Construction Manual

FUFINI MICROCEMENT INSTALLATION MANUAL

2024

Wall microcement project quality acceptance standards 10

Microcement floor layering process diagram 11

Stage 2 Substrate reinforcement & levelling treatment for surface application 12

Stage 3 Application of floor surface microcement 13

Stage 4 Finishing treatment of floor microcement surface layer 15

Floor microcement project quality acceptance standards 16

Microcement layering process diagram for bathroom wet areas 17

Microcement furniture/joinery layering process diagram 18

Installers organization methods 19

Application process considerations | common issues and their causes 20

Routine maintenance and cleaning methods for microcement 22

Microcement first coat mixing ratio reference chart 23

Microcement second coat mixing ratio reference chart 24

Installation Substrate Standards

Wall Substrate Acceptance Standards:

No hollowing, no powdering, no cracking, no delamination, no oil stains, no dust, etc.

The flatness and stability should be excellent (ensure mesh fabric is applied at seams to prevent cracking

and nail head rust treatment).

Wall flatness: <2mm/m (using a level ruler and filler gauge for measurement).

Floor Substrate Acceptance Standards:

For Tiled Floors:

A flat, solid tiled floor without damage or loosening.

Apply two coats of rigid waterproof coating or use joint filler for sealing.

Prevent groundwater from rising

(if not properly treated, moisture may show through the tile joints over time).

For Cement Mortar Floors:

The flatness should be tested with a 2m ruler, not exceeding 3mm.

Apply two coats of rigid waterproof coating.

Compressive strength should be above 25N/mm² (3500psi), with concrete >42 mpa or

higher. Surface tensile strength should be above 1.5N/mm², with the surface being flat,

dense, free of cement slurry, and without loose or brittle particles.

Newly poured concrete must cure for 28 days, with a moisture content not exceeding 6%.

Site Environmental Requirements

Temperature and Humidity for Construction and 24 Hours After:

-Temperature: 8°C < T < 35°C, Relative Humidity: <80%, and substrate moisture content <6%.

-Ensure good ventilation on the construction site; closed environments are not recommended.

Substrate Rectification Methods

Dry Area Walls:

Remove old walls with powdering and uneven surfaces. Directly cover uneven new walls with putty until

the flatness requirement is met. Apply mesh twice with waterproof putty, sand the surface, and start the

microcement application.

New Bare Floor:

Ideally, lay inexpensive engineering tiles flat, then use joint filler to seal the tile joints or apply two

coats of rigid waterproof coating after laying the mesh before applying microcement. This ensures

floor base strength and prevents cracking in microcement. Alternatively, use >40mpa cement with

small stones and sand, lay wire mesh at a thickness of 3-5cm, and cure for about four weeks. For

areas over 50 square meters, cut to leave expansion joints before proceeding with microcement

application.

[Micro-cement floor thickness: 2-3mm. Ensure appropriate construction height is reserved.]

Preparation for Wet Area Application:

Wet Areas include:

Bathrooms, kitchens, pools, wash basins, showers, basements, underground garages, etc.

Dry Areas Include:

Living rooms, bedrooms, stairs, enclosed balconies, covered patios, areas 2m away from wet areas.

Wet Area Walls: Apply two coats of rigid waterproof coating, especially in bathrooms.

Wet Area Floors: Apply waterproof coating, then place 3*3 or 4*4 iron mesh on the base, followed

by leveling with cement mortar.

Leveling Cement Mortar Requirements: Mix 3-5mm and 5-8mm stones with cement mortar and

spread the mixture evenly on the floor, ensuring a deviation of no more than 1-2mm. Finally, use a

high-strength self-leveling compound to achieve the final leveling.

Microcement to Floor Connection: The best way is to have a stainless steel strip (carbon steel, pure

copper, etc.) of 3mm or 5mm width between the floor and microcement.

Precautions: Ensure that the thickness of the floor and the microcement layer are level. The microcement layer should be 2-3mm thick. For the transition between stone and microcement, the stone

thickness should be 16mm or 20mm to ensure it is level with the microcement layer. If an underlay

is required, use a mixture of steel fibers, 3-5mm stones, and cement mortar.

Underfloor Heating Considerations:

Central Heating System: Apply two coats of rigid waterproof coating. Level the floor with steel

fiber mixed with 3-5mm stone and cement mortar. It is best to wait until after the first winter before

applying microcement. In urgent cases, lay engineering tiles before microcement application.

Self-heating Underfloor Heating: Apply two coats of rigid waterproof coating. Lay 3*3 or 4*4 iron

mesh on the base, then level with cement mortar.

Leveling Cement Mortar: Leveling mortar should be 3-5mm or 5-8mm stone mix, and finally use

high-strength self-leveling compound to level the surface. Underfloor heating should be turned on to

the maximum for 5 days, then off for 2 days, and back on for 5 days at normal operating temperature

before application.

Ordinary Heating: Application can proceed at any time. Note: For areas less than 50m², you may

not need steel fiber mortar; use cement mortar mixed with 3-5mm stones for leveling.

Steel Structure Staircase:

Grind seams and weld points of the steel structure staircase flat and treat the surface with antirust primer after welding.

Bar Counter/Seating/Cabinets/Woodwork Features:

Use high adhesion, high-strength anti-cracking materials to treat the seams of furniture boards, fill

gaps thoroughly, and sand the seams and edges to smooth finish with fine sandpaper.

Common Tools for Microcement Application

2 rolls of 100g anti-crack fiberglass mesh

(for base layer crack resistance)

3 stainless steel flexible trowels, 3 scrapers

(for wall and regular floor surface layers)

2 sets of 3mm synthetic fiber rollers (4 in total)(for applying protective coatings)

1-2* 6 inch vibrating orbital sanders with dust

extractors for dust-free sanding (centrifugal

vibrating sanders eliminate manual sanding

marks)

2*3000ml measuring cups (for measuring liquids and microcement powder)

2* 20ml syringes (for measuring precise amounts of pigment)

2*paint trays (for protective coatings, ensuring even application)

Knee Pads: 3 sets (used only for floor application)

Plastic internal corner strips: For seamless wall-floor integration

External corner metal strips: For protecting furniture and stair corners

Common Tools for Microcement Application

High-power handheld dual-rod mechanical mixer

Electronic platform scale

(used for large area applications,measuring

cups can be used for small areas)

Standard 9-Inch & 4-Inch Wool Brushes: 2 sets (for applying primers)

24mm Wide Masking Tape: 5 rolls

(for protecting finished products and color separation)

Manual Sandpaper Holders: 2 units

with 60-grit sandpaper

white sandpaper, 180-grit, in sufficient quantities

Common Materials Table - Usage Instructions

Fufini Microcement Wall Layering Process

Precautions

After completing the wall micro-cement, keep it completely sealed for 24 hours to avoid touching or contamination.

After the 24-hour curing period, it can be used normally.

Micro-cement reaches optimal usage status 30 days post-application for normal use.

During use, maintain regular cleaning to avoid stains. Use recommended cleaning supplies.

Step 5: Application of the First Coat of Two-Component Protective Topcoat

1. Pour an equal weight of clean water into the TOPCO-B Protective

Topcoat Component B and stir thoroughly.

2. Pour the mixed TOPCO-B Protective Topcoat Component B into

Protective Topcoat Component A and stir until the mixture is uniform.

3. Pour the mixed two-component topcoat into a tray. Using a

3mm short-pile synthetic roller, evenly dip the roller into the mixture,

ensuring to remove any excess material. Apply the topcoat evenly

over the microcement surface, rolling in different directions to

ensure complete and uniform coverage with no missed spots.

Drying Time: 24 hours

Tools: 3mm short-pile synthetic roller, sponge

Coverage per Coat: 20m²/kg per coat

Mixed Resin

Topcoat mixing ratio:

Topcoat B 500g + Clean water 500g + Topcoat A 5kg

Step 6: Application of the Second Coat of the Two-Component Protective Topcoat

(Required for Walls in Wet Areas)

1. Pour an equal weight of clean water into the TOPCO-B

Protective Topcoat Component B and mix thoroughly.

2. Pour the mixed TOPCO-B Protective Topcoat Component B

into Protective Topcoat Component A and stir until fully blended.

3. Pour the thoroughly mixed two-component topcoat into a tray.

Using a 3mm short-pile synthetic fiber roller, evenly dip the roller

into the tray, remove any excess material, and roll it onto the surface

evenly, ensuring complete coverage with no gaps.

Drying Time: 24 hours

Tools: 3mm short-pile synthetic roller

Coverage per Coat: 20m²/kg per coat

Mixed Resin

Topcoat mixing ratio:

Topcoat B 1000g + Clean water 1000g + Topcoat A 5kg

Fufini Wall Micro Cement Project Quality Acceptance Standards

Fufini Microcement Floor Layering Process

Precautions

After completing the floor microcement, keep it completely sealed for 72 hours to avoid touching or stepping.

After the 72-hour curing period, protect the site before use, avoiding heavy object pressure on the floor.

Microcement reaches optimal usage status 30 days post-application for normal use.

During use, maintain regular cleaning to avoid stains. Use recommended cleaning products.

Step 1: Base Layer Rolling - Sealing and Curing the Base:

Dilute (AGE02) primer with 40% water and roll it evenly the mixture

onto the absorbent base surface. Non-absorbent bases do not

require the application of the primer. Ensure complete and uniform

coverage with no omissions.

Drying Time: 1 hour

Tools: Standard long-haired roller

Coverage: 10m²/kg/per coat

Step 2: Install Alkali-Resistant Fiberglass Mesh

Lay out the 100G fiberglass mesh flat on the floor, ensuring that

the overlapping sections of the mesh grids exceed 2 cm in width.

Step 3: Apply a Layer of Crack-Resistant Mortar (for very poor substrate conditions)

Using a 0.5mm thick stainless-steel trowel,

evenly apply a layer of crack-resistant mortar.

Drying Time: 24 hours

Tools: 0.5mm thick, 30cm stainless steel trowel

Coverage per Coat: 0.7m²/kg

Stage 2: Floor Microcement Application - Base Reinforcement and Leveling Treatment

Step 4: Application of a Single Layer of Microcement Base Material

1. Follow the mixing ratio of 4 kg MIXED RESIN to 10 kg

Microcement base material. Slowly pour the Microcement Base

into the mixed resin while simultaneously stirring with a high-power

mechanical mixer to ensure thorough mixing.

2. Allow the mixed Microcement BASE material to sit for 5 minutes.

After resting, stir it again with the mechanical mixer before use.

3. Using a stainless-steel trowel with a thickness of 0.5 mm, apply

a single layer of the mixed dual component. Ensure the application

is even and complete, with no missed areas.

Special Precaution: If the substrate’s flatness after the first layer of

base microcement is still relatively poor, it is recommended to apply

a second layer of base microcement to achieve better evenness.

Drying Time: : 6–8 hours

Tools: Stainless steel trowel with a thickness of 0.5 mm

and dimensions of 30 cm

Coverage: 1 m²/kg/per coat

Precaution: Do not dilute with water

Sanding Microcement BASE

After the Microcement base layer has fully dried,

begin sanding using an electric sander.Once sanding is complete,

remove dust with a vacuum cleaner.

For sanding the microcement base, use sandpaper with a grit #60.

Stage 3: Surface Application of Microcement on Flooring

Step 5: Apply First Coat of Microcement SURFACE Layer

1. Strictly follow the recommended ratio to add pigment tint

into the mixed resin and mix thoroughly.

2. According to the ratio of mixed resin (Component B emulsion)

4 kg to 10 kg of surface microcement, slowly add the surface

microcement into the pre-coloured mixed resin. Ensure to add the

powder gradually while mixing with a high-power mechanical mixer

to achieve uniform colour distribution.

3. Allow the prepared surface microcement to stand for 5 minutes

before mixing again with the mixer before use.

4. Using a 0.3 mm thick stainless-steel trowel, apply the first coat

of the pre-mixed coloured surface microcement.

Ensure the application is even, with no missed spots.

Drying Time: : 6–8 hours

Tools: 0.3 mm thick, 30 cm stainless steel trowel

Coverage: 2 m²/kg/per coat

Precaution: Do not dilute with water

Sanding Microcement Surface Layer

Once the first coat of microcement Surface layer has completely dried,

begin sanding using 180-grit sandpaper

(or a vibration dust-suction sanding machine).

After sanding, use a vacuum cleaner to remove dust.

For hand sanding of the Microcement Surface layer, use sandpaper grit #180.

Step 6: Bubble Holes Prevention Treatment (Special Precaution)

1. After completing the application of the first coat of microcement

surface layer, wait until it is approximately 70-80% dry (provided this

is feasible within the same day’s working time). Once the surface of

the microcement is dry enough that no footprints are left when

stepped on, you may proceed with the application of the second

coat. This procedure aims to prevent excessive drying of the base

layer, which could lead to the formation of bubble holes during the

application of the second coat.

2. If the application of the second coat of microcement is scheduled

for the following day, ensure that the microcement surface is properly

sanded. Before starting the second coat of microcement surface layer,

first apply a coat of This step is essential to prevent

excessive drying of the base layer, which significantly reduces the

likelihood of bubble holes forming during the second coat application.

Drying Time: : 15 mins

Tools: Standard Long-Nap Roller

Coverage: 10m²/kg/per coat

Precaution: Do not dilute with water

Step 5: Apply the Second Coat of Microcement Surface Layer

1. Strictly follow the recommended ratio to add pigment tint

into the mixed resin and mix thoroughly.

2. According to the ratio of mixed resin (Component B emulsion)

4 kg to 10 kg of surface microcement, slowly add the surface

microcement into the pre-coloured mixed resin. Ensure to add the

powder gradually while mixing with a high-power mechanical mixer

to achieve uniform colour distribution.

3. Allow the prepared surface microcement to stand for 5 minutes

before mixing again with the mixer before use.

4. Using a 0.3 mm thick stainless-steel trowel, apply the first coat

of the pre-mixed coloured surface microcement.

Ensure the application is even, with no missed spots

Drying Time: : 6–8 hours

Tools: 0.3 mm thick, 30 cm stainless steel trowel

Coverage: 2 m²/kg/per coat

Precaution: Do not dilute with water

Sanding Microcement Surface Layer

Once the first coat of microcement Surface layer has completely dried,

begin sanding using 180-grit sandpaper

(or a vibration dust-suction sanding machine).

After sanding, use a vacuum cleaner to remove dust.

For hand sanding of the Microcement Surface layer, use sandpaper grit #180.

Stage 4: Floor Microcement Application - Completed Surface Treatment

Step 8: Apply 1-2 coats of primer using a roller (dilute with 30% clean water and mix thoroughly). Ensure

complete coverage with no missed spots. Drying time is 2 hours.

Step 9: Apply the First Coat of Two-Component Protective Topcoat

1. Pour an equal weight of clean water into Topcoat-B

protective topcoat and mix thoroughly.

2.. Add the mixed Component B to Component A of the

protective topcoat and mix well.

3. Pour the mixed two-component topcoat into a tray.

Use a 3mm short-pile synthetic roller to evenly load the

material from the tray, remove excess material, and apply

evenly onto the microcement surface. Use a square mop

to smooth and ensure full coverage with no missed areas.

Drying Time: 6–8 hours

Tools: 3mm short-pile synthetic roller, tray.

Coverage: 25m²/kg/per coat

Mixing Ratio: Protective Topcoat B: 750g + Clean Water: 1500g +Two-component topcoat: 5kg

Manual Sanding of the Two-Component Protective Topcoat

After the first layer of the two-component topcoat has fully dried,

proceed with light manual sanding using 800-1000 grit sandpaper.

After sanding, remove the dust using a vacuum cleaner.

Important: Do not use a damp cloth to remove dust.

Step 10: Apply the Second Coat of Two-Component Protective Topcoat

1. Pour an equal weight of clean water into the TOPCP-B

Protective Topcoat Component B and mix thoroughly.

2.. Add the mixed Component B to Component A of the

protective topcoat and mix well.

3. Pour the mixed two-component topcoat into a tray.

Use a 3mm short-pile synthetic roller to evenly load the

material from the tray, remove excess material, and apply

evenly onto the microcement surface. Use a square mop

to smooth and ensure full coverage with no missed areas.

Drying Time: 6–8 hours

Tools: 3mm short-pile synthetic roller, tray

Coverage: 25m²/kg/per coat

Standard Floor Mixing Ratio:

Protective Topcoat B: 1000g + Clean Water: 500g +Topcoat A 5kg

High-Standard Flooring in Wet Areas mixing ratio:

Protective Topcoat B: 1500g + Clean Water: 500g +Topcoat A 5kg

Fufini Floor Microcement Project Quality Acceptance Standards

Fufini microcement bathroom wet area layering process

0. Wall/Floor Base

1. High-strength self-leveling compound/Engineered tile/High-strength

cement mortar with metal mesh

2. Fiberglass mesh + Primer

3. First coat of base microcement for bathroom (two-component) (sanding)

4. Second coat of base microcement for bathroom (sanding)

5. First coat of primer

6. Second coat of primer

7. First coat of surface microcement for bathroom (sanding)

8. Second coat of surface microcement for bathroom (sanding)

9. First coat of two-component protective topcoat (sanding)

10. Second coat of two-component protective topcoat

Fufini microcement furniture & joinery layering process

Method for Organizing Applicator Personnel

Walls:

For large wall areas (>5 square meters), it is important to consider that the edges of the microcement may

dry too quickly, potentially causing visible seams or overlaps that affect the aesthetic appearance.

Therefore, microcement application must involve multiple installers working together. The application should

be done with wet-on-wet overlap and smoothed out. Each installer should handle a horizontal width of 2-3

meters and a vertical height of 1.5-2 meters. For extensive wall areas, coordinated efforts are required to apply and smooth the cement simultaneously. The smoothing technique should follow an “S” pattern, and the

seam locations must form a “W” shape.

Floors:

In projects involving the simultaneous application of micro cement across multiple rooms, coordination

among the installers is crucial to ensure the work is completed seamlessly and continuously. The recommended approach is to start in the room farthest from the residential or building exit, beginning the application from the corner opposite the door. The wider the room, the more workers are needed. To avoid interruptions, it is advisable to keep the last row of microcement moist before reapplying, and a light misting at the

interface of the micro cement can be employed.

Regarding the illustration, we can proceed as follows:

Several installers should start working from different locations and coordinate their progress with their colleagues.

We must consider that installers working in corridors (narrow areas) will complete their tasks more quickly compared

to those responsible for larger areas of work

Application Process Considerations

Progress of Installers:

It is important to acknowledge that the pace of installers in narrow areas such as corridors is generally

faster than that of those responsible for larger areas of construction.

Mixing Method:

Begin by adding the liquid and mixing thoroughly, then gradually add the powder while stirring at

high speed to ensure an even mixture.

Application Technique:

Ensure a visually appealing texture and address edge details to avoid noticeable joint marks. Pay special

attention to the treatment of internal and external corners, ensuring meticulous sanding of detail areas.

Address colour variations in curved internal corners.

Material Usage Planning:

Plan the amount of material for each batch to prevent colour discrepancies or wastage.

Coordination of Application Personnel:

Organize and coordinate the work of the installation team to prevent joint marks.

Material Open Time:

Be aware of the open time for each material, especially for high-strength flooring materials, which have a

shorter open time.

Waterproofing in Wet Areas:

Ensure proper waterproofing of the substrate in wet areas, including the application of a waterproof and

anti-seepage layer as required

Common Issues and Causes During Application

Colour Inconsistency (Colour Variation) and Joint Marks

1. The base surface is not adequately levelled.

2. Environmental conditions are not suitable for the application process.

3. The pigment was not mixed thoroughly, leading to colour floating.

4. Inadequate or Uneven Sanding: The sanding was either incomplete or uneven.

5. Excessive moisture in the base layer causing alkali whitening.

6. Lack of manpower leading to materials drying too quickly and improper wet-on-wet

overlapping, resulting in joint marks.

7. Inconsistency in the application of primer or base coat.

8. Inadequate ventilation on-site or excessively low temperatures during winter.

9. Residual Sanding Dust: Dust from sanding not thoroughly cleaned off.

Reasons for Insufficient Strength and Susceptibility to Scratches:

1. Incorrect ratio of micro cement to mixed resin.

2. Unsuitable temperature and humidity conditions during application.

3. Micro cement has not yet fully cured.

4. Incorrect ratio in the two-component protective topcoat.

5. Uneven application of the two-component protective topcoat.

6. Selection of an incorrect low-grade microcement model.

Reasons for Rough Texture and Difficulty in Cleaning

1. Variations in the experience and skill of applicators can result in uneven

thickness of the microcement layers.

2. Inadequate sanding can lead to areas with an uneven texture.

3. Errors in the mixing ratio of the two-component protective topcoat can affect the surface finish.

4. Not adhering strictly to the required sanding steps in the application process.

Causes of Cracking and Delamination

1. Insufficient substrate strength.

2. Failure to use appropriate absorbent primers or bonding agents.

3. Incorrect ratio of microcement to mixed resin.

4. Unsuitable temperature and humidity conditions during application.

5. Excessive vibration or settling of the substrate.

Causes of Oil/Water Penetration and Appearance Changes

1. Failure to strictly adhere to the application procedures for wet areas.

2. Incorrect mixing ratio of the protective topcoat.

3. Incomplete or improper application of the protective topcoat.

4. Unsuitable temperature and humidity conditions during application.

5. Lack of regular waxing in areas with heavy oil contamination, such as restaurants.

6. Expiration and failure of the protective topcoat.

7. Excessive wear leading to damage of the micro cement coating.

Causes of Uneven and Rough Finishing at Internal and External Corners

1. The wall is not smooth or even.

2. Internal and external corner lines were not pre-installed.

3. The finishing details were not adequately sanded or polished.

4. Masking tape was not neatly applied at the finishing edges, and both sides

of the finishing area were not separated during application.

Recommended Microcement Application Sequence for Walls and Floors

(to Minimize Post-Installation Repairs):

1. Apply putty as the base layer on the wall and ceiling.

2. Apply microcement to the ceiling.

3. Apply the first coat of microcement to the walls and sand it thoroughly.

4. Install air conditioning units, cabinets, and lighting fixtures.

5. Complete the microcement application on the walls.

6. Apply microcement to the floor.

7. Allow the floor to dry completely and protect the surface.

8. Bring in furniture, appliances, and decorative items.

Microcement Daily Maintenance and Cleaning Instructions

1. Initial Care After Microcement Application

After completing the final step of the micro cement application, the surface should be left to dry. Generally,

the surface can be walked on after three days, but it is essential to allow the cement to cure for at least 28

days before placing heavy objects on it.

2. Protection of Newly Applied Microcement

Once the microcement on walls and floors has been completed, if additional construction work or furniture

moving is necessary, protection must be provided for the surfaces after they have fully dried (typically 48 to

72 hours after the final step, assuming good ventilation). Ensure the finished surfaces are adequately protected with cardboard or protective floor coverings to prevent scratches, dents, or other damage. If rolling

objects over the surface, use thick cardboard to shield the areas where the wheels will pass.

The Four Steps for Applying Floor Protection Film

Easy and convenient for single-person operation

3. Microcement Daily Maintenance and Cleaning

For the daily maintenance and cleaning of microcement floors, start by using a vacuum cleaner to remove

large dust particles. Then, clean the surface with a damp sponge mop that has been well wrung out. It is important to wait until the floor is completely dry before walking on it to prevent leaving footprints. For stubborn

substances, you can clean the area with neutral soap or a neutral detergent. When dealing with persistent

stains, a nano cleaning pad can be used as a tool for effective cleaning.