Megapoxy 206 Ultra: A Technical Overview
Megapoxy 206 Ultra is a two-component, 100% solids epoxy grout engineered specifically for civil engineering applications where strength and durability are non-negotiable. Its flowable, water-displacing (hydrophilic) formula is designed to perform in tough site conditions, allowing it to adhere and cure effectively even in cold and damp environments. This heavy-duty grout provides exceptional resistance to vibration, impact, and chemicals, making it the trusted choice for grouting under heavy machinery baseplates, securing rail track pads on critical infrastructure, and locking structural elements in place. With performance proven on major projects like the Sydney Harbour Bridge rail deck upgrade and heavy industrial machinery installations, Megapoxy 206 Ultra delivers ultimate reliability.
120 MPa
Ultimate Compressive Strength. Engineered with strength superior to high-performance concrete, Megapoxy 206 Ultra provides absolute certainty for the most demanding structural and civil engineering applications.
Core Features & Specifications
- Extreme Compressive Strength: Achieves a final compressive strength of 120 MPa, ensuring it can withstand immense static and dynamic loads without failure.
- Superior Flowability: The low-viscosity mixed consistency allows the grout to flow easily into fine gaps and complex voids, ensuring a complete, monolithic fill under base plates as fine as 5mm.
- High Vibration & Impact Resistance: Specially formulated to absorb and withstand the extreme vibrations and impacts common in mining machinery and rail infrastructure applications.
- Hydrophilic Formulation: Adheres and cures effectively even in adverse conditions, including cold and damp environments, reducing project delays due to weather.
- 100% Solids, Solvent-Free System: A completely solvent-free (VOC-free) formula ensures no shrinkage during curing and is safer for use in enclosed environments.
- Excellent Chemical Resistance: Provides a durable, impermeable barrier against a wide range of industrial chemicals, oils, and corrosive substances.
The Megapoxy 206 Ultra Advantage
- Specify with Absolute Confidence: Backed by proven performance on iconic Australian infrastructure, Megapoxy 206 Ultra provides the verifiable technical data and reliability that engineers demand for critical projects.
- Minimise Costly Downtime: The combination of a reliable 24-hour cure and the ability to work in damp, cold conditions allows for faster project completion and minimises shutdowns of essential machinery and transport corridors.
- Achieve a Flawless Grout Fill: The superior flow characteristics ensure that even the most complex baseplates and voids are filled completely, eliminating air pockets and ensuring total load transfer.
- Deliver a Longer Service Life: Create a more robust and longer-lasting foundation for machinery and structural elements, significantly reducing future maintenance costs and extending the asset's operational life.
- Australian Made & Supported: Benefit from a reliable supply of Australian-made product with scalable production capabilities, backed by exceptional local technical support and service to keep major projects on track.
Proactive Troubleshooting
Scenario: Incomplete Mixing of Components
Potential Outcome: The grout will have soft spots or fail to cure to its specified strength. Unmixed resin on the sides of the pail is the most common cause of underperformance.
Adheseal Best Practice: Follow the mixing procedure precisely. After mixing for 2 minutes with a mechanical stirrer, stop and scrape the sides and base of the drum with a straight edge, then mix for another full minute to ensure 100% homogeneity.
Scenario: Application to Unprepared Concrete
Potential Outcome: Poor adhesion and potential delamination under load. The bond will fail at the weak, chalky layer of surface laitance instead of bonding to the solid concrete beneath.
Adheseal Best Practice: All concrete surfaces must be mechanically prepared by grinding, scabbling, or grit blasting to remove laitance and expose a clean, sound, and open-pored surface. Vacuum all dust before pouring the grout.
Applications in Practice: Trade Scenarios
For Infrastructure Contractors: Grouting Critical Rail Components
The Professional's Challenge
Securing rail track pads onto a major bridge deck requires a grout with certified high strength, extreme vibration resistance, and reliable supply to meet tight shutdown schedules, regardless of weather.
The Adheseal Solution: Engineered Certainty in Practice
Megapoxy 206 Ultra is the proven solution for this application. Its flowable nature allows it to be poured into formwork around the rail fasteners, completely encapsulating them. Its immense compressive strength and vibration resistance lock the system onto the concrete deck, ensuring long-term safety and reliability.
Best Practice Note
To ensure a continuous pour and prevent air entrapment under the rail pads, pour the mixed grout from one side of the formwork only, allowing it to flow steadily across and fill the void completely.
For Industrial Installers: Grouting Heavy Vibrating Machinery
The Professional's Challenge
Grouting the sole plates of heavy industrial equipment, like a mine cable winder, demands a grout that can achieve maximum strength, resist constant dynamic loads, and cure quickly to minimise costly production downtime.
The Adheseal Solution: Engineered Certainty in Practice
Megapoxy 206 Ultra is designed for this exact purpose. After levelling the machinery and erecting formwork, the flowable grout is poured to create a solid, high-strength pad. Its superior compressive strength and impact resistance provide a safer, more durable foundation than traditional cementitious grouts.
Best Practice Note
Ensure formwork is completely sealed to prevent leakage of the low-viscosity grout. Coat all formwork surfaces with a silicone-based release agent or Megapoxy Wax to allow for easy stripping once the grout has cured.
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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