Megapoxy HICB: A Technical Overview
Megapoxy HICB is a heavy-duty, 100% solids, pourable epoxy grout, specifically engineered for the extreme environments of the mining and quarrying industries. Its primary function is to provide a solid, impact-absorbing backing for metal liner plates in cone crushers, primary gyratory crushers, and grinding mills. Formulated with zero solvents for nil shrinkage, HICB creates a perfect, void-free fit that transfers impact loads away from the liner to the supporting structure. Its immense compressive strength and excellent vibration damping properties are critical for maximising machinery life and maintaining operational uptime.
115MPa
Compressive Strength. A formidable force-resistance rating engineered to absorb and dissipate the immense, repetitive impact loads generated within primary crushers, preventing liner shift and costly structural fatigue.
Core Features & Specifications
- Extreme Compressive Strength (115 MPa): Provides massive resistance to crushing forces, ensuring the liner is fully supported, which prevents slippage and extends its operational life.
- 100% Solids, Zero VOC Formula: A pure epoxy system with no solvents ensures zero shrinkage upon curing for a perfect, void-free fit and is safer for use in enclosed plant spaces.
- Excellent Impact & Vibration Damping: Specifically formulated to absorb and dissipate intense shock and harmonic vibration, protecting the crusher's main frame and support structures from damage.
- Superior Adhesion to Steel: Achieves a tensile bond strength of 20 MPa to correctly prepared steel, creating a monolithic unit between the liner and the grout.
- Flowable, Pourable Consistency: Pours easily to fill complex voids and narrow gaps completely, eliminating air pockets that can become dangerous stress concentration points.
The Megapoxy HICB Advantage
- Minimise Critical Downtime: Choose between the Standard version for regular maintenance or the HICB Accelerated version (6-hour cure at 25°C) to drastically reduce turnaround time during critical plant shutdowns.
- Enhance Asset Protection & ROI: A solid, impact-absorbing backing extends the life of both the manganese liners and the crusher's main frame, reducing long-term capital expenditure and maximising production output.
- Ensure Application Accuracy: Supplied in convenient, pre-metered 10kg kits to eliminate mixing errors on-site and ensure consistent, reliable performance every time, even under pressure.
- Engineered for Safety and Reliability: Provides a trusted, proven solution for one of the most critical applications in a processing plant, ensuring the safety of personnel and the reliability of major assets.
Proactive Troubleshooting
Scenario: Pouring into a Contaminated or Unprepared Bowl/Liner
Potential Outcome: Poor or non-existent adhesion between the grout and steel liner. This can lead to the liner shifting or cracking under load, causing inefficient crushing, damage to the head and bowl, and unscheduled downtime.
Adheseal Best Practice: All metal surfaces must be completely free of old backing, dust, rust, oil, and grease. Mechanically abrade or grit blast surfaces to a clean, bright metal finish (AS CK 9.4-1964 Class 3) to ensure a strong mechanical and chemical bond.
Scenario: Incomplete Mixing or Air Entrapment
Potential Outcome: Results in soft spots that fail to cure. These soft spots will compress under load, leading to liner movement and premature failure. Mixing too fast can introduce air bubbles, creating voids that weaken the final backing.
Adheseal Best Practice: Use a low-speed (less than 400rpm) mechanical mixer. Mix for a minimum of 2-3 minutes, systematically scraping the sides and base of the bucket to ensure the entire volume is uniform in colour with no streaks. Do not aerate the mix.
Applications in Practice: Trade Scenarios
For Maintenance Fitters: Cone Crusher Liner Change-Out
The Professional's Challenge
Performing a liner change-out during a tight shutdown window, where every minute counts and the backing compound must be mixed and poured quickly, safely, and with absolute certainty of performance.
The Adheseal Solution: Engineered Certainty in Practice
Use Megapoxy HICB Accelerated. The pre-metered kit ensures a perfect mix under pressure, while the 10-minute work time and 6-hour cure time (at 25°C) allows for rapid, confident pouring and a swift return to service, meeting critical path deadlines.
Best Practice Note
Before mixing, ensure all crevices and the pour spout area are fully sealed with Megapoxy PF putty to prevent any leakage of the flowable grout. If ambient temperatures are high (>30°C), store kits in a cool place to maximise the available work time.
For Maintenance Engineers: Specifying Backing for a Primary Gyratory Crusher
The Professional's Challenge
Selecting a backing material with documented high performance to protect a multi-million dollar asset from extreme, continuous operational stress, where failure could halt all plant production.
The Adheseal Solution: Engineered Certainty in Practice
Megapoxy HICB's technical data provides engineered certainty. Its 115 MPa compressive strength and 7.7 GPa Modulus of Elasticity prove its capability to handle immense shock loads and prevent liner deformation, maximising production uptime and asset integrity.
Best Practice Note
Specify a maximum pour thickness of 50mm per layer. For larger voids, subsequent pours can be carried out after the initial layer has hardened. This staged approach manages exothermic heat generation and ensures a solid, uniform cure throughout the entire backing depth.
Frequently Asked Questions
What is the main difference between HICB Standard and HICB Accelerated?
The primary difference is cure speed. At 25°C, the Standard version has a 30-minute work time and 24-hour cure, suitable for planned maintenance. The Accelerated version has a 10-minute work time and 6-hour cure, designed for rapid return-to-service during critical shutdowns.
What is the maximum thickness I can pour Megapoxy HICB in a single layer?
The recommended maximum casting thickness is 50 mm per pour. This is to control the exothermic reaction (heat generation) during curing. For filling larger voids, you must pour in multiple 50mm layers, allowing the previous layer to harden before topping up.
How critical is temperature when using HICB?
Temperature is very critical. The minimum application temperature is 10°C. High ambient temperatures will significantly shorten the usable work time. It is crucial to store kits in a cool place before use and be prepared to work quickly in hot conditions, especially with the Accelerated version.
Can HICB be used for other applications besides crusher backing?
Yes. Due to its extremely high compressive strength and excellent bond, it is also a premium solution for grouting heavy machinery bases, chocking machinery, setting high-load anchor bolts, and rail track grouting where maximum strength and vibration damping are required.
Applications & Benefits
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Backing Crusher Liners For cone, gyratory, and pulveriser units. |
115 MPa compressive strength absorbs impact and prevents liner movement, extending asset life. | Mining & Quarry Maintenance, Shutdown Crews |
| Grouting Heavy Machinery Setting bases for mills, engines, and pumps. |
Provides a solid, high-strength, non-shrink foundation that ensures stability and dampens vibration. | Maintenance Fitters, Mechanical Engineers |
| Setting High-Load Anchor Bolts Anchoring critical equipment. |
Extreme bond strength and hardness creates a permanent, reliable anchor that withstands intense loads. | Industrial Contractors, Engineers |
| Locking Bearings & Chocking Precision alignment of machinery. |
Flowable consistency fills gaps completely for a perfect-fit chock that eliminates movement. | Mechanical Fitters, Marine Engineers |
Applying Megapoxy HICB: Enhanced Protocols & Best Practices
-
Step 1: Preparation & Sealing
Ensure all metal surfaces are prepared as per the adhesion guide. Critically, seal all crevices, joints, and pour spouts to prevent leakage of the flowable grout.
Sealing Method
Use a fast-setting putty, such as Megapoxy PF, to create dams and seals. Check thoroughly for any potential leak paths before proceeding to mix.
Pro Tip: If ambient temperature is high, cool the kits by storing them in a cool room or shaded area prior to mixing. This will maximise the available work time. -
Step 2: Professional Mixing
Pour the entire contents of the Part B hardener into the Part A resin pail. The product is supplied in a pre-metered kit; do not use partial mixes.
Mechanical Mixing
Using a low-speed electric mixer (under 400 RPM), mix for a minimum of 2 minutes. Stop, scrape the sides and base of the bucket thoroughly, then mix for at least another 1 minute until the colour is perfectly uniform and streak-free.
Pro Tip: Do not "whip" or aerate the mixture. Keep the mixing paddle submerged to minimise air entrapment, which can create voids in the cured backing. -
Step 3: Pouring & Curing
The mixture must be used immediately after mixing is complete. Pour steadily into the void from one location to allow air to escape.
Layered Pours
Do not exceed a pour thickness of 50mm. For deeper voids, allow the first layer to harden before applying the next. This manages heat and ensures a full cure.
Curing: Allow the HICB to harden completely before returning the crusher to service. Refer to the cure time chart for your specific ambient temperature and product version (Standard or Accelerated).
Limitations & Safety
Product Limitations
Maximum casting thickness is 50 mm per pour. Exceeding this can lead to excessive heat generation (exotherm) and potential cracking.
Minimum application temperature is 10°C. Curing will be significantly delayed below this temperature. High ambient temperatures will greatly shorten work life.
For Professional Heavy Industrial Use Only. This product is a hazardous material with specific application requirements. It must not be used outside its intended purpose by untrained personnel.
Safety & Handling Requirements
Personal Protective Equipment
Mandatory: Wear chemical-resistant gloves (nitrile rubber), chemical goggles or face shield, and impervious protective clothing. Part A is corrosive and can cause severe skin burns.
Ventilation Requirements
Ensure ventilation is adequate to maintain air concentrations below exposure standards. Use with local exhaust ventilation. Do NOT enter confined spaces where vapour may have collected.
Handling & Storage
Store locked up in a cool, dry, well-ventilated place away from foodstuffs and ignition sources. Avoid all eye and skin contact. Do not eat, drink or smoke when using this product.
Emergency First Aid
Eyes:
Immediately hold eyelids apart and flush continuously with running water for at least 15 minutes. Urgently seek medical assistance. Can cause corneal burns.
Skin:
This material is toxic and can be absorbed through skin. Immediately drench with water, remove all contaminated clothing, and flush skin with running water for 15 minutes. Seek urgent medical help.
Inhaled:
Remove victim from exposure to fresh air. Keep at rest in a comfortable position. Seek medical advice if effects persist.
Swallowed:
Toxic if swallowed. Rinse mouth, do NOT induce vomiting. Give a glass of water. Immediately call a Poisons Centre or doctor.
Refer to the Safety Data Sheet (SDS) for full details. This is a hazardous substance requiring strict handling protocols.
Substrate Adhesion & Preparation Guide
Steel (Manganese, Carbon, and Fabricated)
Surface Preparation
Bonding surfaces must be 100% free of all contaminants, including old backing material, rust, grease, oil, and moisture. Grit blast surfaces to a Class 3 bright metal finish (AS CK 9.4-1964) for maximum adhesion. If blasting is not possible, use mechanical grinders to achieve a clean, bright, and profiled surface.
Primer Requirements
No primer required
Megapoxy HICB is designed for direct, tenacious bonding to correctly prepared metal substrates. No primer is necessary. Focus all effort on achieving a perfectly clean and profiled surface.
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