Megapoxy 206 Ultra

For high-load civil engineering applications like pile splicing, rail track grouting, and anchoring steel bolts into concrete, Megapoxy 206 Ultra provides a 100% solids, flowable epoxy grout that develops high compressive and impact strengths. It is a hydrophilic, water-displacing formulation that maintains adhesion and cures under adverse cold and damp conditions, and complies with AS/NZS 4020:2005 for contact with drinking water.

High-strength structural grouting

Megapoxy 206 Ultra is a solvent-free, two-part epoxy grout designed to pour under plates as thin as 5mm. Its low mixed viscosity of 10,000 cps allows it to flow easily around complex structural components, bridge bearing pads, and machinery bases. The hydrophilic chemistry ensures that the grout displaces water on damp concrete and steel surfaces, achieving a permanent bond that retains its physical strength even after prolonged immersion in water. With a compressive yield strength of 95 MPa and an ultimate compressive strength of 115 MPa, it provides a stable load path superior to standard concrete.

Numbers that matter

• 115 MPa compressive strength (ASTM C579): High ultimate load-bearing capacity for grouting heavy machinery, locking bearings, and high-impact civil applications.
• 9.5 MPa steel bond strength (ASTM D897): High-tensile adhesion directly to prepared steel surfaces, critical for pile splicing and securing anchor bolts.
• 5mm to 50mm pour depth: The allowable thickness limits for a single pour, accommodating thin-plate installations up to deeper core holes.
• 24-hour cure window (at 25°C): Reaches minimum cure in 24 hours at 25°C (extends to 48 hours at 15°C; reduces to 12 hours at 35°C) to manage project handovers.
• 30-minute work time (at 25°C): The practical application window to mix, pour, and align heavy machinery or steel bars before curing begins.

Where to use it

• Piling and foundations: Structural pile splicing, pile repair, and restoration in damp or tidal zones.
• Heavy machinery: Precision grouting under machinery bases, locking structural bearings, and stabilizing bridge bearing pads.
• Civil anchoring: Setting anchor bolts, locking post-tensioning (PT) cables, filling core holes, and filling truncation pockets.
• Infrastructure: Rail track grouting and permanent concrete floor repairs.

Limitations

• Temperature limit: Do not apply if the ambient temperature is below 10°C.
• Coated surfaces: All paint, galvanizing, or previous coatings must be removed; bonding to coated substrates yields inferior bond strength compared to direct contact with prepared concrete or steel.
• Steel preparation: Wire brushing metal surfaces is insufficient and results in minimal adhesion only; steel must be grit blasted and degreased.

Installation and surface preparation

Proper mechanical preparation is essential to prevent bond failure under high service loads.

Concrete preparation: Surfaces must be free from grease and oil. Remove laitance via mechanical scabbling, grit blasting, or grinding. If mechanical preparation is impossible, acid etch using a 1:1 mix of hydrochloric acid and water at 0.5 litres per square metre, allow to react for 10 minutes, wash thoroughly, scrub, and allow to dry for 24 hours. For maximum adhesion, the concrete should be surface dry.

Metal preparation: Grit blast steel to AS 1627.2.2002 to achieve a bright metal finish, then degrease by flooding with an industrial-grade degreaser.

Mixing procedure: Megapoxy 206 Ultra is supplied in pre-metered kits. Pour the entire contents of Part B into the Part A pail. Mix thoroughly for 2 minutes manually or with a low-speed mechanical stirrer (under 200 rpm), scraping the base and corners. Scrape the sides of the pail with a straight edge to release unmixed Part A, then mix for an additional 1 minute. If a black ring of Part B remains at the edge, tilt the mixer approximately 30° to pull it into the flow. Apply the mixed grout immediately. For clean-up of tools and mixing equipment, use Megapoxy Thinners.