For high-strength structural bonding and concrete repair, Megapoxy P1 is a two-component gap-filling epoxy paste formulated for vertical, overhead, and damp-condition applications. It is chemically resistant to hydrogen sulphide in sewage systems and complies with AS/NZS 4020:2018 for contact with potable drinking water, making it suitable for repairing concrete tanks, pipes, and marine or municipal infrastructure.
Megapoxy P1 combines a DGEBA epoxy resin with a carbonate-free filler to create a dark grey structural paste that does not sag on vertical or overhead surfaces. It provides permanent bonding and structural patching across dissimilar materials, including concrete, metals, natural stone, brick, and fibre cement sheet. When applied directly to grit-blasted steel at a minimum thickness of 3mm, the cured epoxy layer provides corrosion protection equivalent to approximately 50mm of concrete cover.
Megapoxy P1 is suitable for the following structural bonding and repair jobs:
Concrete preparation: Clean the surface of all grease and oil. Remove surface laitance using mechanical scabbling, grit blasting, or diamond grinding. If mechanical preparation is not possible, acid etch with a 1:1 mixture of concentrated hydrochloric acid and water at a rate of 0.5 litres per square metre. Allow to react for 10 minutes, wash thoroughly, scrub with a stiff broom, and allow to dry for 24 hours. The substrate should be surface dry for maximum adhesion.
Metal preparation: Grit blast steel and other metals to AS 1627.2.2002. If grit blasting is not possible, mechanically abrade to a clean, bright finish, then flood-degrease with an industrial-grade solvent. Wire brushing is not satisfactory and results in minimal adhesion.
Coated surfaces: Remove all paints, coatings, and galvanising before bonding. For coated concrete, remove paint via flame-cleaning or with a scutching tool, then complete with diamond grinding or scabbling. For coated metals, apply a high-quality paint stripper, then grit blast or grind to a bright metal finish.
Mixing: Thoroughly blend Part A and Part B together at the 1:1 volume ratio. Incorrect ratios or incomplete mixing will lower the physical properties of the cured system, prevent a satisfactory cure, or cause discolouration over time.
Yes, absolutely. Megapoxy P1 has been independently tested and certified to AS/NZS 4020:2018, which is the Australian standard for products used in contact with potable water. This makes it ideal for repairing concrete water tanks, reservoirs, and pipes.
It is the most critical step for ensuring a structural bond. The substrate must be clean, sound, and mechanically abraded to remove all laitance, coatings, and contaminants. For steel, grit blasting is essential. A failure in preparation will lead to a failure in the bond.
Due to its non-sag paste consistency, Megapoxy P1 is excellent for vertical and overhead gap filling. For deep voids or bulk filling applications (e.g., deeper than 25mm), it is best practice to apply the material in layers, allowing each layer to partially cure, to prevent exotherm (heat generation) issues.
Once fully cured, Megapoxy P1 can withstand a continuous service temperature of up to 80°C. This ensures its high strength and bond properties are maintained in demanding industrial and infrastructure environments with significant temperature fluctuations.
| Application / Use Case | Key Benefit | Primary Trades |
|---|---|---|
| Structural Concrete Repair Fixing spalls, cracks, and damaged sections. |
Delivers compressive strength (80 MPa) far exceeding the concrete for a permanent, load-bearing fix. | Remedial Contractors, Civil Engineers, Builders |
| Grouting Bolts, Dowels & Anchors Securing structural elements into concrete. |
High bond strength and nil shrinkage ensures maximum pull-out resistance and reliable load transfer. | Civil Engineers, Precast Installers, Structural Steel Erectors |
| Bonding Precast Concrete Elements Filling gaps and creating structural joints. |
Fills voids to create a monolithic, waterproof, and structural joint between segments and articles. | Precast Manufacturers, Civil Contractors |
| Metal to Concrete Bonding Creating high-strength structural connections. |
Tenacious bond to properly prepared steel and concrete, perfect for fixing plates, tracks, or supports. | Structural Engineers, Fabricators, Builders |
| Potable Water Tank & Pipe Repair Sealing cracks and joints in water infrastructure. |
Fully certified to AS/NZS 4020:2018 for safe, compliant, and permanent repairs in drinking water systems. | Water Authorities, Plumbers, Council Maintenance |
The long-term performance of Megapoxy P1 is entirely dependent on the quality of surface preparation. All substrates must be clean, dry, and structurally sound.
Mechanically abrade the surface via grinding or grit-blasting to remove all laitance and contaminants. The ideal surface profile is clean with exposed aggregate.
Grit blast steel surfaces to a bright metal finish (AS CK 9.4-1964 Class 3). Degrease with a high-quality solvent like Adheseal Surface Prep. Do not wire brush.
Combine Part A (White) and Part B (Black) in a strict 1:1 ratio by volume. Mix thoroughly using a slow-speed drill with a paddle mixer or by hand on a mixing board.
Continue mixing until a completely uniform, streak-free, dark grey colour is achieved. Scrape the sides and bottom of the mixing container to ensure all material is incorporated.
Apply the mixed Megapoxy P1 to the prepared surface using a trowel or spatula. For bonding, apply to one surface and press the components together firmly. For repairs, build up the material to the desired profile.
The creamy, non-sag paste allows for easy tooling on vertical and overhead surfaces. Ensure good contact and pressure to eliminate any air voids.
Mandatory: Wear chemical-resistant gloves (nitrile rubber recommended), safety glasses with side-shields or chemical goggles, and long-sleeved protective clothing. Avoid all skin and eye contact.
Use in a well-ventilated area. If dust or vapours are generated during use, local exhaust ventilation is required to keep air concentrations below exposure standards.
Store in a cool, dry place out of direct sunlight. Keep containers sealed when not in use. Contaminated work clothing should not be allowed out of the workplace and must be washed before re-use.
Refer to the Safety Data Sheet (SDS) for full details. Seek medical attention immediately in all cases of serious exposure.
Surfaces must be structurally sound and free from all contaminants like grease, oil, dust, and curing compounds. Remove surface laitance via mechanical abrasion (grit blasting, scabbling, or grinding) to expose clean aggregate. The surface should be dry before application.
When bonding to a correctly prepared, sound substrate, Megapoxy P1 is self-priming. Ensure all loose material is removed after abrading.
All surfaces must be grit blasted to a Class 3 bright metal finish (AS CK 9.4-1964). Remove all rust, scale, and paint. Degrease the surface with an industrial grade solvent like Adheseal Surface Prep. Wire brushing is not sufficient and will result in minimal adhesion.
For protecting reinforcing steel, Megapoxy P1 can be applied directly to the prepared steel as a protective anti-corrosion barrier and bond coat before applying concrete patch repairs.
Ensure the surface is clean, dry, and completely free of any release agents, waxes, or oils. Thoroughly abrade the bonding area with 80-grit sandpaper to create a deep mechanical key, then wipe away all dust with a clean, dry cloth or a solvent wipe using Adheseal Surface Prep.
A direct bond to a clean and well-abraded fibreglass surface will yield excellent adhesion without the need for a primer.
| Property | Value |
|---|---|
| Appearance | Dark grey paste |
| Tensile Strength | 45 MPa |
| Compressive Strength | 80 MPa |
| Flexural Strength | 33 MPa |
| Bond Strength | >3 MPa |
| Shore Hardness | 75 |
| Pot Life | 60 minutes |
| Full Cure | 4 days |
| Application Temperature | 10°C |
| Service Temperature | 80°C |
| Mix Ratio | 1 Part A to 1 Part B |
| VOC Content | Nil |
| Certifications | AS/NZS 4020:2018 (Potable Water) |
Here are some common examples on where Megapoxy P1 used by our customers.
