Mini Mill, Mini Patcher Pilot Program Yields Huge Results

In summer 2025, the maintenance division in PennDOT Engineering District 2 proved that to achieve big results, sometimes you have to think small. A pilot program aimed at improving the efficiency of patching operations utilized a mini mill and mini patching attachment that cover much narrower sections of roadway than traditional equipment but offer enormous gains in production.  

 The district rented a mini mill, with a cutting width of 21 inches, and a mini patching attachment for use on a skid steer, that together make it possible to repair narrow strips of roadway, while eliminating much of the labor intensive, and much slower process of manual patching.  

 “We went from an average of six tons of material being laid per crew, per day, to around 30 tons per crew, per day using this equipment,” said District 2 Maintenance Operations Manager Jason Powell.  

 The equipment provides gains in efficiency in a variety of ways. First, the mini mill is an independently powered piece of equipment, complete with a conveyor and a chute that loads millings directly into a tailing dump truck, where traditional skid steer attached millers leave behind the material to be removed by hand.  

 “This eliminates a lot of manual labor, a lot of shovel work,” Powell explained, noting that the mini patching attachment does the same in reverse, eliminating manual patching with a shovel. 

This equipment, attached to a skid steer, lays down narrow strips of fresh asphalt, smoothly and evenly, removing the need for the majority of work with hand tools.  

Powell credits Cameron, McKean, and Potter County Maintenance Manager Scott Majot with bringing the mini mill idea to their attention after seeing one in use and suggesting it could speed up the patching process. Maintenance personnel then put their heads together to expand that idea to include the accompanying patching attachment. The results proved beneficial enough to invest in this method in the future, with the district possibly procuring equipment of its own.  

“We’re looking at using the patching attachments on smaller loaders that we already have, getting the most out of our current equipment, and looking at the most beneficial and cost-effective way to continue this method going forward,” Powell said.