Megapoxy P1: A Technical Overview
Megapoxy P1 is a two-component, gap-filling epoxy paste adhesive engineered to deliver permanent, high-strength structural bonds and repairs. Formulated with advanced DGEBA epoxy resin and carbonate-free fillers, it provides a solution of engineered certainty for the most demanding civil engineering and remedial applications. Its performance characteristics, including exceptional compressive strength and tenacious bond to concrete, steel, and stone, ensure that repairs are not just patches, but integral structural restorations. Certified for contact with potable water (AS/NZS 4020:2018) and resistant to a wide range of chemicals, Megapoxy P1 is the definitive choice for projects where performance, compliance, and long-term durability are non-negotiable.
80MPa
Compressive Strength. A formidable rating that exceeds most high-strength concrete, guaranteeing load-bearing repairs that permanently restore structural integrity.
Core Features & Specifications
- Exceptional Compressive Strength (80 MPa): Delivers load-bearing capacity superior to concrete, making it the definitive choice for critical structural repairs where failure is not an option.
- Certified to AS/NZS 4020:2018: Fully approved for direct contact with potable water, ensuring compliance for repairs in tanks, pipes, and reservoirs.
- Non-Sag Paste Consistency: A smooth, creamy texture holds its form on vertical and overhead surfaces, allowing for precise application without slumping or mess.
- High Bond Strength (>3 MPa on Concrete): Forms a tenacious, permanent bond to correctly prepared substrates, ensuring the repair becomes a monolithic part of the structure.
- Excellent Chemical Resistance: Withstands exposure to a broad range of acids, alkalis, and solvents, including resistance to hydrogen sulphide in sewage applications.
- Zero VOC Content: Formulated with nil Volatile Organic Compounds, making it a safer choice for use in enclosed or poorly ventilated environments.
The Megapoxy P1 Advantage
- Achieve Permanent, Compliant Repairs: Forms a permanent, high-strength bond that resists water, chemicals, and vibration, eliminating costly call-backs and future failures.
- Simplify On-Site Workflow: The straightforward 1:1 mix ratio by volume and a generous 60-minute work time at 25°C provide ample opportunity for meticulous application, reducing waste and errors.
- Maximise Project Uptime: Uniquely formulated to adhere and cure reliably even in cold and damp conditions (down to 10°C), minimising downtime and weather-related delays on site.
- Versatile Multi-Material Bonding: Provides one trusted solution for multiple tasks, from concrete repair and grouting to bonding fibreglass, natural stone, and metal components.
Proactive Troubleshooting
Scenario: Bonding to Unprepared Surfaces
Potential Outcome: Delamination or complete bond failure under load. Surface contaminants like laitance, dust, oil, or curing compounds act as a release layer, preventing the epoxy from keying into the substrate.
Adheseal Best Practice: Substrates must be mechanically prepared to achieve a clean, sound, and profiled surface. For concrete, use grinding or grit-blasting. For steel, grit-blast to an AS CK 9.4-1964 Class 3 bright metal finish. Proper preparation is non-negotiable for structural performance.
Scenario: Incorrect Mix Ratio or Insufficient Mixing
Potential Outcome: The epoxy fails to cure correctly, resulting in soft spots, drastically reduced strength, poor chemical resistance, and potential discolouration. This compromises the entire repair.
Adheseal Best Practice: Strictly adhere to the 1:1 mix ratio by volume. Use a slow-speed mechanical mixer or hand mix on a board, scraping the sides and base of the container to ensure all material is combined. Mix until a uniform, streak-free dark grey colour is achieved, indicating full chemical cross-linking has begun.
Applications in Practice: Trade Scenarios
For Remedial Specialists: Structural Concrete Spalling & Crack Repair
The Professional's Challenge
Repairing spalled concrete and structural cracks where the repair must be stronger than the host concrete, protect exposed reinforcing steel, and prevent all future moisture ingress.
The Adheseal Solution: Engineered Certainty in Practice
Megapoxy P1’s 80 MPa compressive strength ensures a load-bearing repair far stronger than the original concrete. Its tenacious bond and impermeability encapsulate prepared reinforcing steel, permanently arresting corrosion and restoring structural integrity.
Best Practice Note
Chase out cracks to form a 'V' groove (min. 5mm deep). Where steel is exposed, grit blast to remove all corrosion and immediately prime the steel with a coat of Megapoxy P1 before bulk filling to ensure maximum protection and bond.
For Civil Engineers & Specifiers: Grouting & Anchoring in Precast Infrastructure
The Professional's Challenge
Specifying a grouting compound for load-bearing dowels, starter bars, or filling gaps between precast segments that guarantees long-term performance, nil shrinkage, and meets strict compliance standards for public works.
The Adheseal Solution: Engineered Certainty in Practice
Megapoxy P1 offers documented proof of performance. Its high bond strength, nil VOC, and AS/NZS 4020 certification make it the definitive choice for critical infrastructure. It forms a perfect, void-free, and dimensionally stable connection between elements, ensuring load is transferred exactly as designed.
Best Practice Note
For deep anchor grouting, ensure holes are clean and completely dry. Dispense P1 from the back of the hole and withdraw the nozzle as it fills to prevent air entrapment, which could compromise the bond.
Frequently Asked Questions
Can Megapoxy P1 be used in contact with drinking water?
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.
How critical is surface preparation before applying Megapoxy P1?
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.
What is the maximum gap that Megapoxy P1 can fill?
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.
What is the service temperature range of fully cured Megapoxy P1?
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.
Applications & Benefits
| 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 |
Applying Megapoxy P1: Enhanced Protocols & Best Practices
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Step 1: Surface Preparation
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.
Concrete & Masonry
Mechanically abrade the surface via grinding or grit-blasting to remove all laitance and contaminants. The ideal surface profile is clean with exposed aggregate.
Metal Surfaces
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.
Pro Tip: After abrading, remove all dust from the substrate with a vacuum or oil-free compressed air. Even a fine layer of dust can compromise the bond. -
Step 2: Mixing
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.
Visual Check for Thoroughness
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.
Work Time: You have approximately 60 minutes of work time at 25°C. This time will be shorter at higher temperatures and longer at lower temperatures. Only mix as much material as can be used within this timeframe. -
Step 3: Application & Curing
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.
Tooling & Finishing
The creamy, non-sag paste allows for easy tooling on vertical and overhead surfaces. Ensure good contact and pressure to eliminate any air voids.
Cure Time: The product achieves initial cure in 24 hours at 25°C, and full cure with maximum properties in 4 days. Do not subject the bond to high loads until a full cure is achieved.Pro Tip: For cleaning un-cured epoxy from tools and equipment, use Megapoxy Thinners. Once cured, the material must be removed mechanically.
Limitations & Safety
Product Limitations
Minimum application temperature is 10°C. Application below this temperature will significantly extend cure times and may compromise performance.
Not intended for use on substrates with active water leaks or negative-side hydrostatic pressure.
For Professional Use Only. This product requires advanced surface preparation techniques and adherence to strict safety protocols outlined in the SDS. It is not suitable for DIY or general handyman use.
Safety & Handling Requirements
Personal Protective Equipment
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.
Ventilation Requirements
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.
Handling & Storage
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.
Emergency First Aid
Eyes:
Immediately hold eyelids apart and flush continuously with running water for at least 15 minutes. Urgently seek medical attention. Part B can cause serious eye damage.
Skin:
Remove contaminated clothing and wash skin thoroughly with soap and water. If irritation or rash occurs, get medical advice.
Inhaled:
Remove victim from exposure to fresh air. Keep at rest in a comfortable position. Seek medical advice if effects persist.
Swallowed:
Rinse mouth with water. Do NOT induce vomiting. Give a glass of water to drink. Seek immediate medical advice.
Refer to the Safety Data Sheet (SDS) for full details. Seek medical attention immediately in all cases of serious exposure.
Substrate Adhesion & Preparation Guide
Concrete & Masonry
Surface Preparation
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.
Primer Requirements
No primer typically required
When bonding to a correctly prepared, sound substrate, Megapoxy P1 is self-priming. Ensure all loose material is removed after abrading.
Steel (Mild, Galvanised, Reinforcing)
Surface Preparation
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.
Primer Requirements
Self-priming for corrosion protection
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.
Fibreglass & Composites
Surface Preparation
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.
Primer Requirements
No primer required
A direct bond to a clean and well-abraded fibreglass surface will yield excellent adhesion without the need for a primer.
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