5 year material warranty, is voidless, requires no compaction and can be trafficked within an hour of completion.

Pacopatch has been laid 0.5 metre deep and was trafficked the same day.

The revolutionary system comprises a hot applied asphalt grout into which factory prepared cold asphalt bricks (containing a minimum 45% of coarse aggregate) are placed.

The cold bricks are designed to absorb the heat from the hot asphalt grout whilst forming a monolithic asphalt structure. The system cools to ambient temperature much more quickly providing engineers with the ability to arrange for repairs to be completed within restricted working periods and the road reopened to traffic.

Pre-coated or dry chippings are applied to the finished surface to provide a non-skid surfacing complying with UK legislative specifications.

Pure Asphalt offers speciality training for third parties either on site or in house both to competent asphalters and other tradesmen especially in the field of paving and reinstatement of roads and footways using Pacopatch®. These include coloured and printed mastic asphalt products and acid and fuel resistant materials.

Pacopatch  Reinstatement System

Pacopatch is a polymer modified mastic asphalt permanent reinstatement system primarily designed for use around manholes and other street ironworks. The system comprises the placing of Quality Assured factory manufactured, mastic asphalt bricks (to BS1447:1998 incorporating 45% recycled coarse aggregate) into a layer of polymer modified mastic asphalt grout.

The process is completed by backfilling with additional grout to produce a voidless, impermeable, monolithic and permanent reinstatement which can be completed in a variety of surface finishes.

Pacopatch requires no compacting, is applied by hand float and enables applicators to economically patch even very small, irregular areas, to a consistent, voidless standard.

There is no waste when using Pacopatch.  The need for and the cost of collecting an excess of hot materials from a quarry is eliminated, as is the reliance on the plant being open for night and weekend collections.

Pacopatch is delivered in a palletised format providing the user with a 24/7 availability all year round.

Pacopatch is a one off application, which produces a permanent reinstatement requiring  no temporary measures or subsequent repair visits.

Description

Pacopatch is a two part mastic asphalt system comprising:

1) Pacogrout® (supplied in 10kg blocks, on pallets, for remelting).
2) Pacobrick® (supplied in 5kg bricks, on pallets, for immediate use).

Specification

Pacogrout®
A paving grade mastic asphalt, manufactured in accordance with the general requirements of BS 1447:1988 with regard to aggregate grading and binder content. Pacogrout® utilises a  purpose designed polymer modified asphaltic cement manufactured under refinery controlled conditions to a BS EN ISO 9001:2008 Quality System. The coarse aggregate content is in accordance with Clause 5.3.1. of BS 1447.

Properties of asphaltic cement: 

Pacobrick®
Pacobricks are factory produced under controlled conditions, to a BS EN ISO 9001:2008 Quality System. They are a proprietorial paving grade of mastic asphalt manufactured within the general specification guidelines of BS 1447:1988 Table 3, Grade H,

The brick manufacturing process utilises a minimum 90% recycled bituminous materials.

Surface Finish

In addition to BS 1447:1988 Appendices A3 & A4, Pacopatch can be completed with a wide variety of alternative surface finishes.

Pacopatch Application Method

1. Mark out the area to be excavated. (We recommend the following minimum dimensions are adopted).

a)  150mm width for Pacobrick® laid to a stretcher pattern (end to end).
b)  300mm width for Pacobrick® laid to a header pattern (side by side).

2. All perimeter edges of area to be reinstated should be diamond saw cut to ensure a clean vertical face is provided.

3. Break out the existing material and remove the spoil from the excavation to a minimum depth of gulleys 60mm and manholes 100mm (see item 10).

4. All faces of the excavation should be coated with an approved jointing compound.

5. Operative (1) should carefully transfer the molten Pacogrout® from the mixer/cauldron into an asphalt bucket and pour into the excavation to an average depth of approximately 20-25mm (see item 11).

6. Operative (2) follows immediately by lightly bedding Pacobricks® into the warm Pacogrout®, broad face down, allowing sufficient space between bricks to facilitate the Pacogrout® flow and so fill the voids around each brick.

7. When all the bricks have been placed, operative (1) should fill the excavation with hot Pacogrout® to the surface level and operative (2) hand floats the Pacogrout® to the finished level.

8. If the surface is to receive pre-coated chippings, a head space of 1-2mm should be left to allow for displacement of the Pacogrout® on application of the chippings.  The chippings should be pressed into the Pacogrout® with a wooden float whilst the material is still in a plastic state.

9. Allow the reinstatement to cool to ambient temperature before opening to traffic.  The cold Pacobricks® act as a heat sink and assist cooling.

10. For deep excavations use 2 or more courses of bricks as required.  Pacogrout® may be used on its own to bring the base level of the excavation up to 100mm of the surface. This additional layer should be allowed to cool prior to finishing as 4 to 8 above.

11. Pacogrout® should not be heated to a temperature exceeding 180oC and particular care should be taken to avoid any localised overheating during the melting process.

Some of the things our customers say... See our Testimonials page for more.

"Northamptonshire County Council started using Pacopatch routinely on every piece of ironwork within carriageway resurfacing schemes about five or six years ago. To date of the many hundreds of manholes and gulleys that have been adjusted using this system we have had one failure and that was attributable to causes other than workmanship or materials."

"We carried out some trials three years ago using Pacopatch. The Pacopatch repairs are still in place today and functioning well."

"The Pacopatch system was initially undertaken as a trial following observations of works undertaken in Northamptonshire. I would like to say that, so far, the results have been very impressive both in terms of application and the finished results. All of the installed ironworks are still in excellent condition with no noticeable deterioration, settlement or defects requiring attention. I cannot recall a recent contract where we have had zero failures or defect corrections within a 2 year period."

"Many of the Pacopatch works were carried out over 5 years ago and infact the adjacent traditional tarmac roadway is breaking away whilst the Pacopatch has not deteriorated in any way."

"The level and ride quality is exceptional and have successfully withstood considerable trafficking in the 18 months since installation."

"I did face some criticism and questioning regarding the retro fitting of the ironworks and the perceived high cost of the works. Following the completion of the schemes, these concerns have been silenced...  The initial increase in cost is offset by not having to return to areas within the same year."

"I have done extensive costs on the use of Pacopatch against conventional techniques and Pacopatch proves efficient and economical in many ways.the reason is simple. Clients/engineers never take into account the stealth costs associated with failure and re-works, the waste the administration time and more importantly LA charges that will soon increase due to permit and fixed penalty notices."

"Pacopatch is in my view the best product on the market..."