Environmentally Sustainable Asphalt Recycling & Pothole Patching Equipment

“Versatile Asphalt Maintenance Equipment – An Asphalt Recycler and an Asphalt  Pothole Patcher in one!”   

Environmental sustainability is about preserving the natural environment, community by community. Falcon contributes to the development of environmentally sustainable communities by building asphalt road maintenance equipment that allows pavement repairs to made with recycled asphalt. Using recycled asphalt to make a pavement repairs reduces landfill use and disposal costs, conserves aggregate and petroleum resources, and eliminates the material and labor waste resulting from temporary winter repairs.

There are four million roadway miles across the United States and Canada valued at $1.75 trillion (about $500,000 per mile); 90% are asphalt. The responsibility for maintaining these roads rests with street departments of the 59,000 cities, towns and counties across North America and state departments of transportation. Other markets dealing with asphalt maintenance include public and private utilities, private contractors, departments of parks and recreation, colleges and universities, airports, golf courses, venues (ex. zoos, racetracks) and railroads.


(Hopper loaded with asphalt RAP waiting to be recycled)

Asphalt is the most recycled material in the U.S. with 3% of the roads being recycled. Asphalt plants are the primary recyclers, however, the number of street departments adding asphalt recycling to their road maintenance program is growing rapidly. The need to reduce costs and a desire to create environmentally sustainable communities is driving this growth. Using recycled asphalt to repair roads reduces disposal costs and landfill use, conserves aggregate and petroleum resources and eliminates the need for temporary repairs during cold weather months.

The most common way for transporting asphalt today is in the unheated bed of a truck. Since asphalt begins to harden in less than 3 hours, transporting asphalt in this manner results in scrap rates that waste natural resources such as aggregate and petroleum. In addition, this approach to road maintenance does not provide the capability needed to repair roads with recycled asphalt.

The Falcon asphalt recycler & pothole patcher has a combustion efficiency rating of over 90% — good for our customers and good for the environment:

  • lower carbon and NOX emissions
  • lower fuel usage
  • less sooty waste by-product responsible for dirty cad cell condition


The elimination of waste is at the core of Falcon’s culture. Falcon is committed to:

  • using environmentally friendly materials, designs and manufacturing processes
  • developing and manufacturing products that help our customers reduce, reuse and recycle
  • buying locally whenever possible

Examples of items included in Falcon’s recycling program include scrap steel, cardboard, office paper, wood pallets, used automotive oil, paint thinner, ink-cartridges, and copper wire. Other examples of Falcon’s commitment to eliminate waste include investments in energy efficient lighting and weatherproofing.

Last, but certainly not least, the most wasteful way to do anything is to do it twice. Falcon is committed to world-class quality — this means, doing things right the first time and, therefore, only doing them one time.

Looking ahead, state and municipal governments will struggle to deal with decreasing budgets. As funds to replace existing roads become increasingly scarce, the emphasis placed on road maintenance and preservation will intensify. Despite the financial challenges ahead, road repairs will continue. More and more, these repairs will be performed with asphalt road maintenance equipment capable of recycling asphalt.