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Megapoxy 206 Ultra is a heavy-duty, solvent-free epoxy grout engineered for critical civil infrastructure and high-impact industrial load-bearing. This hydrophilic, 100% solids system displaces water to ensure bond integrity on damp substrates, achieving a 120MPa compressive strength and 7.7Gpa Modulus of Elasticity.
Its flowable 10,000cps mixed viscosity enables precision grouting of bridge bearing pads, rail tracks, and machinery baseplates under 5mm tolerances. Structural remediation contractors must grit blast metal to Class 3 finish and mechanically abrade concrete to remove laitance, as wire brushing results in minimal adhesion and potential bond failure.
To prevent structural failure from incomplete mixing, the black ring of Part B must be fully incorporated into the grey resin until homogeneity is reached. Pouring from a single entry point is mandatory to prevent air entrapment, ensuring a monolithic seal that withstands intense vibration and chemical attack.
Frequently Asked Questions
What is the minimum gap that Megapoxy 206 Ultra can be poured into?
Megapoxy 206 Ultra has an excellent flowable consistency. It is specifically designed to be poured into tight spaces and can effectively fill gaps under machinery plates as fine as 5mm, ensuring a complete and void-free fill.
Can this grout be used on damp concrete?
Yes. Megapoxy 206 Ultra is a hydrophilic (water-displacing) epoxy. While surfaces should be free of standing water, the grout is designed to adhere and cure reliably on damp surfaces, making it highly effective for challenging site conditions where achieving a perfectly dry substrate is difficult.
How should I prepare steel surfaces like anchor bolts before grouting?
For maximum adhesion, all metal surfaces should be grit blasted to an AS CK 9.4-1964 Class 3 finish. If this is not possible, mechanically abrade the surface to clean, bright metal. After abrading, the steel must be degreased with an industrial-grade solvent before grouting.
Is Megapoxy 206 Ultra UV resistant?
Yes, Megapoxy 206 Ultra has good UV resistance, making it suitable for applications where the grout will be exposed to sunlight, such as external rail track pads and bridge bearing pads. For critical aesthetic applications, a final UV-stable topcoat can be applied.
Applications & Benefits
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Grouting under heavy machinery and industrial equipment baseplates. | High compressive strength and vibration resistance provides a durable, stable foundation. | Civil Engineers, Industrial Installers, Mining |
| Securing rail track pads and bridge bearing pads. | Proven performance in critical infrastructure with exceptional strength and durability. | Infrastructure Contractors, Civil Engineers |
| Setting and anchoring steel bolts, dowels, and starter bars into concrete. | Bond strength is superior to concrete, ensuring anchor pull-out strength is maximised. | Remedial Builders, Structural Engineers |
| Repairing concrete floors and filling core holes or truncation pockets. | Flowable consistency ensures complete filling of voids for a monolithic, high-strength repair. | Flooring Contractors, Concrete Repairers |
Applying Megapoxy 206 Ultra: Professional Protocols
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Step 1: Surface Preparation
Ensure all concrete is clean, sound, and mechanically abraded to remove laitance. Steel must be grit blasted or ground to bright metal and degreased. Erect and seal all formwork.
Pro Tip: The minimum application temperature is 10°C. In high ambient temperatures, store the product in a cool place before use to maximise the 30-minute work time. -
Step 2: Mixing
The pre-metered kits are designed for simple and accurate mixing. Do not alter mix ratios.
Mixing Ratio & Technique
Add the entire contents of Part B into the Part A container. Using a low-speed mechanical stirrer (200rpm or less), mix for 2 minutes. Scrape the sides and base with a straight edge, then mix for 1 more minute until uniform.
Pro Tip: Do not move the mixer up and down, as this can introduce air into the grout. Keep the mixer head submerged. -
Step 3: Pouring & Curing
The mixed grout must be applied immediately. Pour from one side of the formwork to allow air to escape from the other side.
Application
Pour the grout continuously until the void is filled. The flowable consistency will ensure it self-levels and fills the entire space.
Curing: Allow a minimum of 24 hours to cure at 25°C before subjecting the grout to load. The work time is approximately 30 minutes at 25°C.
Limitations & Safety
Product Limitations
Minimum application temperature is 10°C.
It is essential that the correct 5:1 mix ratio is used and that components are thoroughly mixed to achieve specified properties.
While suitable for damp surfaces, do not apply to areas with standing or flowing water.
Safety & Handling Requirements
Hazard Information
DANGER (Part B) / WARNING (Part A). Part B is Corrosive and causes severe skin burns and eye damage. Part A causes skin and eye irritation. Both parts can cause an allergic skin reaction. Read SDS for both components before use.
Personal Protective Equipment (PPE)
Wear chemical-resistant gloves (nitrile rubber), safety glasses with side shields or chemical goggles, and protective work clothing. An eyewash station should be readily accessible.
Handling & Ventilation
Use in a well-ventilated area. Avoid breathing vapours. Wash hands, face, and all exposed skin thoroughly after handling. Contaminated work clothing should not be allowed out of the workplace.
Emergency First Aid
Eyes:
Causes severe burns/damage. Immediately flush with running water for at least 15 minutes. Urgently seek medical attention.
Skin:
Causes severe burns/irritation. Remove contaminated clothing immediately. Flush skin with running water for 15 minutes. Seek medical attention.
Inhaled:
Remove from exposure to fresh air. Seek medical advice if effects persist.
Swallowed:
Harmful if swallowed. Rinse mouth. DO NOT induce vomiting. Give a glass of water and call a POISON CENTRE (13 11 26) or doctor immediately.
Adhesion & Preparation Guide
Concrete
Surface Preparation
Concrete must be free from grease, oil, and laitance. Clean with an industrial degreaser, then remove the surface laitance by mechanical abrasion (grit blasting, grinding, or scabbling). Thoroughly vacuum all dust. Surface can be damp but must be free of standing water.
No primer typically required
Megapoxy 206 Ultra is a penetrating epoxy designed to bond directly to a properly prepared concrete surface without the need for a separate primer.
Metal Surfaces (Steel)
Surface Preparation
For optimal bond strength, metals should be grit blasted to an AS CK 9.4-1964 Class 3 finish. If not possible, mechanically abrade to a clean, bright metal surface. After abrasion, degrease the surface by flooding with an industrial-grade solvent.
No primer required
No primer is required for bonding to properly prepared metal surfaces. The key is achieving a clean, profiled, and degreased finish.
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