Crack and Joint Sealant for Moderate Climates

General Information

 Description: Dura-Fill Gray is a hot pour crack and joint sealant for portland cement and bleached asphaltic pavements. As an economical and effective preventative maintenance treatment, Dura-Fill prolongs pavement service life by sealing cracks and surface joints from water penetration which causes base failure and potholes. Dura-Fill Gray is a single component mix of asphaltic resins, synthetic polymeric rubbers, plasticizers, stabilizers, and a blend of organic and inorganic reinforcing fillers. When properly melted and applied, it forms a resilient and adhesive compound for both cement and asphaltic pavements. Dura-Fill Gray forms a long-lasting seal which resist tracking in warm temperatures and cracking in cold. 

Recommended Uses: Dura-Fill Gray is recommended for sealing joints and cracks in portland cement and bleached asphaltic pavements. It is designed to seal expansion and contraction joints, longitudinal and transverse cracks, joints between concrete and asphaltic shoulders, and random cracks. 

Surface Preparation: Proper surface preparation facilitates adhesion and consequently the maximum ser-vice life of the sealant. In order for proper adhesion, the crack/joint must be free of moisture, dust, loose aggregate, and other contaminates. The substrate and air temperatures must be 40 °F or above. Sawing, routing, and/or sandblasting are the preferred methods of preparation. Use oil-free compressed air and heat to clean and dry the crack/joint immediately prior to sealing. Cracks/joints should be sized so that the maximum extension and compression do not exceed 50% of the width. Best results are obtained when the cracks/joints are opened at least ½ inch wide. 

Melting and Application: Melt Dura-Fill Gray using a conventional oil-jacketed kettle equipped with agita-tor and temperature control devices for both the material and the heat-transfer oil. Carefully insert small quantities of Dura-Fill and the plastic bag into the melting equipment while the agitator is turned off. Load material slowly to avoid splash back. After the initial load has reached the recommended pouring tempera-ture, fresh material may be added to the melter as sealant is used. Melt only the material that will be used during that day. Purge material remaining in the melting kettle lines at the end of each sealing operation. The material may be safely reheated and can be applied using a pressure feed wand system or a pour pot.

Application Equipment: Equipment for applying Dura-Fill Gray is available for rent. Please call for details.  

Note: The temperature of the heat transfer oil should not exceed 525 °F. Do not heat Dura-Fill above the maximum heating temperature and do not maintain it at that temperature for prolonged periods of time. This could cause the material to gel in the equipment or fail in the joints. A significant viscosity increase accompanied by stringiness signals the 

For further details read and follow the Dura-Fill Gray Series SDS, Installation Instructions for Oil Jacketed Dura-Fill products, and P&T Products’ Warranty. 

Product Specification Table

* Specifications are as tested according to ASTM D 5329, 36, modified 3111, & 4402.
Heating Temperature400 °F Max.
Application Temperature370 to 390 °F
Heating Time12 Hours Max.
Penetration77 °F90 dmm Max.
Flow140 °F5 mm Max.
Bond50% Extension at 0 °FPass 5 Cycles
Softening Point176 °F Min.
Viscosity375 °F100 Poise Max.
Specific GravityApproximately 1.29
Asphalt CompatibilityPass
Flash Point400 °F Min.
Optimal ClimateAverage Temperatures0 to 90 °F (-17 to 32 °C)

Product Highlights

  • Flexible to 0°F
  • Versatile Color
  • Excellent Adhesion
  • Rapid Melting
  • Resists Tracking
  • Sets Up Quickly


WidthDepthPounds/100 Linear Feet


ASTM D 1190 ASTM D 6690 Type 1 AASHTO M 173 AASHTO M 324 Type 1 Fed. Spec. SS-S-164 FAA P 605 EN 14188N2


Dura-Fill is packaged in 30lb poly bags and boxed in high-strength corrugated cardboard. Each pallet contains 75 boxes or 2,250lb of sealant.