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NY Highways Pothole Pro Case Study


NY Highways Pothole Pro Case Study

Service Efficiencies

Case Study: JCB Pothole Pro – June 2022 Trial

Date: 10/06/2022

Contact Name: Afzal Deen (NY Highways)

Contact Number: 07890 068639

Contact Organisation: NY Highways Ltd

Contact Details: Terry Whitby (T.C Harrison JCB)


Contact Number: 077687 92884

My good idea was…

The new JCB Pothole Pro is a unique 3-in-1 solution specifically designed to rectify any pothole repair or large reinstatement operations, efficiently, economically, and permanently. Because it comes with 3 dedicated attachments to cut, crop and clean, there’s no need for additional specialist equipment or extra manpower, saving you both time and money.

Reasons to Believe

Safe Productive Permanent
-Eliminate hand arm vibration syndrome -1 pothole in 8 minutes -Dedicated cropping tool to square off edges
-Reduce the time spent in live carriageways -less time roading, more time working -Increased productivity means defects can be repaired while small in size
-Eliminate the need for a sweeper on site -300m2 in a single shift -The ability to repair a wide variety of defects and locations

Please see the rest of the table below:

Economical Trust
-3 machines in 1 -5 year/4000hrs machine warranty (excluding attachments)
-Significantly reducing the cost per defect -2 week operator training (can be split between 1 or 2 operators)
-A variety of different finance options available -Livelink telematics for 5 years and Dealer support

Benefits, environmental, cost savings, Heath and Safety

Utilising the Pothole Pro with NY Highways will enable the team to carry out a variety of repair types, spanning the full breadth of our road network. Designed to operate across rural and urban locations, the Pothole Pro can be used to tackle a range of defects varieties, including hot rolled asphalt.

During the demonstration, the Pothole Pro carried out permanent repairs using the unique cut, crop and clean method.

The machine offered a number of health and safety benefits to all of our employees and the general public on site. The operator has a full 360 view of the surrounding area when inside the cab, spotting every potential hazard. Furthermore, the self-sufficiency of the machine reduces the amount of personal operating in the carriageway.

Image Showing: Step 1 : Cut / Plane , Step 2: Crop , Step 3 : Clean / Sweep , Step 4 : Load , Image showing Transport Position

The machine enables the team to work within a full closure or a single lane closure.

Visibility is also greater for the machine operator thanks to how compact the machine is.

The main benefits of the JCB Pothole Pro over our traditional methods are, safety, productivity, environmental, and cost. The equipment is designed to require only one operator who can set all the attachments and work from the safety of the cab, so there is no exposure to the live road environment and there is no manual handling. It also offers a number of benefits to our employees, in particularly eliminating health and safety concerns that are common with the industry, such as Hand Arm Vibration Syndrome (HAVS). The machine crops the edges with absolutely no need to use vibration tools, this eliminates HAVS exposure and reduces the health impacts and subsequent claims from white finger.

The capacity of the unit allows for a full day of operation, and it delivers significantly lower cost per tonne compared to our traditional road defect repair methods, currently used. PotholePro customer data which encompasses material, labour and machinery has resulted in their customers dramatically reducing their cost per defect – some by up to 50%. With the analysis we have conducted, we expect to see similar results. Furthermore, whilst achieving a permanent repair and easily fixing all of the defects within a location.
The JCB Pothole Pro is fitted with a Stage V EPA compliant engine containing the latest in emissions technology, this means reduced engine emissions and hourly fuel consumption is low. The Pothole Pro operates as a self contained unit, meaning extra vehicles and tools such as sweepers, breakers and transport which would traditionally deliver machinery to site, are no longer required. This has a carbon reduction and a cost reduction, with no additional need to use transport. With the backlog we experience today – the increased output would enable us to tackle this, whilst reducing our cost per defect.


The JCB Pothole Pro was demonstrated was between the 6th and 10th of June, please see below a break down of the demonstration.

Table Showing the machines application over the 7 day demonstration: MondayStokesley We are currently hiring a skid steer with a 350mm planer and a 1 meter sweeper. Demo day 1 feedback from the ground crew is positive. They said the Pothole Pro is more efficient than their current process because of a 600mm planer and no changing between attachments. We closed the road and used 25 tonnes of tarmac . Planer average depth: 50mm Patches repaired: 16 Area achieved: 207.5[m2] Tuesday Stokesley Demo day 2 was under a time slot caused by working on a school road. The demo began at 9.30 and finished at 14.30. 10 tonnes of tarmac used on site. The machine was driven to Thirsk ready for Wednesday, this was a 20 mile trip – showing this machine can easily cover a large geographical area with no additional transport. Planer average depth: 50mm Patches repaired: 6 Area achieved: 83[m2] Wednesday Thirsk Demo day 3 used a stop and go traffic management system. The machine proved it could work effectively with working traffic. The demonstration was successful laying 20 tonnes of tarmac. Planer average depth: 50mm Patches repaired: 10 Area achieved: 166[m2] Thursday Brandsby York Machine was driven 24 miles to Brandsby York. The road was closed for demonstration, 20 tonnes of tarmac was used to repair the defects. Carl Les arrived to watch the demo. The feedback was positive. Planer average depth: 50mm Patches repaired: 11 Area achieved: 166[m2] Friday Shipton Machine driven to Shipton. Road was closed for the final demo day. 15 tonnes of tarmac was used. The machine was then driven back to Thirsk for end of the demonstration. Planer average depth: 50mm Patches repaired: 9 Area achieved: 124.5[m2]

Summary of Demonstration

Table showing the summary of the demonstration : Day Traditional Method Average 5 Tons of tarmac a day Pothole Pro Method Increase in Productivity % Monday 41.5[m2] 207.5[m2] 400% Tuesday 41.5[m2] 83[m2] 100% Wednesday 41.5[m2] 166[m2] 300% Thursday 41.5[m2] 166[m2] 300% Friday 41.5[m2] 124.5[m2] 200%

Week / YTD Comparison

table showing the week/ year to date comparison : Projection Traditional Method Pothole Pro Method Increase in Productivity % Average increase in productivity per week x 5 (working days) 207.5 [m2] 747[m2] 260% Average increase in productivity per year x 252 (working days) 10,458 [m2] 37,648.8 [m2] 260%

As you can see from the table above we could increase our productivity by 260%, with a very high quality of repair.

On Demo day one the machine completed 207.5[m2]  ,this is what our current methods achieve in one week. The ground crew felt they could have potentially doubled their output on the demonstration if there was a hotbox and a Mini Paver on site plus the machine not working in a demonstration environment. To gain the most productivity the ground crew would need a mini paver onsite which would increase cost, yet maintain productivity.  We would also advise a full road closure to allow the machine and prep work to always be in front to maximise the gangs working time on site. Please see in cost analysis that a estimated mini paver cost has been added to the analysis.

Key Live Link (Telematics) Data from demo – 06/06/2022 to 10/06/2022

Please see below the telematics data for the demonstration provided by JCB.

Cost Analysis

Below is a breakdown of our current methods vs the evidence from the PotholePro trial

Labour – 8 men

-2 Traffic Ambassadors

-2 Wagon drivers (waste and tarmac)

-4 land lay tarmacking gang

£34.64 per hr, per man, 8 hr shifts.


-4x vehicles

-1 Roller £180 including delivery and collection per week

– general small tools / power tool

Rate includes average for vehicles and tools.

£11,084.80 for the week.

Plus a rooming supervisor (costs booked to overheads)


10mm close graded surface course

Approximately 90 tonnes over 5 day

£79.45 pet tonnes of material

Total cost for Material: £7,150.50

Cost per week Analysis

Table showing Cost per week analysis: JCB Pothole Pro Comments Material £7,150.50 90 Tonnes tarmac x £79.45 Fuel £405.71 224.9 litres used x current fuel price 180.4 Cost of labour £5,068.62 (Average labour wage £26000 x 7 workers/ 255 working days x5) + (£300 for driver per day x 5 working day) Cost of Hire £4,201 cost of pothole pro £212,400/4 years + £180 Roller per week + mini paver £600 x 5 Total £16,825.98 Square meters per week 747 What was achieved in week [m2] cost per [m2] £22.52 Cost per week Analysis : Current Methods Comments Material £1,986.25 25 tonnes tarmac x £79.45 Fuel £410 11.36 litres per hour x 20 = 227.2 x current fuel price 180.4 Cost of labour £5,068.62 (Average labour wage £26000 x 7 workers/ 255 working days x5) + (£300 for driver per day x 5 working day) Cost of Hire £3,180 Skid steer £600 x 5 + Roller per week £180 Total £10,644.73 Square meters per week 207.5 What was achieved in week [m2] cost per [m2] £51.30

Comparing the rental of a skid steer vs owning the asset of the PotholePro is a challenge. Therefore for the cost comparison, the PotholePro total asset cost is divided by 4 years (208 weeks). Although, this does not include the residual value of the asset after this period.

JCB Pothole Pro / Driver Training

Table showing JCB Pothole Pro / driver training : Cost of driver per day £0 Driver training £0 Cost Machine £177,000.00 Sales Price VAT £35,400.00 Total £212,400.00 Optional Extra £241 (5000 hour service contract) per calendar month

Total cost of ownership for 12 months (Consumable parts)

Table showing Total cost of ownership for 12 months (Consumable parts) : Brush cost (each) £24 Total brush segments needed 24 Total cost to replace brushes £576 Pick Cost (each) £10 Picks per planer 52 Total cost to replace picks £520 Brushes life (Hours) 250 Pick life (Hours) 400 Estimated machine Hours per year 1000 Brush replacements required 3 Pick Replacements required 1.5 Brush replacement costs per year £1,728 Pick replacement cost per year £780 Total £2,508


JCB Pothole Pro – Cut, Crop, Clean, With One Machine | #FixingBritainsRoads – Bing video

JCB Pothole Pro Testimonial – Stoke-On-Trent City Council | FixingBritainsRoads – Bing video

The #JCB Pothole Pro – Man VS Machine – Bing video

Gallery and Final Results

Photos showing the process of filling a pothole using the JCB Hydradig pothole pro