Dura-Fill Mastic®

Durable Repair for All Climates

General Information

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

Recommended Uses: Dura-Fill MASTIC is recommended for sealing wide cracks and joints, as well as repairing a large variety of distresses in concrete and asphalt pavements. It is designed for large cracks and distressed surface areas too small for re-paving 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 using an oil-jacketed kettle designed for mastic materials. 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 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 pre- pared area. Dura-Fill Mastic 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 can be covered with a surface aggregate. Dura-Fill Mastic 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. A significant viscosity increase accompanied by stringiness signals the approach of gelation. If this occurs, immediately remove the materi- al 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.

Product Specification Table

When tested in accordance with ASTM D 5329, 36 and 8260.
Penetration77°400º F Max.
Application Temperature60 dmm Max.
Softening Point200° F Min.
Low Temperature Flexibility1” Mandrel Bend at 0° FPass
Asphalt CompatibilityPass
Flash Point400° F Min.
Heating Temperature410° F Max.
Application Temperature200° F Min.
Heating Time12 Hours Max.
Low Temperature Flexibility1” Mandrel BendPass 32° F
Mastic Resilience50% Min.

Product Highlights

  • ExcellentAdhesion
  • Rapid Melting
  • Resists Tracking
  • For Asphalt and Concrete Surfaces

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


P&T Products’ Specifications


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