Size Matters: Why the Right Rock Makes All the Difference in Spray Patching

Let’s talk about rocks. Not the ones your kid collects or the ones your mower hates—but aggregate, the unsung hero of spray patching.

At The Patchmaster Limited, we may be a little obsessed with rocks. Not just any rocks, though—the right size, shape, and strength. Because when it comes to fixing Alberta’s roads, size absolutely matters.

What the Heck Is Aggregate Anyway?

In simple terms, it’s the crushed rock we spray into potholes. But this isn’t some random gravel we scooped from a ditch. Oh no—we’re talking precision-engineered, spec-approved, tested-and-true chip aggregate.

When combined with our sticky sidekick (aka bituminous emulsion), it creates a patch that holds firm, flexes with the pavement, and tells potholes to stay in their lane.

Alberta Says So: The Official Specs

According to Alberta Transportation’s latest Standard Specifications for Highway Construction (Edition 16)—and yes, we actually read those things—here’s what you need to know:

• Size matters: Spray patching uses Class 10 aggregate, meaning particles around 10 mm. Too big? They bounce. Too small? They clump.

• Clean is queen: No clay, silt, or mystery gunk. It needs to be clean, dry, and crush-worthy.

• Tough love: Must pass Los Angeles Abrasion tests (rock gym, anyone?) and survive Alberta’s freeze-thaw mood swings.

We follow these specs religiously—because nothing ruins a good patch like rogue gravel and a rebel rock.

Emulsion + Aggregate = Road Repair Romance

Here’s how the magic happens:

1. We blast the pothole clean (think leaf blower on steroids).

2. Spray a hot, sticky bitumen emulsion in and around the hole.

3. Fire in the aggregate with force—seriously, it’s like a mini rock cannon.

4. Add a finishing layer of dry rock to prevent sticky tires.

The emulsion grabs each chip like it’s meant to be, and together they form a flexible, sealed, load-bearing bond stronger than your Uncle Bob’s opinions.

Why We Obsess Over This

Because when you’re patching highways, residential streets, and everything in between—you can’t just wing it with “whatever’s in the gravel pile.” Alberta’s roads face:

• 18-wheelers,

• Frost heaves,

• 40°C summers followed by -40°C winters,

• And snowplows that show no mercy.

That’s why we use spec-grade aggregate, tested emulsion, and trained operators who know their chip from their dust.

Rocks Matter

Spray patching might seem simple, but it takes the right materials, applied with care, and done to spec. And the rock? It’s the backbone of it all.

At The Patchmaster Limited, whether it’s asphalt or attitude, we believe in strong foundations.

Want to see our rock stars in action? Contact us today and let’s talk about how spray patching can save your roads (and your budget)