For backing metal liner plates and filling gaps between liners and support structures in cone crushers, gyratory crushers, and grinding mills, Megapoxy HICB is a two-component, 100% solids, pourable epoxy grout. It provides the high impact resistance and compressive strength needed to withstand heavy machinery loads on concrete and metal substrates without cracking or losing adhesion.
Megapoxy HICB cures to form a high-strength backing and reinforcement layer that absorbs extreme mechanical shock in mining and quarry machinery. This pourable, low-VOC epoxy flows into tight clearances between liner plates and support frames, securing locking bearings, chocking machinery, and grouting rail tracks. The formulation is available in both Standard and Accelerated versions, allowing installers to select the required cure speed and working window for the ambient temperature of the site.
Successful application requires thorough preparation and strict mixing sequences to prevent curing failures:
Megapoxy HICB has a maximum casting thickness of 50 mm. Exceeding this limit can affect cure and performance.
Proper surface preparation is essential for achieving the documented 20 MPa tensile bond strength to steel. Metal surfaces must be grit blasted to AS CK 9.4 - 1964 Class 3 or mechanically abraded to a clean, bright finish, then degreased. Wire brushing alone is not sufficient for adequate adhesion.
The minimum application temperature for Megapoxy HICB is 10°C. Colder temperatures will extend cure times, potentially impacting return-to-service schedules.
The accelerated version of Megapoxy HICB significantly reduces cure times. For example, at 25°C, standard HICB cures in 24 hours, while the accelerated version cures in 6 hours. This difference impacts work time and return-to-service.
| Application | Key benefit | Primary trades |
|---|---|---|
| Backing & reinforcement of metal liner plates in crushers | Withstands extreme impact and compression (115 MPa compressive strength, 20 MPa tensile bond to steel), reducing liner movement and extending equipment life. | Mining, quarrying, heavy industrial maintenance |
| Grouting heavy machinery (e.g., Gyratory Crushers, Grinding Mills) | Provides high-strength, void-free support (100% solids, flowable) to maintain precise alignment under dynamic loads and vibration. | Industrial millwrights, plant mechanics, civil contractors |
| Chocking of machinery and setting anchor bolts | Secures critical components with superior bond strength to concrete and steel, ensuring stability and preventing displacement. | Mechanical engineers, structural installers |
| Rail track grouting | Offers robust, durable support and load transfer for rails in demanding industrial or mining environments, resisting chemical attack. | Rail infrastructure maintenance, civil engineering |
| Filling gaps between liners and support structures | Prevents premature wear and failure by eliminating movement and distributing loads evenly with a heavy-duty, impact-resistant fill. | Maintenance technicians, asset managers |
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.
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.
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.
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.
The mixture must be used immediately after mixing is complete. Pour steadily into the void from one location to allow air to escape.
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.
Danger: Megapoxy HICB Part A is toxic if swallowed, toxic in contact with skin, causes severe skin burns and eye damage, and may cause an allergic skin reaction. It is also toxic to aquatic life with long-lasting effects. Megapoxy HICB Part B is harmful if swallowed, harmful in contact with skin, causes skin irritation, causes serious eye irritation, and may cause an allergic skin reaction. It is harmful to aquatic life with long-lasting effects. Both parts are Scheduled Poison S5 (Caution).
Wear safety shoes, nitrile rubber gloves, and safety glasses. PPE must be suitable for the nature of the work. Wash hands thoroughly before eating, drinking, or using the toilet.
Ensure adequate ventilation to maintain air concentrations below exposure standards, particularly for Part A. Use with local exhaust ventilation or an appropriate respirator. Avoid entry into confined spaces where vapour may collect.
Store in a cool, dry, well-ventilated place out of direct sunlight, away from foodstuffs and oxidising agents. Keep containers upright, closed when not in use, and locked up. Part A is classified as a Class 9 Dangerous Good for transport and storage. Dispose of contents and containers according to local regulations.
Proper surface preparation is crucial for Megapoxy HICB to deliver its full bond strength and ensure reliable performance under heavy loads. Inadequate preparation can lead to premature failure.
Surface prep: Grit blast to AS CK 9.4 - 1964 Class 3. Alternatively, mechanically abrade to a clean, bright metal. Follow with degreasing using an industrial-grade degreaser. Wire brushing is insufficient for proper adhesion and should not be relied upon.
Primer: Not required. The product bonds directly to properly prepared metal.
Surface prep: Concrete surfaces must be clean, dry, and free from loose material, dust, and contaminants. Achieve a sound, open-pored surface profile. The product's bond strength to concrete is >3 MPa (ASTM 4541).
Primer: Not required. Megapoxy HICB is designed for direct application to prepared concrete.
| Property | Value |
|---|---|
| Mixing Ratio | Mix complete kit |
| Work Time (Standard HICB, 25°C) | 30 minutes |
| Work Time (Accelerated HICB, 25°C) | 10 minutes |
| Minimum Application Temperature | 10°C |
| Mixed Viscosity (Standard HICB, 25°C) | 17150 cps |
| Mixed Viscosity (Accelerated HICB, 25°C) | 14500 cps |
| Mixed Specific Gravity (Standard HICB) | 1.58 |
| Mixed Specific Gravity (Accelerated HICB) | 1.60 |
| Appearance Mixed | Blue Green |
| Compressive Strength (ASTM D695) | 115 MPa |
| Bond Strength Concrete (ASTM 4541) | >3 MPa |
| Tensile Bond Strength Steel (ASTM D897) | 20 MPa |
| Modulus of Elasticity (ASTM D695) | 7.7 GPa |
| Flexural Strength (ASTM D790) | 30 MPa |
| Tensile Strength (ASTM D638) | 45 MPa |
| Tensile Shear Strength (ASTM 1002) | 13 MPa |
| Hardness (Shore D, ASTM D2240-00) | 80 |
| Maximum Casting Thickness | 50 mm |
| VOC Content | 0 g/Litre |
| Standard Cure Time (15°C) | 48 hours |
| Standard Cure Time (25°C) | 24 hours |
| Standard Cure Time (35°C) | 12 hours |
| Accelerated Cure Time (15°C) | 12 hours |
| Accelerated Cure Time (25°C) | 6 hours |
| Accelerated Cure Time (35°C) | 3 hours |
Here are some common examples on where Megapoxy HICB used by our customers.
