Dura-Fill® Mastic

Formulated 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 thermal 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 re-pairing a large variety of distresses in cement 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 Mastic 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. 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 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. 

Ideal Uses

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

Product Specification Table

Penetration77 °F50 dmm Max.
Softening Point200 °F Min.
Low Temperature Flexibility1” Mandrel Bend at 20°FPass
Asphalt CompatibilityPass
Flash Point400 °F Min.
Heating Temperature400 °F Max.
Application Temperature375 - 400 °F
Heating Time12 Hours Max.
Mastic Resilience50% Min.

*When tested in accordance with ASTM D 5329, 36, & 8260.

Product Highlights

  • ExcellentAdhesion
  • Rapid Melting
  • Resists Tracking

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 mastics are packaged in 45 lb. poly-bags and boxed in high-strength, corrugated cardboard. Each pallet contains 60 boxes or 2,700 pounds of mastic. Dura-Fill mastics are also available in Dura-Melt™ consumable packaging with each pallet containing 64 meltable boxes or 2,880 pounds of mastic.
DURA-FILL Mastic is also available in 45lb. Dura-Melt™ meltable boxes with each pallet containing 64 meltable boxes or 2,880 pounds of mastic.