Belzona 4154
Bulkfill Resin
A two-component, solvent-free epoxy resin for use with aggregates to fill holes and level uneven areas economically.
A two-component, solvent-free epoxy resin designed to be mixed with aggregate (Belzona 4124 or compatible silica sand) for cost-effective bulk-fill concrete and stonework repairs.
- SeriesBelzona 4000 Series
- Documents3
Overview of Belzona 4154
Belzona 4154 (Bulkfill Resin) is a two-component, solvent-free epoxy resin specifically formulated to be combined with aggregate (such as Belzona 4124 Bulkfill Aggregate or compatible silica sand) for cost-effective bulk-fill of large concrete and stonework repairs. The resin and aggregate combination is screeded into prepared substrates and overcoated with Belzona 4111 or 4131 to provide the durable wear surface.
The 6:1 by volume Base-to-Solidifier ratio combines with up to 22.5 kg (50 lb) of aggregate per 3.25 kg unit to produce a high-volume repair compound. Belzona 4154 should not be used alone — it is engineered as a system component. For standalone resin applications without aggregate, use Belzona 4151 (Magma-Quartz Resin) instead.
Key Benefits
No solvents, no shrinkage during cure
100% solids formulation reduces health and safety risks in confined spaces with no shrinkage on cure
Easy to mix and apply without specialist tools
No mixing required - applied directly from the container by brush or roller
Application Areas
What this product handles, grouped by equipment area — each links to the full application.
Floor Problem Areas
1 applicationTechnical Data
Composition
- Type
- Two-component, solvent-free epoxy resin designed for use with aggregate (resin component for Belzona 4124 Bulkfill system)
- Mixing Ratio by Weight (Base : Solidifier : Aggregate)
- 6.7 : 1 : 53
- Mixing Ratio by Volume (Base : Solidifier)
- 6 : 1
- Maximum Aggregate per Unit
- 22.5 kg (50 lb) per 3.25 kg (7.16 lb) unit of Belzona 4154
- Important
- Belzona 4154 is NOT intended for standalone use — always combine with aggregate. For resin-only applications, use Belzona 4151 instead
Mixing Procedure
- Equipment
- Mechanical mixer required for bulk applications due to material stiffness
- Step 1
- Empty entire Base and Solidifier units into mixing bucket. Mix 1–2 minutes for homogeneous resin mix
- Step 2
- Slowly add aggregate to mixed resin while continuing to mix. Mix 5 additional minutes for screeding/trowelling consistency
- Volumes
- 2.55 liter (86.2 US oz) Base + 0.43 liter (14.5 US oz) Solidifier with up to 22.5 kg (50 lb) aggregate
Volume & Coverage (with aggregate)
- Volume Capacity
- 770 in³ (12,700 cm³) per 22.5 kg (50 lb) aggregate (typical — varies with aggregate characteristics)
- Coverage Rate
- 10.7 ft² (1.0 m²) at 0.5 in (12 mm) per 22.5 kg (50 lb) aggregate
Working Life (with aggregate added)
- 50°F (10°C)
- 2 hours
- 59°F (15°C)
- 1 hour
- 68°F (20°C)
- 45 minutes
- 77°F (25°C)
- 30 minutes
- Use of small aggregate amounts will reduce usable life
Cure Times
- 50°F (10°C)
- Overcoat 12 hours / Full mechanical hardness 3 days
- 59°F (15°C)
- Overcoat 8 hours / Full mechanical hardness 2 days
- 72°F (22°C)
- Overcoat 6 hours / Full mechanical hardness 24 hours
- 77°F (25°C)
- Overcoat 5 hours / Full mechanical hardness 16 hours
Aggregate Recommendation (third-party)
- Dry, clean, round/rectangular silica sand
- Smaller or larger particle sizes will affect final product performance
- Contact Belzona Technical Service for guidance on non-Belzona aggregates
Overcoat Schedule
- Overcoat with Belzona 4111 or 4131 within 24 hours, using Belzona 4911 between layers
- If overcoat window exceeded, surface of Belzona 4154 must be abraded prior to overcoat
- Apply Belzona 4154 within 6 mm of final desired surface, then 6 mm screed of Belzona 4111 or 4131 on top
Substrate Preparation
- Allow new concrete to cure 28 days minimum, or until moisture content is below 6% (Protimeter)
- Damp surfaces must be conditioned with Belzona 4911 (Magma TX Conditioner) prior to application
- Substrates subject to severe loads should be conditioned with Belzona 4911
Working Life
From commencement of mixing, with aggregate added, use within:
- 50°F (10°C)
- 2 hours
- 59°F (15°C)
- 1 hour
- 68°F (20°C)
- 45 minutes
- 77°F (25°C)
- 30 minutes
Curing Time
Allow Belzona 4154 to solidify before subjecting it to the conditions indicated:
At 50°F (10°C)
- Overcoating
- 12 hours
- Full mechanical hardness
- 3 days
At 59°F (15°C)
- Overcoating
- 8 hours
- Full mechanical hardness
- 2 days
At 72°F (22°C)
- Overcoating
- 6 hours
- Full mechanical hardness
- 24 hours
At 77°F (25°C)
- Overcoating
- 5 hours
- Full mechanical hardness
- 16 hours
Service Temperature Limits
- Application Temperature Range
- 50°F (10°C) to 77°F (25°C) — below 50°F material is too stiff for mixing; above 77°F material becomes fluid with reduced working life
- Storage Recommendation
- Maintain Base storage above 77°F (25°C) to minimize crystallization risk; if crystallization occurs, warm Base to 104-122°F (40-50°C) until crystals dissolve
- Service temperatures depend on overcoat selection (Belzona 4111 or 4131)
Product PDFs
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Frequently Asked Questions
What is Belzona 4154 (Bulkfill Resin) used for?
Belzona 4154 (Bulkfill Resin) is a multi-purpose epoxy resin system designed to be mixed with locally sourced aggregates such as sand, quartz, or crushed stone for the bulk repair of large uneven concrete surfaces, deep holes, and cracks. It must be subsequently overcoated with a Belzona 4000 Series repair material or protective coating.
What is the mixing ratio of Belzona 4154 (Bulkfill Resin)?
The mixing ratio of Belzona 4154 (Bulkfill Resin) is 6.7 : 1 (Base : Solidifier) by weight and 6 : 1 (Base : Solidifier) by volume. The mixed resin is then combined with locally sourced aggregate per the Instructions for Use. Please see the Product Specification Sheet (PSS) for more information.
How do you apply Belzona 4154 (Bulkfill Resin)?
To apply Belzona 4154 (Bulkfill Resin), the surface must be clean, firm, and dry, free of any contamination, and conditioned with Belzona 4911 (Magma TX Conditioner). Mix the Base and Solidifier components until homogeneous, then slowly add the locally sourced aggregate at the prescribed ratio while mixing. Apply the mortar to the conditioned area, compact to remove entrapped air, and screed level. Once cured, overcoat with the appropriate Belzona 4000 Series repair material or protective coating. Please see the Instructions for Use (IFU) for more information.
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