FORSPEC ACTFLEX Epoxy Grout two-component solvent-free structural epoxy grout system with Part A resin and Part B hardener.

ACTFLEX Epoxy Grout (Structural) 30kg Kit

Name: ACTFLEX Epoxy Grout (Structural) 30kg Kit
Brand: Forspec Protective Coatings
SKU: AACT145
Price: 765.00 AUD
Availability: OutOfStock

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Flowable structural epoxy for voids, baseplates and deep concrete repairs. Pour up to 100 mm in one lift, 80 MPa at 7 days.

ACTFLEX EPOXY GROUT is a two-part, solvent-free, low-viscosity structural epoxy grout for concrete repair. Form it up and pour it into large voids, deep defects and damaged sections, in single pours up to 100 mm.

Where to use it

Formed filling of large static voids and deep defects in concrete
Load-transfer grouting under baseplates, bearing plates, machine bases and plinths
FORSPEC PREFLEX basement tanking: pile caps, formed repairs and substrate transitions
Primer and bonding coat for ACTFLEX HBR and ACTFLEX CRYSTAL BOND, or binder for aggregate-filled repairs

Why waterproofers buy it

80 MPa compressive strength at 7 days
Low viscosity, 250 to 450 mPa.s, flows into open-textured concrete
Bond to prepared concrete greater than 2.5 MPa, concrete fails first
Bonds to concrete, masonry, stone and prepared steel
Pot life about 40 minutes, initial cure 10 to 12 hours, full cure 7 days
30 kg kit, Part A 20 kg plus Part B 10 kg, mixed 2 to 1. Solvent free

Coverage

30 kg kit: approximately 28.5 L of void as formed grout, or 9.5 m² as a coating or patch at 3 mm.

Not for

Hairline crack injection, movement joints, active cracks or flexible substrates, concrete over 4% moisture, rising moisture, hydrostatic pressure or standing water, concrete under 28 days or 25 MPa, pours over 100 mm in one lift, outside 10°C to 35°C.

All times at 25°C and 50% RH. Typical Forspec R&D values.

Deep single pours up to 100 mm with the approved pour plan

Compressive strength of 80 MPa at 7 days

Low viscosity of 250-450 mPa.s wets and penetrates open-textured concrete

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Pickup currently unavailable at The Waterproofing Shop

ACTFLEX Epoxy Grout (Structural) 30kg Kit

The Waterproofing Shop

Pickup currently unavailable

22/872 Canterbury Road
Roselands NSW 2196
Australia

+61280213517

Product Details

ACTFLEX EPOXY GROUT is a two-component, high-strength, low-viscosity structural epoxy resin formulated for deep penetration, crack injection, and structural grouting applications. It is designed to restore and enhance the structural integrity of cracked or deteriorated concrete by forming a dense, high-performance bonding matrix.

The system is solvent-free, non-shrink, and moisture-tolerant, delivering excellent adhesion to concrete, masonry, stone, and metal surfaces. Its ultra-low viscosity allows deep penetration into fine cracks and porous substrates, ensuring maximum substrate consolidation and long-term durability.

ACTFLEX EPOXY GROUT provides superior chemical, impact, and vibration resistance, making it suitable for demanding industrial, civil, and marine environments. It also serves as an effective primer for epoxy mortars such as ACTFLEX HBR and protective coatings like ACTFLEX CRYSTAL COAT.

Key Features

Ultra-low viscosity for deep crack penetration and pore saturation
High structural strength—excellent compressive, tensile, and shear performance
Restores and enhances load-bearing capacity of concrete structures
Excellent adhesion to concrete, masonry, stone, and metals
Moisture-tolerant formulation suitable for slightly damp substrates
Non-shrink system for stable, long-term structural performance
High resistance to chemicals including fuels, oils, acids, and alkalis
Superior vibration and cyclic load resistance
Low thermal expansion compatible with concrete behavior
Low exotherm curing for controlled application in deep sections
Solvent-free, low-odor, and safe for confined-space use
Pre-proportioned kits ensure consistent mixing and on-site reliability
Durable under industrial, marine, and infrastructure exposure conditions
Acts as a primer and bonding agent for epoxy mortars and coatings

Recommended Applications

Structural bonding and consolidation of cracked, delaminated, or weakened concrete
Pressure or gravity injection of static, hairline, and structural cracks in slabs, beams, and walls
Grouting beneath base plates, machine foundations, and anchor bolts
Sealing and strengthening of porous concrete substrates prior to coatings or overlays
Priming system for epoxy mortars such as ACTFLEX HBR and protective systems like ACTFLEX CRYSTAL COAT
Repair and rehabilitation of industrial, commercial, marine, and infrastructure structures
Restoration of structural integrity in vibration-prone and high-load environments
Deep penetration strengthening of deteriorated concrete elements in civil engineering works

How to Use

Form up with rigid, sealed, leak-proof formwork and pour continuously from one side in single lifts up to 100 mm, or apply as a primer and bonding coat by brush, roller or squeegee at approximately 0.2-0.3 L/m2Confirm concrete is sound, clean and free of oil, laitance, curing compounds and dust, minimum 28 days old and minimum 25 MPa compressive strength
Mechanically prepare by diamond grinding, captive shot-blasting or scarifying to a clean, open profile and vacuum immediately before priming or placement
Confirm concrete moisture content does not exceed 4%, with no standing water, condensation, rising moisture or active leakage
Where steel is involved, abrasive-blast to ISO 8501-1 Sa 2.5 bright metal, degrease, remove dust and salt, and coat before flash rusting
Build rigid, braced, sealed and leak-proof formwork that resists full grout pressure, with a pour point, vents at high locations, a headbox and clearance for uninterrupted flow
Apply a compatible release agent to the formwork without contaminating bond surfaces
Condition both components to 18-29C before mixing, 21-25C preferred, and never locally heat containers
Add the entire contents of Part B into Part A and mix with a low-speed mechanical mixer at 300-400 rpm for 2-3 minutes, scraping the sides and base
Transfer to a clean container and remix for 1 minute to a streak-free, homogeneous blend using the double-pot method, without whipping or aerating
Complete placement within the pot life, approximately 40 minutes at 25C
Pour the mixed grout continuously from one side to drive unidirectional flow and exclude air, maintaining a hydrostatic head until the void, defect or baseplate detail is completely filled
Keep single pours to 100 mm and use the approved staged-pour sequence for deeper placements
Where priming, apply by brush, roller or squeegee at approximately 0.2-0.3 L/m2 to fully wet the surface without ponding, and second-coat highly porous concrete once the first has absorbed
Place ACTFLEX HBR or the compatible mortar, coating or overlay while the primer is in its wet or tacky recoat condition, typically 30-60 minutes at 25C
Check continuous flow with no cold joints, vents running full and formwork tight throughout
Protect the placement from movement, vibration, impact, water, contamination and temperature extremes for a minimum of 24 hours
Remove formwork after initial cure at 10-12 hours and allow 7 days full cure before structural loading, immersion or chemical exposure
Clean uncured material from tools with FORSPEC EPOXY CLEANER; cured material can only be removed mechanically

Technical Specifications

Product Type: Two-component, solvent-free, high-strength, low-viscosity structural epoxy grout
Form: Part A amber resin; Part B clear hardener; mixed translucent amber
Packaging: 30 kg pre-proportioned kit, Part A 20 kg and Part B 10 kg
Mix Ratio: 2:1 by volume; 2:1 by packaged weight (20 kg : 10 kg)
Mixed Density: Approximately 1.05 kg/L at 25C*
Theoretical Yield: Approximately 28.57 L per 30 kg kit
Mixed Viscosity: 250-450 mPa.s at 25C, Brookfield-type*
Compressive Strength: 80 MPa at 7 days, 25C (ASTM C579 basis)*
Flexural Strength: 73 MPa at 7 days, neat resin casting (ASTM D790)*
Tensile Strength: 35 MPa at 7 days, neat resin casting (ASTM D638)*
Bond Strength to Prepared Concrete: Greater than 2.5 MPa, concrete substrate failure*
Pot Life: Approximately 40 minutes @ 25C, 50% RH, reducing with temperature and mixed mass*
Mixing: 2-3 minutes at 300-400 rpm, then double-pot and remix 1 minute
Initial Cure: 10-12 hours @ 25C, 50% RH*
Formwork Removal: After initial cure*
Protection From Vibration, Traffic, Water and Contamination: Minimum 24 hours
Full Cure: 7 days @ 25C, 50% RH, before structural loading, immersion or chemical exposure*
Maximum Single-Pour Depth: 100 mm, deeper placements staged per the approved pour plan
Application Temperature: 10-35C ambient and substrate; component conditioning 18-29C
Maximum Substrate Moisture: 4%, with no standing water, condensation or active flow
Concrete Requirement: Minimum 28 days old, minimum 25 MPa compressive strength
Consumption, Formed Grouting: 1.05 kg of mixed product per litre of void volume
Consumption, Neat Coating or Patching: Approximately 3.15 kg/m2 per 3 mm of thickness
Consumption, Priming: Approximately 0.2-0.3 L/m2 per coat (0.21-0.32 kg/m2), porosity dependent
Coverage, Formed Grout: Approximately 28.5 L of void volume per 30 kg kit
Coverage, Neat Coating at 3 mm: Approximately 9.5 m2 per 30 kg kit
Coverage, Primer: Approximately 95-143 m2 per coat per 30 kg kit, theoretical before losses
Shelf Life: 24 months, unopened, stored at 5-35C
Governing Standard: No Australian Standard prescribes performance classes for structural epoxy grouts of this type
Test Basis: ASTM chemically-resistant grout series, C579 compressive, C580 flexural, C307 tensile. Formal testing can be commissioned
Hazard Classification: Both components HAZARDOUS CHEMICALS and DANGEROUS GOODS, environmentally hazardous, Poisons Schedule S5 (Part A Chemwatch 9041-09; Part B Chemwatch 9041-08)
* Typical characteristic values determined by Forspec R&D on standard production material, on the test bases stated. Typical values are general guidance, not specification limits

Product Files

Technical Data Sheet (TDS) PDF Download

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System Build-Up Guide

Correct application makes all the difference.

View All Details

Pool System Build-Up

1 Concrete Substrate
2 Crack Repair (if required)
3 ACTFLEX FLEXPLUS
4 ACTFLEX HYDROPLUG
5 ACTFLEX AT MESH
6 ACTFLEX 988 CWP (2 Coats)
7 Tile Adhesive
8 Pool Finish

Retaining Wall System Build-Up

1 Concrete Substrate
2 Crack Repair (if required)
3 ACTFLEX MS PRO
4 ACTFLEX AT MESH
5 ACTFLEX 988 CWP (2 Coats)
6 Protection Board (Optional)
7 Drainage System
8 Backfill

Tank System Build-Up

1 Concrete Substrate
2 Crack Repair (if required)
3 ACTFLEX FLEXPLUS
4 ACTFLEX AT MESH
5 ACTFLEX 988 WMP (2 Coats)
6 Protective Coating (Optional)
7 Water

Technical overview

ACTFLEX EPOXY GROUT is a two-component, solvent-free, high-strength, low-viscosity structural epoxy grout for concrete repair, formed and poured into large voids, deep defects and damaged sections in single pours up to 100 mm. It also grouts baseplates, machine bases and plinths, primes ACTFLEX HBR, and binds approved aggregate-filled repair and heavy-duty floor systems. Supplied as a pre-proportioned 30 kg kit. No Australian Standard prescribes performance classes for structural epoxy grouts of this type. The recognised industry test basis is the ASTM chemically-resistant grout series, against which formal testing can be commissioned. All published figures are typical Forspec R&D characteristic values, not accredited test results.

Key applications

Formed filling of large, static voids and deep defects in concrete, in single lifts up to 100 mm
Structural and heavy-duty patch repairs to prepared concrete, including formed edge repairs and high-traffic repair zones
Flowable grouting beneath baseplates, bearing plates, machine bases, plinths and confined load-transfer details
FORSPEC PREFLEX basement and below-ground tanking systems, pile caps, formed repairs, localised void filling and substrate transitions
Low-viscosity epoxy primer and bonding coat for ACTFLEX HBR, ACTFLEX CRYSTAL BOND and compatible FORSPEC repair mortars, coatings and overlays
Resin binder for approved epoxy mortar, aggregate-filled repair and heavy-duty patching systems
Hard-wearing rigid epoxy floor coating or binder layer for approved industrial and high-traffic floor systems
Gravity feeding or low-pressure filling of accessible static cracks and voids where the opening permits free flow

Surface suitability

Concrete (minimum 28 days old, minimum 25 MPa compressive strength, diamond ground, captive shot-blasted or scarified to a clean open profile and vacuumed, moisture content not exceeding 4%)
Steel (abrasive-blast to ISO 8501-1 Sa 2.5 bright metal where specified, degreased, dust and salt removed, coated before flash rusting)
Metal inserts and plates (cleaned and degreased immediately before placement)
Masonry and stone (sound and clean; the TDS states tenacious bond to concrete, masonry, stone and prepared steel)

Maximum single-pour depth is 100 mm. Deeper or large-volume placements are only made by an approved staged-pour or aggregate-extension plan, because large or confined mixed masses generate hazardous exothermic heat, accelerated cure, cracking, smoke or thermal damage. Maximum substrate moisture content is 4% and the product must never be applied over rising moisture, hydrostatic pressure, standing water, condensation or active leakage. Concrete must be a minimum of 28 days old with a compressive strength of at least 25 MPa. This is a rigid product and must never be used across movement joints, active cracks, flexible substrates or interfaces expected to move independently. Apply only at 10-35C ambient and substrate and not where temperatures are forecast to fall below 5C within 24 hours. Do not dilute or extend with solvents or thinners and do not mix partial kits. It is not represented as a dedicated hairline crack-injection resin. Chemical and marine exposure must be checked against the current FORSPEC chemical-resistance guidance. Protect fresh placements for a minimum of 24 hours and allow no structural loading, immersion or chemical exposure before full cure at 7 days. Both components are hazardous chemicals and dangerous goods, environmentally hazardous, Poisons Schedule S5.

Technical Specifications

Product Type	Two-component, solvent-free, high-strength, low-viscosity structural epoxy grout
Form	Part A amber resin; Part B clear hardener; mixed translucent amber
Packaging	30 kg pre-proportioned kit, Part A 20 kg and Part B 10 kg
Mix Ratio	2:1 by volume; 2:1 by packaged weight (20 kg : 10 kg)
Mixed Density	Approximately 1.05 kg/L at 25C*
Theoretical Yield	Approximately 28.57 L per 30 kg kit
Mixed Viscosity	250-450 mPa.s at 25C, Brookfield-type*
Compressive Strength	80 MPa at 7 days, 25C (ASTM C579 basis)*
Flexural Strength	73 MPa at 7 days, neat resin casting (ASTM D790)*
Tensile Strength	35 MPa at 7 days, neat resin casting (ASTM D638)*
Bond Strength to Prepared Concrete	Greater than 2.5 MPa, concrete substrate failure*
Pot Life	Approximately 40 minutes @ 25C, 50% RH, reducing with temperature and mixed mass*
Mixing	2-3 minutes at 300-400 rpm, then double-pot and remix 1 minute
Initial Cure	10-12 hours @ 25C, 50% RH*
Formwork Removal	After initial cure*
Protection From Vibration, Traffic, Water and Contamination	Minimum 24 hours
Full Cure	7 days @ 25C, 50% RH, before structural loading, immersion or chemical exposure*
Maximum Single-Pour Depth	100 mm, deeper placements staged per the approved pour plan
Application Temperature	10-35C ambient and substrate; component conditioning 18-29C
Maximum Substrate Moisture	4%, with no standing water, condensation or active flow
Concrete Requirement	Minimum 28 days old, minimum 25 MPa compressive strength
Consumption, Formed Grouting	1.05 kg of mixed product per litre of void volume
Consumption, Neat Coating or Patching	Approximately 3.15 kg/m2 per 3 mm of thickness
Consumption, Priming	Approximately 0.2-0.3 L/m2 per coat (0.21-0.32 kg/m2), porosity dependent
Coverage, Formed Grout	Approximately 28.5 L of void volume per 30 kg kit
Coverage, Neat Coating at 3 mm	Approximately 9.5 m2 per 30 kg kit
Coverage, Primer	Approximately 95-143 m2 per coat per 30 kg kit, theoretical before losses
Shelf Life	24 months, unopened, stored at 5-35C
Governing Standard	No Australian Standard prescribes performance classes for structural epoxy grouts of this type
Test Basis	ASTM chemically-resistant grout series, C579 compressive, C580 flexural, C307 tensile. Formal testing can be commissioned
Hazard Classification	Both components HAZARDOUS CHEMICALS and DANGEROUS GOODS, environmentally hazardous, Poisons Schedule S5 (Part A Chemwatch 9041-09; Part B Chemwatch 9041-08)
* Typical characteristic values determined by Forspec R&D on standard production material, on the test bases stated. Typical values are general guidance, not specification limits