Asphalt Epoxy Mortar Patch & Repair Kit
Stop patching the same pothole twice. Our tar-based epoxy mortar with proprietary aggregate blend forms a permanent repair — 10x stronger than existing asphalt, flexible enough to move with the pavement, and rated for airport runway duty.
Stop Patching the Same Pothole Twice
If you've been using off-the-shelf cold patch products or even hot-mix asphalt and watching those same cracks and potholes return season after season, the problem isn't the application — it's the material. Standard asphalt patches are the same material as the failing surface. They fail the same way, at the same rate.
ArmorGarage Asphalt Epoxy Mortar is a completely different product. Our proprietary tar-based epoxy combined with a specially engineered aggregate blend forms a patch that chemically bonds to the existing asphalt — not just sits in the hole. The result is a repair that's 10x stronger than the surrounding pavement, remains flexible to move with the asphalt through freeze-thaw cycles, and looks like asphalt when cured.
Airport runway rated. This is the same specification used for demanding high-traffic pavement applications including airport runways — where a patch failure isn't just an inconvenience, it's a safety event. For your driveway or parking lot, it's effortless overkill.
Goes in and never comes out. Once cured, ArmorGarage asphalt patch will not crack, chip, or work its way loose. If the substrate underneath lets go, the patch goes with it — which is why we recommend rebar anchoring on large repairs (see application instructions below). 1/4" of ArmorGarage Asphalt repair equals 4" of traditional asphalt repair products.
How to Repair Asphalt Potholes
Learn how to repair asphalt potholes permanently using a high-strength epoxy mortar system. Unlike temporary cold patch products, this method creates a structural repair that bonds to the existing asphalt and won’t loosen, crack, or fail over time.
- Remove all loose material — clean out the pothole completely. Remove broken asphalt, loose debris, and dust so the repair material can properly bond to the surface.
- Mix the epoxy mortar — open the kit and mix Part A and Part B per the label instructions. Then mix in the supplied aggregate until the material becomes thick and pasty. Apply at 1/4" thickness, that's all that's needed due to it's incredible strength when cured.
- Reinforce large repair areas — for bigger/deeper potholes or heavy-traffic areas, hammer one or two short pieces of 1/4 " rod vertically into the repair area. You can also tie them together with horizontal pieces. This creates an anchor for the epoxy to harden around and lock the patch to the ground. Increase the thickness to 1/2" when doing this.
- Fill and smooth — pour the epoxy mortar into the repair area and work it smooth with a trowel. Feather the edges slightly for the best finished appearance.
- Allow the patch to cure — keep traffic off the repair until cured. Once hardened, the patch becomes many times stronger than the surrounding asphalt and forms a long-lasting structural repair.
Permanent pothole repair: Unlike cold patch asphalt that loosens over time, this epoxy mortar chemically bonds to the existing surface and creates a long-lasting structural repair.
Why This Outperforms Every Cold Patch Product
Why cold patch keeps failing: Standard cold patch products use the same emulsion-based asphalt as the original surface. They don't chemically bond — they just fill the void. Traffic, water infiltration, and thermal cycling work them loose within months. You end up doing the same repair every season.
Kit Sizes & Coverage
Free shipping on orders of 4 gallons or more. For large parking lot or road repair projects, contact us for volume pricing.
Deep potholes: For potholes deeper than 1/2", infill with compacted sand first to minimize material usage, then apply the epoxy mortar as the final 1/4" repair layer. This significantly reduces cost on deep repairs without compromising final strength.
Detailed Application Instructions
- Prepare the repair area — remove all loose debris, crumbled asphalt, and standing water. The repair area should be clean and free of loose material. Dry surface preferred but not required.
- Mix Part A and Part B per the label instructions until fully combined. Then add the supplied aggregate and mix until the material becomes thick and pasty — similar consistency to mortar.
- Pour into repair area and work smooth with a trowel. For repairs flush with the surrounding surface, feather the edges slightly for best appearance.
- Allow to cure before returning to traffic. Cure time varies with temperature — warmer conditions accelerate cure. Avoid foot traffic during initial cure period.
Pro tip for large repairs — rebar anchoring: For large potholes or heavy-traffic areas, drive one or two short pieces of rebar or rod vertically into the repair area and increase thickness to 1/2". The cured epoxy hardens around the rebar, creating a mechanical anchor that physically locks the patch to the substrate. This eliminates any possibility of the patch loosening even if the surrounding asphalt continues to deteriorate.
Important: If the base material underneath the asphalt is unstable or eroding (common with sinkholes and severe base failure), the patch will move with it. Address base instability before patching for a permanent result.
Where It Gets Used
Frequently Asked Questions
How is this different from store-bought cold patch products?
Cold patch products use the same emulsion-based asphalt as the original failing surface — they fill the void but don't chemically bond to it. Traffic, water, and freeze-thaw cycles work them loose within months. ArmorGarage's tar-based epoxy mortar chemically bonds to existing asphalt, creating a repair that's 10x stronger than the surrounding material and remains flexible through thermal cycling. It's a fundamentally different product category.
What does "airport runway rated" mean?
It means the product meets the performance specifications required for pavement repair in airport runway environments — one of the most demanding applications for any repair material due to extreme aircraft loads, thermal stress, fuel exposure, and zero tolerance for patch failure. If it performs on runways, your driveway or parking lot is well within its capability.
Will it crack in winter freeze-thaw conditions?
No — the formula remains flexible after curing, allowing it to move with the surrounding asphalt through freeze-thaw cycles. Rigid epoxy patches can crack out in extreme cold because they don't flex. This product is specifically formulated to stay bonded through seasonal temperature extremes.
How much material do I need for my repair?
The 2-gallon kit covers 6 square feet at 1/4" thickness. The 5-gallon kit covers 24 square feet at 1/4" thickness. For deeper potholes, we recommend infilling with compacted sand first, then applying the epoxy mortar as the final 1/4" layer — this dramatically reduces material usage on deep repairs without affecting final performance. When in doubt, order extra — leftover material stores well.
Can I use this on concrete as well as asphalt?
This product is specifically formulated and colored for asphalt repair. For concrete crack and pothole repair, see our concrete repair products. Using asphalt patch on concrete will produce a visible black repair that doesn't match the concrete color.
How long does it take to cure?
Cure time depends on temperature — warmer conditions (above 70°F) accelerate cure significantly. In warm weather you can typically return to light foot traffic within hours and vehicle traffic within 24 hours. In cold conditions allow more time. The patch continues to gain strength over the first several days after application.
Do you offer volume pricing for large projects?
Yes — contact us for project pricing on parking lot repairs, municipal road work, or any large-volume application. Free shipping applies on orders of 4 gallons or more.
Stop Patching the Same Pothole Twice
Questions about your project or need volume pricing? We're here to help.
