Hot boxes address these problems and can result in longer-lasting repairs. However, how can a municipality decide if the investment is financially justified? Read on to learn more about hot boxes and determine if they’re right for your road maintenance department.
What is an Asphalt Hot Box?
Cold asphalt is extremely challenging to work with and can lead to poor-quality patch jobs with a high failure rate. A hot box is a purpose-built machine that maintains the asphalt at optimal working temperatures throughout the day.
Workers no longer have to race against the clock and try to squeeze in as many jobs as they can before the material starts to cool. This often results in inferior and short-lived patch jobs due to the rushed nature of the work.
Crews can even hold the leftover material overnight (for up to 72 hours) to avoid waste and making a round-trip to and from the asphalt plant. Adding an optional 2nd burner turns the hotbox into an asphalt recycler that can reuse leftover millings and chunks.
Asphalt hot boxes also contain the necessary tools that enable municipality workers to perform their jobs efficiently and safely. This integration of equipment and tools in one unit helps streamline the patching process and improves overall work efficiency.
Falcon is an industry-leading manufacturer that builds hot boxes that range from 2 tons to 10 tons. We use high-quality parts designed to withstand the toughest operating conditions. The result is a durable asphalt hot box that adds tremendous value to any patching operation.
How Does an Asphalt Hot Box Operate?
A Falcon Asphalt Hot Box is a very simple machine to operate. The worker pulls up to the asphalt plant, loads the desired amount of material into the hopper and sets the temperature using the digital controller.
The machine does the rest of the hard work by automatically monitoring and adjusting the burner to ensure the asphalt remains in a workable state throughout the day. There’s no need for manual intervention by the work crews. Simply set it and forget it.
An optional dump function lets crews unload asphalt with the push of a button. Falcon Hot Boxes have the largest unloading doors in the industry for easy access. This allows them to carefully meter out the right amount of material at the desired speed.
Watch this short video to see just how quickly asphalt cools when stored in an open dump truck bed versus a Falcon Hot Box:
Heating Mechanism and Technologies
Falcon’s Hot Boxes feature a heated shoveling apron that extends seamlessly into the hopper for easy access and prevents leftover asphalt from hardening. The insulation between the outer and middle walls helps retain heat and maintains the asphalt at the desired temperature.
A Beckett burner fires directly into a patented seamless, one-piece combustion chamber within the hot box. This design creates a tumbling action, forcing the blending of air, fuel, and heat to ensure proper distribution into the hopper walls.
The triple-wall construction allows the interior to reach up to 280 degrees while the exterior walls remain cool to the touch. An air-jacketed design introduces heat at the floor of the hopper to ensure consistent temperature throughout the asphalt.
While the standard Falcon Hot Box uses a diesel fuel source we can also build propane options to meet specific needs.
Consistent Heating and Insulation
The digital controller on Falcon Hot Boxes allows operators to set a precise temperature. The burner automatically adjusts, turning off when the desired temperature is reached and firing up again when the temperature starts to fall. This system ensures that the asphalt remains at the optimal temperature throughout the day, reducing waste and improving the quality of road repairs.
Safety Features of Falcon Hot Boxes
At Falcon, we design our machines with safety as the first and foremost consideration. For example, we placed the shoveling apron slightly below the average waist height to lessen operator fatigue. This helps to reduce strain on the worker’s arms and backs.
A large material unloading door makes it easier for crews to access the asphalt without excessive effort. The heated shoveling apron ensures that leftover asphalt does not harden, reducing the need for manual scraping at the end of a shift.
We also prioritize safety during the unloading process. The controlled dump function keeps workers off to the side and away from traffic/hot material when unloading at the job site.
How Hot Boxes Save Money and Improve Repairs
Asphalt hot boxes provide significant benefits for municipalities. They extend asphalt’s working time, reduce waste, and enhance repair quality. Additionally, these tools enable crews to work more efficiently, leading to savings in labor and materials, and fewer repeat repairs.
Choosing quality road maintenance equipment like Falcon’s Hot Boxes offers substantial long-term value. These machines help maintain roads more effectively and decrease the need for frequent pothole repairs, making them a wise investment for any municipality.
Falcon’s Asphalt Patch Trucks: A Step Beyond
The Falcon Asphalt Patch Truck offers an advanced solution for pothole repairs. They’re engineered to handle larger volumes of asphalt and come equipped with features that enhance efficiency and repair quality. They offer the same benefits as a truck-mounted hot box but with added capabilities that make them a more comprehensive solution.
However, the biggest advantage of the Falcon Patch Truck is that the driver can legally operate the vehicle without needing a CDL license. Municipalities can save a tremendous amount of money by not having to hire a specialized driver to operate this patch truck.
Partner with Falcon for Superior Pothole Repairs
Asphalt hot boxes are an essential tool for municipalities looking to improve their road maintenance processes. They offer numerous benefits, from extended working time to reduced waste and better repair quality.
At Falcon, our expertise in hot box technology ensures that workers have access to the best equipment available for their specific needs. Click below to explore our range of asphalt hot boxes and patch trucks to find the solution that’s right for you.
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