GemSeal DuraCrack® Crack Fillers
The hot-pour rubberized crack sealant Quality Paving uses to stop water intrusion before it becomes a pothole.
At A Glance
- Manufacturer
- GemSeal Pavement Products
- Product Type
- Hot-applied rubberized asphalt crack sealant
- Primary Purpose
- Sealing cracks in asphalt and concrete pavement
- Recommended Uses
- Parking lots, driveways, roadways, industrial pavement
- Surface Type
- Asphalt and concrete cracks 1/8" to 1" wide
- Application Temperature
- Melted and applied hot per manufacturer spec
- Flexibility
- Rubberized formula flexes with freeze-thaw and thermal movement
- Bond
- Strong adhesion to properly cleaned crack walls
- Color
- Black, blends with asphalt surface
- Typical Service Life
- Several years depending on traffic and crack movement
- Maintenance Recommendation
- Inspect annually; reseal new cracks as they form
What DuraCrack Is
DuraCrack® is a hot-applied rubberized crack sealant manufactured by GemSeal, engineered for professional pavement maintenance crews. It ships as solid blocks that are melted in a jacketed kettle-and-wand applicator on site, then poured into cleaned cracks where it cools into a flexible, watertight seal.
Cracks are the single biggest failure point in an asphalt pavement. Once a crack opens, water works its way to the base, undermines support, and freeze-thaw expansion turns a hairline into a pothole. Sealing cracks early — before they widen — is the highest-return maintenance a lot owner can perform, and it's the step that has to happen before any sealcoating goes down.
DuraCrack is formulated with polymer-modified asphalt and recycled rubber so it stays flexible year-round. Rigid fillers crack out the following winter; a rubberized hot-pour sealant flexes with the pavement as temperatures cycle, which is why it remains the specification of choice for professional crack repair on commercial and residential jobs across the Southeast.
Why We Use It
We pair DuraCrack with GemSeal PolyTar on virtually every sealcoating job we run. The two products are engineered by the same manufacturer to work together — crack fill first, sealer second — and specifying both from one technical program keeps our maintenance system consistent from lot to lot.
In the field, DuraCrack melts cleanly, wands out at a controlled rate, and cools to a durable seal that traffic can run on within a short window. That matters on commercial lots where we need to finish crack filling, sealcoat, and re-stripe on a tight overnight or weekend schedule.
Hot-pour rubberized sealant is a professional material option because it stays flexible through temperature swings and is designed for use with commercial crack-sealing equipment. On a re-seal program, we inspect crack conditions each visit and address new movement as needed.
Advantages & Limitations
- Bonds to properly cleaned crack walls and stays watertight
- Rubberized formula flexes with freeze-thaw and thermal movement
- Blocks water intrusion that undermines the base and causes potholes
- Compatible with GemSeal PolyTar sealcoating for a full maintenance system
- Fast return to service compared with cold-pour repair products
- Professional-grade material with published technical data and manufacturer support
- Uniform black finish that blends into asphalt surfaces
- Not a structural repair — will not fix potholes, alligator cracking, or areas of failed base. Those conditions require patching or resurfacing.
- Cracks must be clean and dry at the time of application; debris or moisture in the crack will compromise the bond.
- Very narrow hairline cracks (under roughly 1/8") may not accept hot-pour sealant and are typically addressed at the sealcoat stage instead.
- Requires specialized melter and wand equipment; not a DIY product.
- Fresh sealant must be allowed to cool before traffic to avoid tracking.
- Extreme crack widths may require a backer rod or a different repair strategy — we spec the right approach on inspection.
Typical Applications
Commercial Parking Lots
Retail centers, medical offices, and shopping plazas where sealing cracks early prevents pothole formation and protects the asphalt investment.
HOA & Church Lots
Community and church parking areas managed on multi-year maintenance programs where consistent, professional crack repair extends the re-seal cycle.
Industrial Facilities
Warehouse yards, loading areas, and truck aprons where heavy loads accelerate crack growth and water intrusion is a real base-failure risk.
Residential Driveways
Homeowner driveways where hot-pour crack sealing is an appropriate professional repair method for qualifying cracks.
Pre-Sealcoat Prep
Standard prep step before every PolyTar sealcoat application — cracks are sealed and cured before the sealer goes down.
How We Apply It
- 01
Inspection
We map cracks by width and type, flag any structural failures that need patching instead of sealing, and confirm the pavement is a candidate for crack filling.
- 02
Cleaning
Each crack is cleaned with wire wheel, blower, or heat lance as conditions require, so the sealant bonds to sound crack walls — not dust or vegetation.
- 03
Routing (as needed)
Where cracks warrant a reservoir cut for better sealant volume and bond, we rout to spec before filling.
- 04
Melting
DuraCrack blocks are melted in a jacketed kettle to the manufacturer's application temperature — monitored throughout the shift, not guessed at.
- 05
Application
Sealant is wanded into the crack at a controlled rate, slightly overfilled, then squeegeed flush or shaped per the specification for the job.
- 06
Cool-Down
The sealed cracks are allowed to cool before the lot returns to traffic; we post the site so no one drives on hot material.
- 07
Integration with Sealcoating
On combined crack-fill and sealcoat jobs, PolyTar sealcoat is applied after the crack sealant has fully cured, producing a uniform finished surface.
- 08
Final Inspection
Quality control walk with the customer, documentation of the work performed, and recommendations for the next maintenance cycle.
Frequently Asked Questions
What's the difference between DuraCrack and a hardware-store crack filler?
DuraCrack is a hot-applied rubberized sealant melted in professional equipment and installed by trained crews. Consumer squeeze-bottle fillers are cold-pour caulks that shrink, harden, and fail within a season or two. The installed performance is not comparable.
How wide of a crack can be filled?
Hot-pour rubberized sealant is designed for cracks roughly 1/8" to 1" wide. Narrower cracks are typically addressed at the sealcoat stage; wider defects or alligator cracking usually require patching or resurfacing instead.
Do you crack fill before sealcoating?
Yes — always. Crack filling is a required prep step before sealcoating. Skipping it means the sealer bridges an active crack that will re-open within months.
How long does DuraCrack last?
Properly installed hot-pour rubberized sealant typically remains effective for several years, depending on traffic loads, crack movement, and freeze-thaw exposure. On a re-seal program, we inspect and address new cracks each visit.
How soon can I drive on a filled crack?
Fresh sealant needs time to cool before traffic. We publish a specific re-open window on every job, typically the same day for driveways and within a short traffic-controlled interval for commercial lots.
Can you fill cracks in concrete too?
Yes — DuraCrack is used on both asphalt and concrete pavement cracks. We evaluate the substrate and crack condition on inspection to confirm it's the right product for the job.
Technical Data Sheets & SDS
We link directly to GemSeal's official Technical Data Sheet (TDS) and Safety Data Sheet (SDS) hosted by the manufacturer — always current, never a stale copy.
Official Documentation
We link directly to GemSeal's official resources rather than hosting copies. Always refer to the current manufacturer documentation for authoritative specifications.
What We've Learned Using DuraCrack
Real crew observations from Middle Georgia installations of DuraCrack — weather, cure, customer feedback, and long-term performance notes captured on the job.
DuraCrack In The Field
Explore More
- Projects using DuraCrack will be linked here as they are added.
- → Aggregate Base: The Foundation Under Your Pavement
- → Annual Inspection Checklist: What To Look For
- → Asphalt 101: A Property Owner's Guide
- → Asphalt Life Expectancy: How Long Should Your Pavement Really Last?
- → Asphalt Mixes: Why One Size Does Not Fit All
- → Benefits of GemSeal PolyTar: Why We Chose This Sealer
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