Cement concrete as a construction material was first developed more than 100 years ago. However, researchers and innovators continue to explore new types, properties and forms of concrete even today, producing ingenious variations that fulfil various specific needs. One such innovation has been micro concrete, which has gained popularity globally due to its diverse applications in buildings. Keep reading to understand exactly what micro concrete is, its properties and benefits in construction, the process of applying microtopping, important applications of microcrete, and discover the micro concrete price in India.
What is Micro Concrete?
Micro concrete or microcrete is a pre-packed composite material composed of cement, fine aggregates and sometimes polymers and admixtures. These components together create high-performance thin-layered concrete that can be applied to a variety of substrates including concrete, wood, metal, and even existing tiles. The polymers and additives are typically added to enhance properties like strength, adhesion, flexibility and durability. Visually, this material resembles normal concrete, but can be applied in much thinner layers, making it useful for many applications such as repair and flooring in the construction industry.
Micro Concrete Vs Normal Concrete
Although microcrete and normal concrete have similar components, they vary in other aspects, including:
| Micro Concrete | Normal Concrete | |
| Application | Available in a ready-mix powder form, which is mixed with water and then poured onto surfaces. It does not require any compaction. | All the individual components are mixed before application and then poured. The poured mix needs adequate compaction to prevent issues like honeycombs and cracks. |
| Aggregates Used | Only micro fine aggregates are present. | Both coarse and fine aggregates are present. |
| Thickness | 2 – 50 mm. | Minimum of 75mm. |
| Reinforcement | Does not consist of any reinforcement. | PCC doesn’t consist of reinforcement, but RCC does. |
| Uses | Mainly used as a surface finish or for repairing concrete components in buildings. | Mainly used to make structural components like foundations, slabs, columns, staircases and beams. |
| Curing Period | 2 – 7 days | 28 days |
Process of Applying Micro Concrete
- Surface Preparation: The surface on which microcrete needs to be applied is cleaned thoroughly. In case of use for repair purposes, the deteriorated or corroded portion of the old concrete is removed. If required, a bonding coat is applied with a brush or by spraying or sprinkling it on the surface.
- Mixing: The microcrete powder (available in a pre-mixed bag form) is mixed with water in a ratio of around 1:8. This is generally done manually for small quantities and in a mixing machine for larger quantities.
- Application: The mixture is poured directly onto the surface while maintaining a uniform thickness. The finished surface is then wiped clean with cleaning tools.
- Curing: Although elaborate curing is not necessary, most brands advice sprinkling a little water for 2-7 days after application.
Benefits of Using Micro Concrete in Construction
- Easy Application: Microcrete powder requires only mixing with water before it can be poured, making it a simple and quick process. Unlike normal concrete, this process does not involve steps that need intense labour, such as bending and laying of steel reinforcement and shuttering.
- Water Resistance: Microtopping flooring, walls and other surfaces have excellent water resistance. Thus, they can effectively be used in wet areas like bathrooms and kitchens to form waterproof spaces.
- Smooth Finish: Micro concrete floors and other surfaces have a very smooth appearance and finish. However, the micro concrete texture is slip-resistant, making it ideal for wet and/or outdoor spaces.
- Versatility and Adhesion: Although bonding coats are sometimes necessary, microcrete can typically adhere well to diverse surfaces and materials, including concrete, timber/ wood, stone, tiles and metal.
Uses of Micro Concrete
Micro Concrete Flooring
Microcrete flooring is highly popular in contemporary designs due to its seamless appearance and durable surface. Micro concrete flooring is ideal for both indoor and outdoor use, and its anti-slip surface makes it suitable for living rooms, kitchens, bathrooms, patios, and even commercial spaces like offices and retail stores. It is easy to maintain, resistant to heavy traffic, and can be customised in various finishes, from matte to satin and glossy.
Decorative Finishes
Micro cement and concrete micro topping are often used to refresh old surfaces and create a uniform, sleek finish. Such a microcrete topping is applied in thin layers, usually between 1 to 3 mm, creating a durable finish that is resistant to moisture and easy to clean. Diverse patterns and textures can also be created on its surface. It is often used to make seamless surfaces in bathroom and kitchen sinks and countertops.
Repair Work
Many issues in both PCC and RCC, such as honeycombs, cracks, concrete corrosion and spalling can be fixed using microcrete. Here, the microcrete is poured into the old concrete to fill its gaps or replace damaged portions (after the old portions are removed), creating healthier building components. This process is especially beneficial because it is simple, cost-effective and does not require compaction.
Preventing Damage
Damage to old as well as new structural components of buildings (such as columns, beams and slabs) can be prevented by using micro concrete. This is done by coating these components with a thin layer of microcrete in a process called Concrete jacketing, which acts as a protective barrier and also strengthens the underlying concrete layers.
Limitations of Micro Concrete in Construction
- Skilled Labour Requirement: Although the number of labourers required for applying microcrete is low, these labourers need to be skilled and adept with the process to ensure that issues like cracks and non-uniformity are prevented.
- Temperature Fluctuations: Similar to normal concrete, micro concrete can also experience contractions and expansions under extreme temperature variations, making it unsuitable for use in many regions.
Micro Concrete Price
Microcrete is generally available in bags with a weight of 10 – 50 kgs. The cost of a 25kg micro concrete bag is typically between ₹350 – ₹500, meaning that the average micro concrete rate varies from ₹14 – ₹25/ kg. However, these are approximate values and can vary widely based on several factors like location, availability, brand, type, quality, application purpose, strength and market conditions.
Using Micro Concrete in Construction Projects
In India, microcrete is still a material that is not very frequently used because it is assumed to be expensive (although it is cost-effective) and due to a lack of awareness. However, distinguished construction companies in India, such as Brick & Bolt, always endeavour to use new materials like this in their residential and commercial projects. With end-to-end construction services and a streamlined building materials supply, this company also ensures the lowest building prices in the industry. 470+ quality checks are conducted for every project through a patented system (QASCON), also verifying that top-quality is maintained throughout. To get your home or commercial building designed and built with innovative materials like micro concrete, get in touch with Brick & Bolt today!
Hemali Patel