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.
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.
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.
Yes, Megapoxy 206 Ultra complies with AS/NZS 4020:2005 for products used in contact with drinking water. This makes it suitable for potable water infrastructure applications where compliance is critical.
The maximum recommended single pour depth is 50mm. For applications requiring greater depths, it is necessary to consult Megapoxy technical services for specific guidance.
Yes, it is formulated to adhere and cure effectively under adverse conditions, including cold and damp environments. The minimum application temperature is 10°C, and it exhibits good strength retention even after prolonged water immersion.
Drill a hole approximately 1.5 times the steel diameter. Blow out dust with oil-free compressed air. Ensure the steel is grit blasted and degreased for optimal bond, then pour from one side to release air.
No, it is strongly recommended to remove all coatings before bonding. Bonding to coated surfaces will result in significantly inferior bond strengths and may lead to product failure.
| Application | Key benefit | Primary trades |
|---|---|---|
| Pile splicing and repair | Develops 115MPa compressive strength, ensuring high structural integrity and longevity, even in damp conditions. | Civil contractors, structural engineers |
| Machinery grouting and backing crusher parts | Provides high compressive (115MPa) and impact strength for heavy machinery, reducing wear and vibration. | Industrial engineers, mechanical fitters |
| Setting anchor bolts and locking PT cables | Achieves >150kN pull-out strength for 25mm rebar, providing reliable anchoring and secure post-tensioning. | Structural engineers, concreters |
| Bridge bearing pads and rail track grouting | Offers strong bond to concrete and steel (>9.5MPa), maintaining critical alignments and resisting dynamic loads. | Rail infrastructure, civil contractors |
| Core hole filling and floor repairs | Superior to concrete with 28MPa tensile strength and 80 Shore D hardness, resisting heavy traffic and chemical attack. | Concreters, maintenance crews |
| Contact with drinking water infrastructure | AS/NZS 4020:2005 compliance ensures suitability and safety for potable water applications. | Civil infrastructure, water treatment specialists |
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.
The pre-metered kits are designed for simple and accurate mixing. Do not alter mix ratios.
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.
The mixed grout must be applied immediately. Pour from one side of the formwork to allow air to escape from the other side.
Pour the grout continuously until the void is filled. The flowable consistency will ensure it self-levels and fills the entire space.
DANGER
Wear safety shoes, protective clothing, nitrile rubber gloves, safety glasses, and a suitable respirator. Contaminated work clothing must not leave the workplace. Always wash hands thoroughly after handling, before eating, drinking, or using the toilet.
Ensure adequate ventilation to keep air concentrations below exposure standards. Use in well-ventilated areas, with local exhaust ventilation or an appropriate respirator. Prevent vapour concentration in hollows or sumps.
Store in a cool, dry, well-ventilated place, out of direct sunlight and away from foodstuffs, incompatible materials, and sources of heat/ignition. Store locked up with containers closed and upright. Dispose of material and containers in accordance with local, regional, national, and international regulations. Part A is Class 9 Dangerous Goods, Part B is Class 8 Corrosive.
Proper surface preparation is crucial for Megapoxy 206 Ultra to achieve its documented performance, ensuring long-term bond strength and structural integrity.
Surface prep: Remove all grease and oil with an industrial heavy-duty degreaser. Mechanically abrade the surface using scabbling, grit blasting, or grinding to remove surface laitance. If mechanical methods are not possible, acid etching can be performed using a 1:1 mixture of concentrated hydrochloric acid and water, spread at 0.5 L/m². Allow to react for 10 minutes, then wash thoroughly and scrub. Allow 24 hours to dry. Concrete must be surface dry for maximum adhesion.
Primer: Not required for prepared concrete.
Surface prep: Grit blast to AS 1627.2.2002. If grit blasting is not possible, mechanically abrade to a clean, bright metal finish. Degrease the abraded surface by flooding with an industrial-grade degreaser. Wire brushing alone is not sufficient for optimal adhesion.
Primer: Not required for prepared metal.
Surface prep: All existing coatings must be removed entirely. For concrete, this involves flame-cleaning or mechanical scutching, followed by diamond grinding or scabbling. For metals, use a quality paint stripper, then grit blast or grind to a bright metal finish, ensuring all paint and galvanising are removed.
Primer: Not required after complete coating removal and substrate preparation.
| Property | Value |
|---|---|
| Mixing Ratio by Volume | 5 Part A to 1 Part B |
| Work Time at 25°C | 30 minutes |
| Minimum Cure Time at 15°C | 48 hours |
| Minimum Cure Time at 25°C | 24 hours |
| Minimum Cure Time at 35°C | 12 hours |
| Minimum Application Temperature | 10°C |
| Viscosity Part A at 25°C | 45000 - 55000 cps |
| Viscosity Part B at 25°C | 75-90 cps |
| Mixed Viscosity at 25°C | 10000 cps |
| S.G. Part A at 25°C | 1.60 - 1.70 |
| S.G. Part B at 25°C | 0.97 - 0.99 |
| Mixed S.G. at 25°C | 1.54 |
| Colour Part A | Grey |
| Colour Part B | Black |
| Appearance Mixed | Grey |
| Ultimate Compressive Strength - ASTM C579 | 115 MPa |
| Yield Compressive Strength - ASTM C579 | 95 MPa |
| Bond Strength Concrete - ASTM D4541 | >3 MPa |
| Tensile Bond Strength Steel - ASTM D897 | 9.5 MPa |
| Modulus of Elasticity - ASTM C579 | 3 GPa |
| Flexural Strength - ASTM D790 | 60 MPa |
| Tensile Strength ASTM D638 | 28 MPa |
| Tensile Lap Shear Strength - ASTM D1002 | 8 MPa (steel to steel) |
| Hardness - Shore D - ASTM D2240-00 | 80 |
| Dielectric Strength (kV/mm) | 58 |
| Surface Resistivity (Ohm) - ASTM D257 | 10¹² |
| Volume Resistivity (Ohm.cm) | 5.1x10¹⁰ |
| Peak Exotherm Temp - ASTM D2471 | 93.7°C (415ml) |
| VOC (g/l) - ASTM D3960 | 3 |
| Water Vapour Transmission - ASTM E96/E96M | 0.095 (gram/hr m²) |
| Water Absorption - ASTM D570 | 0.066 Increase in weight (%) |
| Minimum Grout Depth | 5 mm |
| Maximum Grout Depth | 50 mm |
Here are some common examples on where Megapoxy 206 Ultra used by our customers.
