Reliable Asphalt Hot Boxes & Patch Trucks for Long-Lasting Road Repairs

Trusted for over 20 years as the industry standard

Cost-Effective Asphalt Repair Equipment for Municipalities & Contractors

Whether you are filling potholes or repairing utility cuts we have the right asphalt hot box to fit your needs! Falcon is trusted by thousands of contractors, DOT’s & municiaplities across North America.

WHY Does The Right Asphalt Repair Equipment Matter?

Efficiently repairing potholes presents an ongoing challenge for many municipalities and contractors tasked with road repair. Using the right repair equipment can help transform a seemingly continuous uphill battle into a streamlined operation. Falcon is well known as manufacturing the most reliable asphalt repair equipment in the industry. With machines in multiple different sizes and configurations, Falcon has the correct machine for you. Click on any of the videos below to learn more about Falcon, our equipment and how it can help your road repair operation.

It’s a Hot Box. It’s Easy to Use. It’s a Falcon.

Falcon Asphalt Repair Equipment manufactures portable asphalt hot boxes & asphalt recycler utilized by thousands of municipalities and contractors worldwide.

When used as a hot box, it keeps asphalt hot all day and holds it overnight. When used as an asphalt recycler or reclaimer, it provides year-round access to hot mix asphalt. Falcon manufactures a variety of models.

Choose from a truck or trailer-mounted hot box to meet the needs of your asphalt patching operation. Save money while increasing productivity with an asphalt recycler hot box from Falcon.

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What equipment is right for your needs?

Patch Truck

Falcon’s innovative patch trucks offer far more advantages than traditional dump trucks or other pothole repair methods.

No CDL required
Reduced maintenance
Ability to hold material overnight

Truck Mount

Falcon truck-mounted hot boxes are available in multiple configurations to fit the truck you already have:

Hook-lift system
Slip-in/Roll-off system
Chassis-mount

Trailer Mounted

Falcon Hot Box Trailers make it easy for your work crews to repair utility cuts, patch asphalt and fix potholes.

Industries largest unloading door
Patented heat management system
Lifetime frame warranty

Superior Hot Boxes and Asphalt Recyclers

A red Falcon trailer-mounded asphalt repair machine

Versatile to fit your current operational goals

Recycle leftover asphalt, chunks, and millings. Transport hot mix and keep it hot all day. Hold hot mix overnight and up to 48 hours. Heat and re-heat cold patch.

Increased Efficiency to Reduce Operating Cost

As a hot box, it eliminates asphalt waste from an unheated truck bed. As a recycler, it reclaims waste asphalt, chunks torn up from the pavement, and millings. A Falcon asphalt repair machine uses less than 3 gallons of diesel fuel per 8-hour shift.

It's Simple to Operate

VIP Technology automatically prevents burner damage from low battery voltage. To prevent material from cooling, a Falcon machine is the only hot box engineered to allow the burner to run while in tow.

The Industries Longest Warranty Program

Two-year machine warranty* with a lifetime frame warranty. We engineered the patented heat management system to provide even hopper temperatures. This helps prevent material scorching from hot spots and material hardening from cold spots.

Make recycling easy

Falcon’s patented

heat management system

All Falcon asphalt hot boxes include our patented heat management technology. Improve work quality and environmental impact while maintaining integrity of materials, reducing fuel consumption and minimizing emissions.

See Our Equipment In Action

Prevents asphalt from cooling while being transported. This is due to special engineering that allows the burner to run while in tow.

Delivers even hopper temperatures to eliminate material scorching from hot spots and material hardening from cold spots.

Utilizes a one-piece, seamless, ceramic combustion chamber rated for 2,300F.

Achieves 92% fuel efficiency by incorporating a combustion chamber shape and construction that creates a tumbling action to force a complete blending of fuel, air, and heat (uses less than three gallons of diesel fuel per 8-hour shift).

Minimizes carbon and NOX emissions and eliminates dirty cad cells caused by uncombusted fuel.

Hot Box & Recycler FAQ

What type of burner system do Falcon Asphalt Hot Boxes utilize?

All Falcon trailers have a powerful, single-burner diesel-fired heating system. This allows for fast and efficient heating while ensuring optimal asphalt temperatures. You can upgrade to an optional dual propane burner system that allows your crew to recycle asphalt millings and chunks.

Are Falcon Hot Boxes ideal for both road repairs and parking lot maintenance?

Absolutely! Falcon Hot Boxes are versatile and suitable for road and parking lot asphalt repairs. We designed them to streamline your operations and increase your crew’s efficiency. All of our asphalt hot boxes are designed with the largest material unloading door in the industry making it easy to repair both potholes and utility cuts.

When used on highways or high traffic areas, Falcon machines are specifically designed to maximize crew safety. With all primary equipment such as the control box, dump control, unloading door, tool holder and much more accessible from the curbside of the vehicle.

How does a Falcon Hot Box reduce asphalt repair cost?

All pavement—whether in a parking lot or on a highway—requires ongoing maintenance. Traditionally, crews load hot or cold mix asphalt into a dump truck at the start of the day and complete as many repairs as possible before the material becomes unworkable. The challenge is that asphalt cools quickly, even on warm days. Once temperatures drop below roughly 240°F, the material no longer compacts properly, leading to weaker, short-term repairs.

A Falcon hot box is fully insulated and thermostatically controlled to keep asphalt at the proper working temperature throughout the day—and even hold it for up to 48 hours. This ensures consistent, high-quality repairs while reducing material waste that would otherwise need to be discarded. The result is more efficient operations and longer-lasting, permanent patches.

What seperates Falcon from other hot box manufacturers?

While all asphalt hot boxes are designed to heat and transport asphalt, Falcon hot boxes stand out with industry-leading features, durability, and efficiency that competitors simply don’t offer.

Falcon units feature the largest material unloading door in the industry, allowing multiple crew members to work at the same time for faster job completion. The heated shoveling apron floor seamlessly extends into the hopper, making material handling easier and more efficient—especially in cold conditions.

Falcon also backs its equipment with the most comprehensive warranty program in the industry, including a lifetime frame warranty, a 5-year maintenance-free combustion chamber, and a 2-year machine warranty—giving you long-term reliability and peace of mind.

At the core of every unit is Falcon’s patented heat management system, designed to maximize performance and efficiency. This includes voltage interruption protection to prevent burner damage from low-voltage starts, a seamless one-piece combustion chamber that fully blends air, heat, and fuel for optimal efficiency, and true triple-wall construction with stainless steel baffles to ensure even heat distribution throughout the hopper.

The result: better heat retention, improved productivity, reduced material waste, and equipment built to last in demanding road maintenance environments.

Can a Falcon Hot Box recycle and reclaim unused asphalt.

Yes, Falcon hot boxes are designed to reheat and recycle leftover asphalt, allowing crews to reuse existing material instead of disposing of it. This reduces material costs, improves efficiency, and supports more sustainable road maintenance practices.

Many paving contractors also use Falcon hot boxes to reheat leftover asphalt from paving jobs. Uncompacted (virgin) asphalt is broken into manageable pieces—often called “cookies”—and stockpiled for later use. When needed, this material can be reheated in a Falcon hot box and reused for repairs, helping maximize material value and minimize waste.