Our advanced range of microcement overlays for floors and walls use a high percentage of recycled media as aggregate and fine filler, a unique low CO2 cement binder and a high solids polymer to reduce water usage.
In a nutshell, our microcement not only looks amazing, it is ground breaking.
The MicroFloor and MicroWall microcement products by CARRcrete are leading the field with advanced ECO friendly features. Not only is our product only 3mm thick, so it uses much less material than a normal concrete floor and requires far less energy than tiles, vinyl and timber flooring to produce at the manufacturing stage. It also uses far less raw ingredients; a greatly reduced amount of water in comparision to concrete or self levelling screeds. Better for the environment, better for your wallet by reducing energy requirements for heating such a thin floor veneer.
Most cement binders used in a microcement formula are based on a ternary binder system. This often consists of ordinary portland cement plus high alumina cement, possibly a small amount of a pozzolan such as silica fume or fly ash. If you’re really lucky they may have included a shrinkage compensating additive to balance out the natural tendencies of OPC and HAC cements to shrinkage.
Whilst this ternary binder does work and has worked for a long time, it is full of problems which require multiple additives to be included to prevent shrinkage, cracking, adequate working time, accelerated hardening etc. Binders which include high alumina cements are also prone to something called conversion, where without warning they lose their strength, become fragile and often crack. This is why HAC cement is not allowed for use in structural concrete.
This is why we developed a microcement product line around a far more advanced binder solution. A binder that is naturally crack free, shrinkage compensated and rapid hardening. With CARRcrete being the only company in Europe to be using our specific binder, we can tell you straight, that no other microcement has a binder with anywhere near as advanced as the one used in our products.
As much as it pains our competitors, we do not need additives to improve our cements shrinkage characteristics, it is inherently crack and shrinkage free, meaning it is the perfect binder for cement overlays.
This novel and unique cement also hardens at an accelerated rate, in fact within 24 hours our cement binder will achieve a hardness an average concrete would require 28 days to accomplish.
During manufacture our cement requires less energy to produce during the kiln firing stages and produces 20% less CO2 than either OPC or HAC cements. So it is by far a more ECO friendly solution than the competition can offer.
Again most microcement products on the market use the least expensive and most abundant ingredients available, silica sand and marble sand being just two of them. They sound impressive, but the reality is they are inexpensive and not very hard; which is important for impact and abrasion resistance.
But these fine sands which are used as aggregate within microcement and microconcrete products, have to come from somewhere. Where? Most often or not they are quarried from selected sand deposits in our countryside which are each day being depleted by over use and industry over reliance of these fine sands.
There has been talk for years of how the government is trying to reduce silica sand usage and in some cases close down quarries. There is already an aggregate levy within the UK.
This depletion and destruction of natural resources is what spurred us on to create products that use no sand. This was not as easy as it sounds, finding a suitable replacement was quite difficult and required a lot of testing. Sand is always close at hand, alternative fine aggregates are not, but it doesn’t matter if it’s silica or marble sand, there isn’t any in our products.
After what seemed like an endless amount of testing, we evidentually settled on a really pure and clean form of recycled glass. Recycled glass is not only very hard and highly abrasion resistant, but is also fits the bill for finding an environmentally friendly aggregate.
When comparing our glass filled product versus marble sand based products, we have found that our range offers significant improvements in impact and abrasion resistance. Two of the most important factors to consider when selecting a floor finish.
With our glass being clear, it often glistens when sanded back to the grains. This offers a unique texture to our products, which we feel is a positive that our product looks slightly different to the rest of the pack. We don’t want to be the same, we want to be better and to improve where possible.
Calcium carbonate is widely used within the microcement scene, it is very inexpensive and common within many aspects of cement overlay products. It creates a much creamier, less grainy mix when applying, lightens the products base colour and reduces costs.
The problem with calcium carbonate based products is that they are soft, weak and very porous. Not exactly what you need when you are trying to create a robust surface finish.
That’s why we chose ground quartz, which is 100’s of times harder on the mohs scale. Quartz still has the same ability to smooth out mixes, produce nice light powders but with serious strength advantages.
Increased strength is just one reason why trade professionals return to using our products time after time.
Our products are mixed with a premium grade, high solids liquid polymer of our design opposed to plain water. This allows us to reduce the overall impact of our product by using considerably less water. A factor we feel is incredibly important as we do not make new water, it is the same water the dinosaurs drank. Without a doubt, a precious commodity.
We also ship our polymer in a pigmented form, this enables us to reduce shipping costs, associated fuel and plastic container usage by not having separate colour bottles.
This amazing polymer really does work some magic by increasing flexibility, abrasion resistance and reduces porosity of the product. It is the polymer that enables our microcement overlays to adhere to such a wide range of substrates and cope with flex issues, underfloor heating etc.
Our high solids polymer initially looks white but when dried and cured it is completely clear, this enables us to pigment the actual polymer used with our products, for a more true, longer lasting colour.