For underground cable jointing and the encapsulation of electrical components, Megapoxy 34 is a low-viscosity, 100% solids epoxy resin formulation designed for electrical insulation and casting. It conforms to AS3100-1990 (including amendments 1 and 2 by AGL) for the encapsulating and potting of electrical components and cable joints, protecting sensitive connections against moisture ingress and electrical failure.
Megapoxy 34 pours easily into tight electrical switchgear housings, cable joints, and transformer casings due to its mixed viscosity of 905 cps. The low-viscosity liquid flows completely around intricate wiring, coils, and terminals to eliminate air voids that cause electrical tracking. Once cured, the formulation provides high dielectric strength (315 kv/cm) and volume resistivity ($10^{13}$ ohm.cm) to prevent short circuits in power transformers, lighting transformers, and instrument transformers. It also carries a high compressive strength of 90 MPa and resists chemicals and mechanical stress, protecting underground connections from soil pressure, shifting ground loads, and moisture.
To achieve reliable adhesion, clean all target surfaces with acetone or isopropyl alcohol to remove oil, moisture, and dust. For clean-up, use Megapoxy Thinners to clean mixing paddles and tools before the resin cures.
Megapoxy 34 is formulated for underground cable jointing and encapsulation of electrical components such as instrument transformers, lighting transformers, small power transformers, and coils. It is also used for casting electrical switchgear components and in applications requiring mechanical and chemical resistance.
Yes, Megapoxy 34 conforms to AS3100-1990, including amendments 1,2 by AGL. This ensures it meets the specified requirements for encapsulating and potting electrical components and cable joints for critical infrastructure.
Proper pre-treatment of surfaces is critical for good adhesion. All surfaces should be cleaned with acetone or isopropyl alcohol to remove impurities. Wire brushing is not an adequate method and will lead to poor adhesion.
Both Part A and Part B can cause irritation. Part B is corrosive, toxic, and causes severe skin burns and eye damage. Always wear safety shoes, nitrile gloves, and safety glasses. Ensure adequate ventilation and avoid skin and eye contact.
| Application | Key benefit | Primary trades |
|---|---|---|
| Underground cable jointing | Provides robust electrical insulation and mechanical protection for cable joints, meeting AS3100-1990 standards. | Electrical contractors, energy utility technicians |
| Encapsulation of instrument and power transformers | Ensures superior electrical and dielectric properties up to 150°C, protecting components from environmental factors. | Electrical component manufacturers, industrial electricians |
| Encapsulation of electrical coils | Offers high dielectric strength (315 kv/cm) and robust mechanical properties for long-term coil integrity. | Electrical component manufacturers |
| Casting electrical switchgear components | Delivers 90 MPa compressive strength and excellent chemical resistance for durable, compliant components. | Electrical switchgear manufacturers |
The Engineering Challenge: A newly designed transformer requires complete environmental sealing and mechanical support for its windings, along with guaranteed electrical insulation to prevent internal arcing under load.
The System-Based Solution with Megapoxy 34: After preparing the transformer housing and components, pour the mixed, low-viscosity Megapoxy 34 to fully encapsulate the core and windings. The resin flows into every void, curing to a solid 90 MPa block that resists vibration, while its 315 kv/cm dielectric strength provides insulation far exceeding the operational requirements.
Best Practice Note: For best results, consider pulling a light vacuum on the assembly during or after pouring to assist in removing any stubborn air bubbles from the transformer windings.
The Engineering Challenge: Creating a fully waterproof, mechanically robust, and electrically sound seal for a high-voltage underground cable joint that must withstand ground pressure and moisture for decades.
The System-Based Solution with Megapoxy 34: Use Megapoxy 34 to completely fill the jointing shell or mould around the prepared cable connection. It cures to form a 100% solids, impermeable barrier that prevents water ingress and resists chemical attack from the soil. Its dielectric properties ensure the long-term integrity of the electrical connection, in full conformance with AS3100-1990.
Best Practice Note: Ensure the 4 parts A to 3 parts B mix ratio is measured accurately by volume or weight. An incorrect ratio will compromise the cure and all final electrical and mechanical properties.
WARNING (Part A): Causes skin irritation, may cause an allergic skin reaction, causes serious eye irritation. Toxic to aquatic life with long lasting effects.
DANGER (Part B): Toxic if swallowed, toxic in contact with skin, fatal if inhaled. Causes severe skin burns and eye damage. Toxic to aquatic life with long lasting effects.
Wear safety shoes, nitrile gloves, and safety glasses. A suitable respirator is required if vapours or aerosols are present. Contaminated work clothing should not be worn outside the workplace.
Ensure ventilation is adequate. Use with local exhaust ventilation or while wearing an appropriate respirator. Do not enter confined spaces where vapour may have collected.
Store in a cool, dry, well-ventilated place, out of direct sunlight and away from foodstuffs or incompatible materials. Keep containers closed and standing upright. Store locked up. Dispose of contents and container according to local regulations.
Correct surface preparation is essential to ensure maximum bond strength and long-term performance when encapsulating or jointing electrical components with Megapoxy 34.
Surface prep: Clean all surfaces with acetone or isopropyl alcohol to remove any impurities, grease, or contaminants. Poor cleaning reduces bond strength and can inhibit effective encapsulation. Wire brushing is not sufficient for proper surface preparation.
Primer: Not required. The product bonds directly to properly cleaned surfaces.
| Property | Value |
|---|---|
| Mixing Ratio | 4 parts "A" to 3 parts "B" by volume or weight |
| Pot Life | 30 Minutes at 25ºC |
| Setting Time | 6 Hours at 25ºC |
| Cure Time | 24 Hours at 25ºC |
| Viscosity Part A | 1300 - 1900 cps |
| Viscosity Part B | 300 - 500 cps |
| Viscosity Mixed | 905 cps |
| Peak Service Temperature | 150ºC |
| Volume Resistivity | 10^13 ohm.cm |
| Dielectric Strength | 315 kv/cm |
| Compressive Strength | 90 MPa |
| Standards Conformance | AS3100-1990 including amendments 1,2 by AGL |
Here are some common examples on where Megapoxy 34 used by our customers.
