How Much Do Asphalt Patch Trucks Cost?

by | Apr 4, 2023 | Uncategorized

Asphalt Patch Trucks offer everything your work crews need to efficiently and effectively perform regular pothole repairs. Unlike a tow-behind trailer, patch trucks can easily navigate city streets which makes them ideal for tight spaces.

A standard patch truck consists of a truck, a hopper, and other essential components. Generally speaking, you will need a Class 6 or greater truck, which is any vehicle weighing between 19,501 lbs and 26,000 lbs.

If you’re in the market for one, you might wonder how much asphalt patch trucks cost. The short answer is that you can expect to pay anywhere between $150,000 to $400,000. The long answer depends on several key factors.

Read on to learn more about key asphalt patch truck pricing factors and how to keep the overall cost down.

CDL Driver

The vast majority of asphalt patch trucks use an auger, conveyor belt, and hydraulics to move asphalt from the hopper to the ground. The problem is that these parts are heavy and cause the truck to exceed 26,000 lbs.

Consequently, most patch trucks require an operator with a commercial driver’s license (CDL). Due in part to the labor shortage, CDL drivers can be extremely challenging to locate and require a fairly large salary. This makes the driver the most expensive aspect of a patch truck over its lifespan.

However, Falcon asphalt patch trucks do not require a CDL driver. Instead of using heavy augers, conveyors, and hydraulics, Falcon patch trucks utilize gravity to move material from the hopper to the ground. As such, anyone with a standard driver’s license can drive and operate one.

The Truck

Asphalt patch trucks come in a wide range of makes, models, and sizes. The bigger the truck and the more material you need to carry, the more expensive it will be. Additional features such as air conditioning and other options can significantly affect the cost.

If you’re on a tight budget, consider purchasing a used truck. But remember that it could require more frequent repairs and maintenance, leading to increased downtime.

Considering the rugged operating conditions most asphalt trucks operate under, it’s not uncommon for a used truck to require an expensive transmission or engine teardown and rebuild. Fuel economy (or lack thereof) can also play a massive role in the lifetime cost.


Most patch trucks utilize a complicated and expensive auger and conveyor system, which moves material from the hopper to the ground. When they break down, it results in costly repairs and two to three weeks of potential downtime. 

A Falcon patch truck, however, uses gravity dump instead of an auger and conveyor to move asphalt. As such, you won’t have to worry about expensive repairs or lengthy repair times.


The more components a patch truck has, the more potential for something to break. This is another key advantage of Falcon patch trucks—they’re built with simplicity and durability in mind. 

However, like any vehicle, the truck may require maintenance and repairs in the future. For example, if there is a maintenance recall, you’ll need to work with the truck manufacturer or dealership (Ford, etc.) to resolve it. 

As such, be sure to perform due diligence when selecting the right make and model for your new patch truck. You can choose from one of seven different brands for a Falcon patch truck:

  • Ford F750
  • Freightliner M2 106
  • Hino 268A
  • International MV
  • Kenworth T270
  • Mack MD6
  • Peterbilt 536/7

Alternatively, you can also supply your own truck. However, check with Falcon first to see if it is compatible with our equipment.


Add-on parts and features can exponentially increase the overall cost of a patch truck. You should know exactly what you need for asphalt repair so that you don’t inadvertently choose options you don’t need. 

Falcon Asphalt Patch Truck Benefits

A Falcon asphalt patch truck is an excellent investment. In addition to not needing an expensive CDL driver, it offers the following benefits:

  • Increased uptime—Thanks to minimal moving parts, you won’t have to worry about the auger or hydraulics breaking down in the future.
  • Improved maneuverability—It’s challenging to navigate tight city streets with a trailer. Asphalt patch trucks allow your workers to operate in the city with ease.
  • Lower maintenance costs—Augers and conveyors are expensive to repair and even more expensive to replace. Thanks to the gravity dump used by Falcon patch trucks, you won’t have to deal with expensive maintenance or repair costs.
  • Improved productivity—You can keep material overnight for use the next day with a Falcon patch truck, eliminating the need for workers to sit in rush-hour traffic or long lines at the asphalt plant. Simply turn the burner up in the morning, and yesterday’s material is ready for today’s shift.
  • Increased durability—At Falcon, we build our patch trucks using the same materials as our other highly popular hot boxes. You’ll get the same brand-name components and high-quality materials that make our hot boxes so reliable.

Falcon Patch Trucks Save Time and Money

Falcon patch trucks offer an excellent way to save time and money while performing regular pothole repairs. Click below to learn more about the many available patch truck options we offer.

See Our Asphalt Patch Truck Options

Asphalt patching is essential in maintaining roadways, parking lots, and other paved surfaces. Patch trucks are the de facto workhorse used by many municipalities and patching operations thanks to their efficiency and cost-effectiveness. 

The downside to traditional asphalt patching trucks is that they require a CDL license to operate. Hiring CDL workers is difficult because there are few out there, and if you do find one, you’ll need to pay them a higher salary.

Non-CDL asphalt patch trucks are the answer to this costly problem. Non-CDL patch trucks look and operate the same as traditional ones. However, they weigh less than 26,000 pounds, which is the cutoff for requiring a CDL license.

Read on to learn more about Falcon non-CDL asphalt patch trucks, their features, and the benefits they will add to your patching operation.

CDL Requirements

Part of the reason why CDL drivers are so expensive to hire and somewhat challenging to find is that it’s not easy to become one. The FMCSA (Federal Motor Carrier Safety Administration) Safety Act of 1986 sets forth the requirements for obtaining a CDL license.

All applicants must first apply for and receive a Commercial Learner’s Permit (CLP). This enables them to legally drive a commercial motor vehicle while being supervised by an instructor.

To apply for a CDL, applicants must:

  • Have a valid non-commercial driver’s license
  • Be at least 21 years old (if transporting hazardous materials or driving across state lines)
  • Have proof of citizenship and residency
  • Pass all background checks
  • Pass an intensive medical examination
  • Provide a statement that certifies they’re not subject to disqualification as per FMCSA 383.51
  • Pass a state-approved written test and road test

Competition to hire CDL drivers is relatively intense and often results in very high salary and benefits packages. Many municipalities and smaller patching operations often cannot afford to offer competitive salaries and benefits commensurate with what large corporations will pay.

How Non-CDL Asphalt Patching Trucks Work

The FMCSA requires all trucks that weigh 26,001 lbs or more to have a driver with a CDL license. Falcon non-CDL asphalt patch trucks weigh under 26,000 lbs—meaning anyone with a valid standard driver’s license can operate them.

How is that possible?

For starters, a Falcon non-CDL patch truck does not utilize an auger or conveyor belt like a traditional one. Instead, Falcon uses a gravity dump to deliver the material to the patch site.

Augers, conveyors, and the hydraulics used to run them are extremely heavy. The lack of those parts allows the Falcon patch truck to weigh less than 26,000 lbs.

Benefits of a Falcon Non-CDL Asphalt Patch Truck

In addition to not requiring a CDL license, Falcon non-CDL asphalt patch trucks have a user-friendly design that offers several other benefits, such as:

Faster material delivery

Traditional patch trucks that utilize an auger and conveyor belt are limited in the quantity of material and speed they can deliver it due to their significantly smaller unloading opening. This can substantially slow down worker productivity and cause each patch job to take longer.

Falcon non-CDL asphalt patch trucks have the largest delivery doors on the market. This means workers have the flexibility to determine how much material they want and at what speeds they will get it. Those same large doors also allow for easier access to the hopper for cleaning.

Lowered lifetime cost

Falcon non-CDL asphalt patch trucks are more cost-effective than their counterparts, thanks to the lack of hydraulics, augers, and conveyor belts. Fewer components mean fewer things that can break down in the future.

Another significant cost saver is that you won’t have to hire an expensive driver with a CDL license. If that driver should suddenly resign or call in sick, you’d be scrambling to find someone qualified to drive a CDL truck.

More fuel efficient

Because Falcon non-CDL asphalt patch trucks do not have hydraulic motors or pumps to turn an auger, they also burn less fuel. That adds up to significant cost savings over an 8-hour shift. 

Fewer trips to the asphalt plant

Workers also have the option to hold material overnight, which allows them to start working immediately the next day instead of waiting in line at the asphalt plant—which might be located on the other side of town—in rush hour traffic. 

Fewer moving parts

Due to not having an auger, hydraulic pump, or conveyor belt, Falcon non-CDL asphalt patch trucks have fewer parts than their traditional counterparts. This directly translates into increased uptime availability and lower maintenance and operating costs over the truck’s lifetime.

Sufficient capacity

Non-CDL asphalt patch trucks from Falcon have an 8,000 lb carrying capacity—which is more than enough material to be held at the optimum temperature.  


One of the most significant benefits of the Falcon non-CDL asphalt patch truck is that it uses the same guts, hopper, and tack tank as their other highly popular and durable hotboxes, trailers, and recyclers. 

Your choice of truck

The Falcon non-CDL asphalt patch truck requires a class 6 truck. You can supply your own truck or choose from one of seven different models that we’ll provide:

  • Ford F750
  • Freightliner MD6 106
  • Hino 268A
  • International MV
  • Kenworth T270
  • Mack MD6
  • Peterbilt 536/7

The size, brand, options, etc. of the truck we supply will determine the final cost. If you have a different brand truck than listed above, call us and we’ll help you figure out if we can make it work. We’re more than happy to consider alternative truck options.

Non-CDL Asphalt Patch Truck Required Maintenance

Falcon non-CDL asphalt patch trucks require very little maintenance compared to their traditional counterparts. However, basic maintenance requirements are the same as other patchers, including burner and battery maintenance, keeping the hopper clean, and truck upkeep.


Falcon Non-CDL Asphalt Patching Trucks

Falcon non-CDL asphalt patching trucks will save you time, money, and headaches in the long run. They’ll increase productivity and efficiency while reducing the need for expensive maintenance and operators. Click below to learn more.


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