Frozen premix, fillet-holding urethane adhesives/sealants

A process for forming a frozen premix urethane elastomer consisting of:

• (a) forming a first mixture consisting of a polyol component, a thixotropic agent, and at least one filler, said at least one polyol component consisting of a first polyol consisting essentially of hydroxyl-terminated polybutadiene and, optionally, at least one second polyol selected from the group consisting of castor oil, polyoxypropylene, and polyoxytetramethylene in an amount such that said polyol component has less than about 20 percent by weight of ether and ester moieties, said thixotropic agent consisting of hydrophobic fumed silica, said at least one filler being substantially free of water;
• (b) stirring said first mixture at an elevated temperature near the boiling point of water under vacuum until a substantially homogeneous mixture is obtained;
• (c) cooling said first mixture to room temperature;
• (d) adding an organo-metallic catalyst and at least one aliphatic polyisocyanate to said first mixture to form a second mixture;
• (e) stirring, said second mixture under vacuum until a substantially homogeneous mixture is obtained;
• (f) packaging said second mixture by placing it in a container for later dispensing therefrom and placing said container in a water vapor-proof material;
• and
• (g) quick-freezing said second mixture to a temperature below about -40.degree. F. (-40.degree. C.) and storing it at a temperature not greater than about -40.degree. F. (-40.degree. C.).