The relentless grind of industrial operations or the constant scour of abrasive slurries takes its toll on vital equipment, leading to premature failure and costly downtime. Megapoxy Megadure Ceramic provides the answer, a high alumina bead reinforced epoxy paste engineered specifically to protect critical assets from extreme abrasive wear. It forms a robust, gap-filling lining that extends service life, reduces maintenance, and keeps production running in the toughest environments.
Megapoxy Megadure Ceramic was developed as a robust, high-performance solution for extreme industrial wear challenges. This two-component, gap-filling epoxy paste integrates high alumina beads, transforming it into a formidable shield against continuous impact and erosion. It ensures critical machinery, like ball mills, slurry pumps, and coal-fired plant components, remain operational longer, directly addressing the significant operational costs and production interruptions caused by premature equipment failure.
The decision between the standard and quick-set formulations often hinges on the job's urgency and temperature. Standard Set offers 30 minutes of work time at 25°C, extending to 60 minutes at 15°C, providing ample time for precise application on complex geometries. For rapid turnarounds, the Quick Set formulation reduces working time to 10 minutes at 25°C, allowing equipment to return to service faster with a full cure in 12 hours. Planning coverage is straightforward: a 2 kg kit yields 0.5 m² at a 2mm thickness, assisting accurate material estimation for extensive lining projects.
Applying Megadure Ceramic requires careful attention to detail for optimal performance. The two-part system demands thorough mixing, ensuring Part B (hardener) is slowly incorporated into Part A (resin) until a uniform consistency is achieved. Incomplete mixing significantly compromises the final physical properties and wear resistance. Surface preparation is critical: metals require grit blasting to AS CK 9.4 Class 3, or mechanical abrasion and degreasing where grit blasting is impossible. Wire brushing is insufficient for reliable adhesion.
For concrete, surfaces must be clean, dry, and free of laitance, achieved through mechanical abrasion like scabbling or grinding. For optimal cure, a minimum application temperature of 10°C is required. Lower temperatures will extend both the work time and the full cure duration.
Megapoxy Megadure Ceramic excels in the most demanding industrial environments where constant abrasion is the primary threat to equipment. Mining contractors regularly apply it to line critical equipment like chutes, hoppers, and cyclones, extending their operational lifespan in severe abrasive conditions. In power generation, it protects components within coal-fired plants, resisting continuous impact and erosion. Industrial maintenance teams rely on it for safeguarding abrasive slurry pumps and dredging equipment, where high alumina beads effectively counter erosive wear from high-velocity slurries. Furthermore, it is the specified material for grouting high alumina ceramic wear tiles, providing a robust, gap-filling bond on steel surfaces in high-wear fabrication workshops.
Megapoxy Megadure Ceramic is a specialised solution and has specific application boundaries:
Megapoxy Megadure Ceramic is engineered specifically for extreme abrasion resistance and wear-resistant lining. Its high alumina bead reinforcement targets applications where continuous friction, impact, and erosion are the primary concerns. For general structural adhesion, or for bonding applications that do not require this extreme level of wear protection, other Megapoxy products offer a better fit. For instance, if the primary job is a load-bearing structural bond between metal and concrete, products like Megapoxy-69 are formulated to provide high tensile and shear strength for those specific requirements, rather than the specialised wear resistance of Megadure Ceramic.
Megadure Ceramic is engineered for extreme abrasion resistance in heavy industries. This includes protecting equipment in mines, ball mills, coal-fired plants, dredging operations, and abrasive slurry pumps.
Metal surfaces must be grit blasted to AS CK 9.4 Class 3 finish for optimal adhesion. If grit blasting is not possible, mechanically abrade to a clean, bright metal surface and degrease thoroughly. Wire brushing is not sufficient.
At 25°C, the fast-setting Megadure Ceramic has a 10-minute work time and achieves initial cure in 2 hours. The standard-setting version offers 30 minutes of work time, with initial cure in 6 hours. Both require a minimum application temperature of 10°C.
No, the minimum application temperature for Megadure Ceramic is 10°C. Applying below this temperature may compromise proper curing and performance, leading to poor physical properties and reduced abrasion resistance.
| Application | Key benefit | Primary trades |
|---|---|---|
| Lining and protection in mines | Extends equipment service life in severe abrasive conditions, reduces downtime. | Mining contractors, industrial maintenance |
| Wear protection in ball mills and coal-fired plants | Resists continuous impact and abrasion, preventing premature wear and failure. | Power generation, heavy industrial maintenance |
| Protection for abrasive slurry pumps and dredging equipment | High alumina beads counter erosive wear from high-velocity slurries. | Dredging operators, pump service technicians |
| Grouting high alumina ceramic wear tiles | Provides a strong, gap-filling, wear-resistant bond between ceramic tiles and steel surfaces. | Specialised applicators, fabrication workshops |
| Bulk handling and processing equipment lining | Shields surfaces from constant friction and impact in material transfer systems. | Manufacturing, logistics, bulk handling facilities |
Danger: This product causes severe skin burns, serious eye damage, and may cause an allergic skin reaction. Harmful if swallowed or in contact with skin. It is toxic to aquatic life with long-lasting effects. Avoid breathing dust, fume, gas, mist, vapours, or spray.
Wear safety shoes, protective gloves (nitrile rubber recommended), safety glasses or face protection, and suitable respiratory protection. Contaminated work clothing must not leave the workplace. Wash hands thoroughly after handling and before eating, drinking, or smoking.
Natural ventilation is adequate under normal use. Ensure adequate ventilation to avoid inhalation of vapours or dust, especially during mixing or in confined spaces. If inhalation is unavoidable, wear suitable respiratory protection.
Store in a cool, dry, well-ventilated place, out of direct sunlight, and away from foodstuffs and incompatible materials. Keep containers closed and standing upright. Store locked up. Dispose of contents and container in accordance with local, regional, national, and international regulations. This material is a Scheduled Poison (S5, Caution) and is classified as Dangerous Goods for transport (Class 9 for Part A, Class 8 for Part B).
Proper surface preparation is critical for Megadure Ceramic to achieve its documented adhesion and wear resistance. Incomplete preparation compromises performance and product longevity.
Surface prep: Grit blast to AS CK 9.4 Class 3 finish. If grit blasting is not possible, mechanically abrade to a clean, bright metal surface. Follow with degreasing using a proprietary degreaser. Wire brushing is not recommended as it provides minimal adhesion only.
Primer: Not required. The epoxy paste adheres directly to properly prepared metal.
Surface prep: Remove all grease, oil, and surface laitance. Clean with an industrial heavy-duty degreaser if needed. Mechanically abrade surfaces via scabbling, grit blasting, or grinding. Concrete must be completely dry and free of loose particles, dust, and dirt for maximum adhesion.
Primer: Not required. The epoxy paste adheres directly to properly prepared concrete.
Surface prep: Remove all existing paint. For painted metal, follow the grit blasting or mechanical abrasion process described for metals. For painted concrete, flame clean or mechanically treat (grinding, scabbling, shot blasting, or scarifying) to remove all paint traces, then follow the concrete preparation steps.
Primer: Not required after complete removal of paint and proper substrate preparation.
| Property | Value |
|---|---|
| Product Type | Two-Component Gap-Filling Epoxy Paste |
| Formulation | High Alumina Bead, Wear-Resistant Lining |
| Colours (Cured) | Green |
| Available Formulations | Standard Setting, Fast Setting |
| Packaging | 2 kg kit |
| Kit Yield | 0.5 m² at 2mm thickness (per 2 kg kit) |
| Minimum Application Temperature | 10°C |
| Work Time (Standard Set) @25°C | 30 minutes |
| Work Time (Standard Set) @15°C | 60 minutes |
| Work Time (Quick Set) @25°C | 10 minutes |
| Work Time (Quick Set) @15°C | 20 minutes |
| Initial Cure (Standard Set) @25°C | 6 hours |
| Initial Cure (Standard Set) @15°C | 12 hours |
| Initial Cure (Quick Set) @25°C | 2 hours |
| Initial Cure (Quick Set) @15°C | 4 hours |
| Full Cure (Standard Set) @25°C | 24 hours |
| Full Cure (Standard Set) @15°C | 48 hours |
| Full Cure (Quick Set) @25°C | 12 hours |
| Full Cure (Quick Set) @15°C | 24 hours |
| Part A Form | Paste |
| Part A Colour | White |
| Part A Solubility | Insoluble in water |
| Part A Specific Gravity @25°C | 2.00-2.06 |
| Part A Vapour Pressure @20°C | <0.01 Pa |
| Part A Flash Point | >200 °C |
| Part A Boiling Point/Range | >200 °C |
| Part A Decomposition Point | >200 °C |
| Part A Total VOC | Nil (0 g/L) |
| Part B Form | Liquid |
| Part B Colour | Blue |
| Part B Odour | Amine |
| Part B Solubility | Soluble in Water |
| Part B Specific Gravity @25°C | 0.98-1.02 |
| Part B Vapour Pressure @20°C | <0.01 kPa |
| Part B Flash Point | 149 °C |
| Part B Boiling Point/Range | 277 °C |
| Part B Decomposition Point | >200 °C |
| Part B Total VOC | Nil (0 g/L) |
| Dangerous Goods Class (Part A) | 9 |
| Hazchem Code (Part A) | •3Z |
| Dangerous Goods Class (Part B) | 8 |
| Hazchem Code (Part B) | 2X |
| Poison Schedule | S5. Caution |
Here are some common examples on where Megapoxy Megadure used by our customers.
