DURA-FILL® Mastic - Gray

Formulated for All Climates

General Information

Description: Dura-Fill Mastic Gray is a hot-applied repair mastic comprised of a polymer-modified binder and select aggregate. This material is self adhesive. Dura-Fill Mastic Gray resists cracking, delamination, and spalling. It is a flexible material that can withstand heavy loads, weather, traffic and thermal movement. Mastic Gray provides a high-friction surface to ensure driver safety. Compaction equipment is not necessary with Dura-Fill Mastic Gray. This repair system is formulated to provide a feathered edge. 

Recommended Uses: Dura-Fill Mastic Gray is recommended for sealing wide cracks and joints, as well as repairing a large variety of distresses in cement and asphalt pavements. It is designed for large cracks and distressed surface areas too small for repaving yet too large for traditional hot applied crack sealants.

Surface Preparation: Proper surface preparation facilitates adhesion and consequently the maximum service life of the mastic. In order for proper adhesion to occur, the surface must be free of moisture, dust, loose aggregate, and other contaminates. Avoid use in highly distressed areas that require reconstruction. The substrate and air temperatures must be 40 °F or above. Use oil-free compressed air and heat to clean and dry the area immediately prior to application. Heating the pavement will promote bonding between the mastic and pavement surface. Caution do not to overheat/oxidize the pavement. 

Melting and Application: Melt Dura-Fill Mastic Gray using an oil-jacketed kettle designed for mastic mate-rials. The kettle should be equipped with an agitator and temperature control devices for the material and heating oil. Carefully insert small quantities of Dura-Fill product and the plastic bag into the melter while the agitator is turned off to avoid splash back. Once material has reached application temperature, apply to freshly prepared area. Dura-Fill Mastic Gray can be applied directly from the melter using an appropriate flute, bucket, or mastic wagon. Immediately following application, the mastic shall be leveled and smoothed using mastic flutes. In deep installations, mastic may be applied in layers, cooling in between. When mastic is installed where added skid resistance is desired, Dura-Fill Mastic Gray can be covered with Dura-Top™ surface aggregate. Dura-Fill Mastic Gray is ready for traffic when it has cooled and solidified.

Note: The temperature of the heating oil should not exceed 525 °F. Do not heat material over the maxi-mum 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 on the pavement. Boiling indicates polymer degradation, and a significant viscosity increase accompanied by stringiness signals the onset of gelation. If either occurs, immediately remove the material from the melter and dispose of it.

For further details read and follow the Dura-Fill SDS, Mastic Installation Instructions, and P&T Products’ Warranty.

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). 

Ideal Uses

• Pavement cracks or joints over 1.5 inches wide 
• Potholes, utility cuts, manhole covers 
• Spalls, pop-outs, and corner breaks 
• Localized skin patch repairs 
• Repairs prior to surface treatments 
• Bridge approaches or faulted areas
• Depressed thermal cracks 

Product Specification Table

Penetration77 °F90 dmm Max.
Resiliency77 °F60% Min.
Softening Point176 °F Min.
Low Temperature Flexibility1” Mandrel Bend at 20 °FPass
Viscosity375 °F100 Poise Max.
Heating Temperature400 °F Max.
Application Temperature375 - 395 °F
Heating Time12 Hours Max.
Specific GravityApproximately 1.8

* Specifications are as tested according to ASTM D5329 and D36.

Product Highlights

  • Excellent Adhesion
  • Rapid Melting
  • Resists Tracking
  • Versatile Color Shade


P&T Products’ Specifications


Dura-Fill mastics are packaged in 45 lb poly bags in a high strength, corrugated box with each pallet containing 60 boxes or 2,700 pounds of mastic.