DURA-FILL® Bridge Joint Mastic 

Formulated for All Climates

General Information

Description: Dura-Fill Bridge Joint Mastic is a pre-packaged, hot-applied material for bridge deck expan-sion joints. It meets ASTM D 6297 standards, offering a durable, waterproof, and flexible bond with a smooth surface transition. The product includes a polymer-modified binder and granite aggregate, conven-iently pre-measured for jobsite use. 

Recommended Uses: Dura-Fill Bridge Joint Mastic is suitable for exposed concrete or asphalt overlaid bridge decks. It can replace existing small movement expansion devices or be used for new installations of small movement joints. Application is limited to joints with movement up to 1 inch (25 mm) as per ASTM D 6297. Standard block-out dimensions are 2 to 8 inches (5 to 20 cm) deep and 20 to 24 inches (51 to 61 cm) wide. Avoid installation in excessive skew, incline, or severe stop-and-go configurations. 

Surface Preparation: Ensure proper construction and/or repair of joints for vertical sidewalls and a level bottom. The joint surfaces should be dry, clean from dust, dirt, grease, and loose materials. Install backer rods in the deck gap, followed by applying Dura-Fill Bridge Joint Adhesive to the prepared surface. Embed a steel or aluminum bridging plate centered in the joint with hot joint adhesive. Trowel the joint adhesive over the plate and all uncoated vertical sidewalls and horizontal surfaces. 

Melting: Heat the material in an oil-jacketed melter with horizontal-shaft paddle agitation. Start agitation once the material is sufficiently melted. Additional material can be added to the melter, ensuring heating and agitation until all added material is mixed and reaches a temperature of 350-400°F (193-204°C). During application, maintain continuous agitation to prevent aggregate settling. It is recommended to empty the melter or leave only small amounts of material. 

Application: After surface preparation, place Dura-Fill Bridge Joint Mastic into the joint up to a maximum depth of 2 inches. Allow it to air cool to 140°F or below before adding the next layer. Level the final layer smoothly with the adjacent pavement. For improved skid resistance, apply Dura-Top™ aggregate on top of the final layer. Spread Dura-Top aggregate at a rate of approximately 3 lbs. per lineal foot, depending on the joint width, once the surface temperature reaches 225-250°F (107-121°C) as measured by an infrared thermometer. The roadway is ready for traffic once the mastic has cooled. Do not apply Dura-Fill Bridge Joint Mastic when the pavement temperature is below 40°F (4°C). 

Note: The temperature of the heating oil should not exceed 525°F. Avoid heating the material beyond the maximum temperature to prevent gelation. If gelation is detected, remove the material from the melter im-mediately. Refer to the Dura-Fill SDS and P&T Products’ Warranty for more information. 

Ideal Uses 

• Bridge Deck Expan-sion Joints and Ap-proaches 
• Fixed End Joints 
• Pressure Relief Joints 
• New construction or Rehabilitation

Product Specification Table

Softening Point181 °F (83 °C) Min.
Tensile Adhesion700% Min.
Ductility77 °F (25 °C)400 mm Min.
Penetration77 °F (25 °C)75 dmm Max.
Penetration0 °F, 200 g, 60 s10 dmm Min.
Flow140 °F (60 °C), 5 hrs.3.0 mm Max.
Resiliency77 °F40 - 70%
Asphalt CompatibilityPass
Application Temperature360 - 390 °F (182 - 199°C)
Bond19°F (-7°C), 100% elongationPass 3 Cycles
Low Temperature Flexibility1/4” Mandrel Bend at -9 °F (-23 °C)Pass

* Specifications are as tested according to ASTM D36, D3529, D113, and D6297.

Surfacing Aggregates

Dura-Top surface aggregates are available in both ⅛ inch size and ¼ inch size with a maximum abrasion loss of 35% (ASTM C 131).

Granite Aggregate (68% Min.)

Screen Size, in. Passing, %
½90 to 100
¼0 to 40

Product Highlights

  • No Field Blending
  • Easy to Apply
  • Highly Durable
  • Maximum Flexibility
  • For Asphalt and Concrete
  • Cost Effective


WidthDepthPounds/100 Linear Feet


ASTM D 6297


Dura-Fill Mastics are packaged in 45 lb. polybags in a high-strength corrugated box. Each pallet contains 64 boxes or 2,880 pounds of Dura-Fill product.