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At a Glance: Key Applications
Use Megapoxy 84 for: Bonding high-alumina ceramic tile linings to steel or concrete surfaces in high-temperature and high-abrasion industrial environments like chutes, hoppers, and processing equipment.
Megapoxy 84: A Technical Overview
Megapoxy 84 is a specialist two-component epoxy paste adhesive, engineered specifically for the demanding application of fixing high-alumina ceramic wear tiles. This is not a standard tile adhesive; it is a structural bonding system designed to perform in environments where extreme abrasion and elevated temperatures are constant. Its formulation delivers an immense ultimate compressive strength of 120 MPa, creating a rigid, load-bearing foundation for the tile lining. Crucially, it maintains this bond integrity at a continuous service temperature of 120°C, ensuring industrial assets are protected and service life is maximised in the harshest conditions.
Comparative Performance Overview
| Metric | Megapoxy 84 | Standard Cementitious Adhesive | Advantage |
|---|---|---|---|
| Max Service Temperature | 120°C | <80°C | Maintains its structural bond integrity in high-temperature industrial processes where standard adhesives would soften, fail, and cause lining detachment. |
| Compressive Strength | 120 MPa | ~15-20 MPa | Provides an incredibly rigid, structural base that fully supports the ceramic tiles, enabling the system to withstand extreme impact and point loading. |
| Adhesion to Steel | Engineered for direct bonding | Requires specialised primers | Forms a tenacious chemical bond directly to correctly prepared "white metal" steel surfaces, simplifying installation and ensuring a robust, reliable bond. |
| Chemical Resistance | High (Epoxy-based) | Low (Porous Cement) | The dense, cross-linked epoxy structure provides excellent resistance to chemical attack, protecting the substrate and the bond line in corrosive environments. |
Using Megapoxy 84 in a Complete System
Megapoxy 84 is the critical link in a three-part industrial lining system designed for ultimate asset protection. This engineered system consists of the substrate (steel or concrete), the adhesive layer (Megapoxy 84), and the wear-resistant layer (high-alumina ceramic tiles). Megapoxy 84’s role is to form an unbreakable, monolithic bond that perfectly transfers the extreme thermal and mechanical stresses encountered in service from the ceramic tiles through to the base structure. Its performance ensures the entire composite system functions as a single, durable unit.
How Megapoxy 84 Prevents Common Failures
Common failure prevention information
Failure Mode: Tile De-bonding in High Temperatures
Engineered for a continuous service temperature of 120°C, Megapoxy 84 maintains its powerful adhesive and cohesive strength. This prevents the bond from softening and failing under thermal load, which is the primary cause of lining detachment in high-temperature industrial processes.
Failure Mode: Adhesive Layer Fracture Under Impact
With an ultimate compressive strength of 120 MPa and flexural strength of 55 MPa, Megapoxy 84 cures to form an exceptionally rigid, structural layer. This fully supports the ceramic tiles, preventing the adhesive bed from cracking or crushing under high point loads and direct impacts.
Failure Mode: Delamination from Steel Substrates
The formulation is specifically designed to create a tenacious chemical bond with properly prepared steel surfaces (ground or grit blasted to a "white metal" finish). This direct, high-strength adhesion prevents delamination, even when subjected to the differential thermal expansion and contraction between steel and ceramic.
Core Features & Specifications
- High Service Temperature (120°C): Guarantees bond integrity and performance in elevated temperature applications where other adhesives would fail.
- Ultimate Compressive Strength (120 MPa): Provides an incredibly strong, rigid foundation that protects tiles from fracture under extreme loads and impacts.
- Ultimate Flexural Strength (55 MPa): Resists bending and shear forces, critical for maintaining bond integrity on surfaces subject to flex or vibration.
- Direct Adhesion to Steel & Concrete: Engineered to bond directly to correctly prepared industrial substrates, ensuring a reliable and permanent installation.
- Practical Work Time (30 Minutes): Allows applicators a sufficient window at 25°C to mix, apply, and accurately bed tiles before the adhesive begins to set.
- Trowelable Paste Consistency: Easy to apply with a notched trowel, allowing for consistent coverage and bond line thickness.
The Megapoxy 84 Advantage
- Maximise Asset Uptime: Install a lining system that lasts. The combination of high temperature resistance and extreme strength prevents premature failures, reducing downtime and maintenance costs.
- Engineer a Robust Protective System: Use an adhesive with quantifiable engineering properties to create a durable, composite lining that protects valuable steel and concrete assets from abrasion and heat.
- Simplify High-Performance Installations: Achieve a tenacious bond to steel without the need for complex primers, streamlining the application process while ensuring a superior result.
- Ensure Performance in Extreme Conditions: Trust a purpose-built solution designed to handle the dual challenges of high heat and heavy abrasion, providing peace of mind in critical industrial applications.
Applications in Practice: Trade Scenarios
For Industrial Applicators: Lining a Steel Feed Chute with Alumina Tiles
The Engineering Challenge: The chute is exposed to constant, severe abrasion from raw materials and process temperatures regularly exceeding 100°C. A durable, heat-resistant lining is essential to prevent rapid wear of the steel structure.
The System-Based Solution with Megapoxy 84: After grit blasting the steel interior to a "white metal" finish, apply the mixed Megapoxy 84 with a notched trowel at a rate of 1.25 L/m². Bed the high-alumina ceramic tiles firmly into the adhesive. The resulting system will withstand the extreme abrasion and maintain its bond at the 120°C service temperature.
Best Practice Note: The product develops its toughness after 48 hours. Ensure the newly lined chute is not exposed to elevated temperatures or heavy impact during this initial curing phase for optimal results.
For Asset Maintenance Teams: Repairing a Concrete Hopper Lining
The Engineering Challenge: Sections of a ceramic-tiled concrete hopper have failed due to impact and thermal cycling. The repair must be performed in-situ and provide a bond that is stronger and more heat-resistant than the original.
The System-Based Solution with Megapoxy 84: Scabble the damaged concrete areas to remove loose material and expose a solid, aggregate-filled surface. Apply the pale blue Megapoxy 84 paste and install new ceramic tiles. The paste consistency allows for vertical and overhead application, and the 72-hour full cure ensures a permanent, high-strength repair ready for service.
Best Practice Note: To avoid mixing errors on-site, it is advisable to mix the whole 2.5L kit at one time. Ensure thorough mixing for a minimum of 3 minutes, scraping the sides and bottom of the container.
Certifications & Regulatory Compliance
Megapoxy 84 is a high-performance industrial adhesive manufactured to stringent quality controls. Its ultimate strength and thermal resistance properties are specified to provide clear performance metrics for engineering and industrial applications. Surface preparation guidelines reference industry best practices, such as "white metal" finish for steel, to ensure system integrity. The formulation contains Nil VOCs (Volatile Organic Compounds), and all components are listed on the Australian Inventory of Chemical Substances (AICS).
Storage & Shelf Life Considerations
Store Megapoxy 84 kits in a cool, dry, well-ventilated area, and protect from direct sunlight. Containers must be kept tightly sealed when not in use. Part B is a corrosive substance and must be stored locked up in accordance with regulations. Proper storage is essential for maintaining the product's specified performance and ensuring safety on site.
At a Glance: Key Applications
Use Megapoxy 84 for: Bonding high-alumina ceramic tile linings to steel or concrete surfaces in high-temperature and high-abrasion industrial environments like chutes, hoppers, and processing equipment.
Megapoxy 84: A Technical Overview
Megapoxy 84 is a specialist two-component epoxy paste adhesive, engineered specifically for the demanding application of fixing high-alumina ceramic wear tiles. This is not a standard tile adhesive; it is a structural bonding system designed to perform in environments where extreme abrasion and elevated temperatures are constant. Its formulation delivers an immense ultimate compressive strength of 120 MPa, creating a rigid, load-bearing foundation for the tile lining. Crucially, it maintains this bond integrity at a continuous service temperature of 120°C, ensuring industrial assets are protected and service life is maximised in the harshest conditions.
Comparative Performance Overview
| Metric | Megapoxy 84 | Standard Cementitious Adhesive | Advantage |
|---|---|---|---|
| Max Service Temperature | 120°C | <80°C | Maintains its structural bond integrity in high-temperature industrial processes where standard adhesives would soften, fail, and cause lining detachment. |
| Compressive Strength | 120 MPa | ~15-20 MPa | Provides an incredibly rigid, structural base that fully supports the ceramic tiles, enabling the system to withstand extreme impact and point loading. |
| Adhesion to Steel | Engineered for direct bonding | Requires specialised primers | Forms a tenacious chemical bond directly to correctly prepared "white metal" steel surfaces, simplifying installation and ensuring a robust, reliable bond. |
| Chemical Resistance | High (Epoxy-based) | Low (Porous Cement) | The dense, cross-linked epoxy structure provides excellent resistance to chemical attack, protecting the substrate and the bond line in corrosive environments. |
Using Megapoxy 84 in a Complete System
Megapoxy 84 is the critical link in a three-part industrial lining system designed for ultimate asset protection. This engineered system consists of the substrate (steel or concrete), the adhesive layer (Megapoxy 84), and the wear-resistant layer (high-alumina ceramic tiles). Megapoxy 84’s role is to form an unbreakable, monolithic bond that perfectly transfers the extreme thermal and mechanical stresses encountered in service from the ceramic tiles through to the base structure. Its performance ensures the entire composite system functions as a single, durable unit.
How Megapoxy 84 Prevents Common Failures
Common failure prevention information
Failure Mode: Tile De-bonding in High Temperatures
Engineered for a continuous service temperature of 120°C, Megapoxy 84 maintains its powerful adhesive and cohesive strength. This prevents the bond from softening and failing under thermal load, which is the primary cause of lining detachment in high-temperature industrial processes.
Failure Mode: Adhesive Layer Fracture Under Impact
With an ultimate compressive strength of 120 MPa and flexural strength of 55 MPa, Megapoxy 84 cures to form an exceptionally rigid, structural layer. This fully supports the ceramic tiles, preventing the adhesive bed from cracking or crushing under high point loads and direct impacts.
Failure Mode: Delamination from Steel Substrates
The formulation is specifically designed to create a tenacious chemical bond with properly prepared steel surfaces (ground or grit blasted to a "white metal" finish). This direct, high-strength adhesion prevents delamination, even when subjected to the differential thermal expansion and contraction between steel and ceramic.
Core Features & Specifications
- High Service Temperature (120°C): Guarantees bond integrity and performance in elevated temperature applications where other adhesives would fail.
- Ultimate Compressive Strength (120 MPa): Provides an incredibly strong, rigid foundation that protects tiles from fracture under extreme loads and impacts.
- Ultimate Flexural Strength (55 MPa): Resists bending and shear forces, critical for maintaining bond integrity on surfaces subject to flex or vibration.
- Direct Adhesion to Steel & Concrete: Engineered to bond directly to correctly prepared industrial substrates, ensuring a reliable and permanent installation.
- Practical Work Time (30 Minutes): Allows applicators a sufficient window at 25°C to mix, apply, and accurately bed tiles before the adhesive begins to set.
- Trowelable Paste Consistency: Easy to apply with a notched trowel, allowing for consistent coverage and bond line thickness.
The Megapoxy 84 Advantage
- Maximise Asset Uptime: Install a lining system that lasts. The combination of high temperature resistance and extreme strength prevents premature failures, reducing downtime and maintenance costs.
- Engineer a Robust Protective System: Use an adhesive with quantifiable engineering properties to create a durable, composite lining that protects valuable steel and concrete assets from abrasion and heat.
- Simplify High-Performance Installations: Achieve a tenacious bond to steel without the need for complex primers, streamlining the application process while ensuring a superior result.
- Ensure Performance in Extreme Conditions: Trust a purpose-built solution designed to handle the dual challenges of high heat and heavy abrasion, providing peace of mind in critical industrial applications.
Applications in Practice: Trade Scenarios
For Industrial Applicators: Lining a Steel Feed Chute with Alumina Tiles
The Engineering Challenge: The chute is exposed to constant, severe abrasion from raw materials and process temperatures regularly exceeding 100°C. A durable, heat-resistant lining is essential to prevent rapid wear of the steel structure.
The System-Based Solution with Megapoxy 84: After grit blasting the steel interior to a "white metal" finish, apply the mixed Megapoxy 84 with a notched trowel at a rate of 1.25 L/m². Bed the high-alumina ceramic tiles firmly into the adhesive. The resulting system will withstand the extreme abrasion and maintain its bond at the 120°C service temperature.
Best Practice Note: The product develops its toughness after 48 hours. Ensure the newly lined chute is not exposed to elevated temperatures or heavy impact during this initial curing phase for optimal results.
For Asset Maintenance Teams: Repairing a Concrete Hopper Lining
The Engineering Challenge: Sections of a ceramic-tiled concrete hopper have failed due to impact and thermal cycling. The repair must be performed in-situ and provide a bond that is stronger and more heat-resistant than the original.
The System-Based Solution with Megapoxy 84: Scabble the damaged concrete areas to remove loose material and expose a solid, aggregate-filled surface. Apply the pale blue Megapoxy 84 paste and install new ceramic tiles. The paste consistency allows for vertical and overhead application, and the 72-hour full cure ensures a permanent, high-strength repair ready for service.
Best Practice Note: To avoid mixing errors on-site, it is advisable to mix the whole 2.5L kit at one time. Ensure thorough mixing for a minimum of 3 minutes, scraping the sides and bottom of the container.
Certifications & Regulatory Compliance
Megapoxy 84 is a high-performance industrial adhesive manufactured to stringent quality controls. Its ultimate strength and thermal resistance properties are specified to provide clear performance metrics for engineering and industrial applications. Surface preparation guidelines reference industry best practices, such as "white metal" finish for steel, to ensure system integrity. The formulation contains Nil VOCs (Volatile Organic Compounds), and all components are listed on the Australian Inventory of Chemical Substances (AICS).
Storage & Shelf Life Considerations
Store Megapoxy 84 kits in a cool, dry, well-ventilated area, and protect from direct sunlight. Containers must be kept tightly sealed when not in use. Part B is a corrosive substance and must be stored locked up in accordance with regulations. Proper storage is essential for maintaining the product's specified performance and ensuring safety on site.
Applications & Benefits
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Ceramic Tile Linings on Steel | Provides high-temperature (120°C) resistance and a tenacious bond to steel. | Industrial Applicators, Asset Maintenance |
| Wear Linings in Concrete Hoppers | Extreme compressive strength (120 MPa) withstands high impact and abrasion. | Remedial Contractors, Industrial Tilers |
| Lining of Industrial Chutes & Bins | Creates a durable, seamless system that protects parent structures from wear. | Asset Maintenance, Specialist Contractors |
| High-Temp Process Equipment | Maintains structural adhesion in continuous elevated temperature service. | Mechanical Engineers, Plant Maintenance |
Applying Megapoxy 84: Protocols & Best Practices
General Application Steps:- Preparation: Ensure all steel, concrete, and tile surfaces are prepared to the required standard as per the Adhesion & Preparation Guide.
- Mixing: For best results, mix the entire pre-measured kit at once. Combine the entire contents of Part B (Blue liquid) into the Part A (White paste) container. Mix thoroughly for a minimum of 3 minutes using a putty knife or spatula, ensuring you scrape the sides and bottom of the container to achieve a uniform, streak-free, pale blue paste.
- Application: Apply the mixed Megapoxy 84 to the prepared steel or concrete substrate at a coverage rate of approximately 1.25 litres per square metre. Spread evenly with a notched trowel to the desired bed thickness.
- Tiling & Curing: Firmly press the high-alumina ceramic tiles into the wet adhesive bed, ensuring full and even contact with the tile surface. Allow the system to cure undisturbed for a minimum of 72 hours at 25°C before subjecting it to service conditions, especially elevated temperatures.
For Industrial Applicators: Lining a Steel Feed Chute with Alumina Tiles
The Engineering Challenge: The chute is exposed to constant, severe abrasion from raw materials and process temperatures regularly exceeding 100°C. A durable, heat-resistant lining is essential to prevent rapid wear of the steel structure.
The System-Based Solution with Megapoxy 84: After grit blasting the steel interior to a "white metal" finish, apply the mixed Megapoxy 84 with a notched trowel at a rate of 1.25 L/m². Bed the high-alumina ceramic tiles firmly into the adhesive. The resulting system will withstand the extreme abrasion and maintain its bond at the 120°C service temperature.
Best Practice Note: The product develops its toughness after 48 hours. Ensure the newly lined chute is not exposed to elevated temperatures or heavy impact during this initial curing phase for optimal results.
For Asset Maintenance Teams: Repairing a Concrete Hopper Lining
The Engineering Challenge: Sections of a ceramic-tiled concrete hopper have failed due to impact and thermal cycling. The repair must be performed in-situ and provide a bond that is stronger and more heat-resistant than the original.
The System-Based Solution with Megapoxy 84: Scabble the damaged concrete areas to remove loose material and expose a solid, aggregate-filled surface. Apply the pale blue Megapoxy 84 paste and install new ceramic tiles. The paste consistency allows for vertical and overhead application, and the 72-hour full cure ensures a permanent, high-strength repair ready for service.
Best Practice Note: To avoid mixing errors on-site, it is advisable to mix the whole 2.5L kit at one time. Ensure thorough mixing for a minimum of 3 minutes, scraping the sides and bottom of the container.
Limitations & Safety
Product limitations and safety information
Limitations:
- The product is initially brittle after setting and requires 48 hours at 25°C to develop toughness.
- Do not expose the application to elevated temperatures during the initial 48-72 hour cure period.
- The 4:1 mix ratio is critical and must be measured accurately for the product to perform as specified.
- Not suitable for applications requiring flexibility. This is a rigid, high-modulus adhesive.
Safety & Handling:
- Danger: This product is a Hazardous Chemical and Dangerous Good. Part B is corrosive and can cause severe skin burns and eye damage.
- PPE: Wear protective clothing, nitrile rubber gloves, and safety glasses with a face shield when mixing and applying.
- Ventilation: Use in a well-ventilated area. Natural ventilation is typically adequate for normal use.
- Handling: Avoid all contact with skin and eyes. If contact occurs, flush immediately with plenty of water. Refer to the SDS for detailed first aid measures.
Megapoxy 84 Adhesion & Preparation Guide
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Substrate preparation guidelines
- Steel: For maximum adhesion, the surface must be cleaned to a "white metal" finish. This is achieved by grinding or, preferably, abrasive grit blasting to remove all contaminants, rust, and scale. The prepared surface must be clean and dry before application.
- Concrete: The concrete surface must be structurally sound and free of laitance, curing compounds, and contaminants. Preparation should be done by mechanical means such as scabbling, grinding, or grit blasting to expose a solid surface with firmly held aggregate.
- High Alumina Ceramic Tiles: The bonding surface of the tiles must be completely clean and free from any dust or grease from the manufacturing or handling process. Wipe with a clean, dry cloth or a suitable solvent if required.
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