No matter where you are situated, whether an urban or rural setting, concrete is bound to form an integral part of any housing or industrial structure. It is made possible through the mechanical ingenuity of the concrete mixer. Through the concrete mixing process, cement, sand and other aggregates are blended with water to create a durable and robust mixture forming the foundation of a successful construction project.

 

What exactly makes concrete mixers so effective and what are the underlying mechanisms behind its ability to support construction projects. The answer can be explained in three parts, namely the synthesising of technology, innovative drum and mechanical design and the correct operation of the equipment.

 

In this article, the mechanics behind the high-performance concrete mixers will be explored as well as which models are the best fit for a particular project. Specifically with regards to saving valuable time, labour and resources while optimising concrete quality. Furthermore, particular models of concrete mixers which BS Power have available will be discussed and compared so that you can make the right choice for your next construction project.

 

The Science Behind The Mixing Process: How A Concrete Mixer Works

 

If we were to break this down into the simplest explanation – a concrete mixer is responsible for creating a homogenous base mixture through the rotating and amalgamation of raw materials. The quality output of this mixture can be variable however and is impacted by the following factors which will be discussed.

 

One of the fundamental components of how cement is made is through the internal rotation of the paddles or mixing blades in the drum, drum rotation speed has a large impact on the outcome of the final product. For this, you would ideally want a well-calibrated speed to ensure an even distribution of water and cement to avoid hazardous clumping or segregation of the raw materials.

 

Building on this, the next component to take into consideration is the mixing blades of the cement mixers. The positionality of the blades inside the drum are paramount in order to break up any stubborn clumps and ensure the even distribution of materials.

 

Following this, you need to carefully plan the mixing time as over or under mixing can damage the integrity of the cement. This is why a well-engineered mixer, like the ones we provide at BS Power, ensures the optimal mixing time to reap the best results. Equally important is taking load capacity into account. Depending on how much you expect to yield, your cement mixer should be appropriately sized so that the motor does not undergo unnecessary strain which will minimise overall efficiency.

 

What Makes A Concrete Mixer Efficient?

 

When considering the various aspects behind what makes concrete mixers efficient, there are five core areas these include, a high-quality drum design, power source and engine performance, optimal mixing capacity, ease of transportation, moveability and automation and smart features.

 

First on this list is the need for a high-quality drum design. Considering that the drum serves as the heart of the mixer, its efficiency relies on its shape, materials and rotational speed. For this reason, steel drums are mostly preferred for this purpose as they offer durability while reinforced internal fins are prized for their superior mixing abilities. Fortunately, BS Power has this exact product available with their 400L Mixer with a Baumax Engine which sports a robust drum which is guaranteed to deliver on durability and high-performance output.

 

Coming in second as a priority for mixer efficiency is power source and engine performance. Truly efficient concrete mixers have powerful and reliable engines which increases overall efficacy and smooth operation. For remote worksites, the best type of mixers is gasoline and diesel-powered, while for more urban and populated worksites, electric mixers are far quieter and are the preferred option for eco-friendly operations. On this score, BS Power provides the 360L Concrete Mixer with Baumax Engine for this purpose as it delivers on effectively providing a robust power source while simultaneously maintaining fuel efficiency.

 

Third on the list to take into account for desired mixer efficiency is maintaining an optimal mixing capacity. By choosing the correct mixing capacity you will prevent overloading the mixer’s drum so that it maintains peak operationality. If you are conducting a more small-scale project – then opting for a compact mixer would be first prize, while larger industrial jobs benefit more from high-capacity models which is specifically designed for large-scale undertakings.

 

Fourth, is the importance of the ease of transport and moveability of cement mixers. Having these mixers be largely portable is a crucial factor in mixer efficiency. This is why mixer models should ideally be equipped with sturdy wheels and tow bars so that they can easily be relocated as needed. This in turn will prevent time wasted on negotiating and strategizing the manoeuvring of these machines and thereby increases productivity. Even in rough terrain – a well-designed mixer should be able to move freely and with minimal hassle for the construction team.

 

Finally, for the true secret to the diligent efficiency of your concrete mixer lies in the automation and smart features programmed into the modern mixer. By incorporating smart technologies, modern mixers are able to achieve automated water control systems, GPS tracking, self-loading mechanisms, digital batch recording and remote monitoring and IoT integration.

 

Automated water control systems are a sure way for your mixer to have very precise water-cement ratios as this is crucial for producing uniform concrete which is both strong and of a high quality. Implementing these systems effectively reduces the chance of human error in how they are able to measure the exact quantities of water needed so that the mix is correct. This is especially helpful for large-scale projects which require uniform and precise mixes for visual and structural integrity.

 

By using GPS tracking, fleet managers are able to closely monitor the mixer’s location and usage. For construction companies where multiple sites are being used and real-time data is needed to monitor equipment usage, GPS tracking is a surefire way to prevent theft and the potential misuse of expensive machinery.

 

If you are a construction company or builder who is interested in reducing labour costs, then self-loading mechanisms are the perfect solution. Through this mechanism, automated material loading occurs which negates the need to use extra machinery like front-end loaders. This results in a far more seamless and cost-effective loading process which is beneficial for locations which are particularly remote, or if labour is limited.

 

On the higher end of concrete mixers, you can find digital batch recording. This is a process whereby digital recording systems track each and every batch that is mixed. Why this is useful is that it allows for better quality control and consistency, as well as allowing better compliance with project specifications. Further, it can allow construction companies better insight into what raw materials are being utilised so that they can minimise waste as far as possible.

 

Through remote monitoring and IoT integration (internet of things) technology, companies are able to monitor a cement mixer’s performance in real-time. The benefit of this lies in the fact that this software allows operators to track performance indicators such as drum rotation speed, engine health and the mixing time. Additionally, they do not need to necessarily be on site when doing these checks. This allows project managers the ability to monitor progress from a far. By tracking the mixer’s operationality this also allows for less maintenance and downtime over time while being able to ensure that the equipment continues to run at optimal efficiency.

 

 

Selecting The Right Mixer For Your Project Needs

 

Rather than deciding on which mixer to select based on type or model, it is far more beneficial to conduct an evaluation according to the actual specific need of a particular construction project. The following section will assist you to choose the best mixer based on the project’s scale and requirements.

 

For Small Residential And DIY Projects

 

Perhaps you have decided to buy a fixer-upper and want to flip it for maximum resell value, or maybe you are doing some home renovations or other small construction jobs, if this is your situation then a portable drum mixer is the most practical solution.

 

The Why

 

These mixers are lightweight, they are easy to transport and best of all – cost-effective. For operations which do not require high-volume of output, their simple design ensures a quick setup and operation. Delivering on this score is the 360L Concrete Mixer with Baumax Engine offered by BS Power which is a wonderful candidate for small-scale use where a compact, yet powerful mixer is required.

 

For Precast Concrete And Precision Mixing

 

Pan mixers are the chief choice for precast concrete production as it provides a more thorough and uniform mix when compared to drum mixers. Further, these mixers are used in environments where speciality concrete with a high strength is favoured.

 

The Why

 

The rotating blades of the pan mixer means that the material is incorporated more effectively producing a uniform mix and an overall more consistent product. Thus, for a project intended for a specialised architectural design, a pan mixer is the best choice for you.

 

For Large Infrastructure And Road Projects

 

For a large construction project which requires a high volume of concrete, there really isn’t a better option than a continuous mixer.

 

The Why

 

Operating continuously, these mixers are able to keep the raw materials moving and mixing non-stop. This is vital for large-scale projects, for example, road paving or bridge construction where a continuous supply of concrete is needed to ensure that you can adhere to a tight schedule.

 

While BS Power does not currently offer a continuous mixer, they do offer a high-capacity drum mixer – the 500L Concrete Mixer with Baumax Engine. This is a great alternative for a construction operation which needs maximum concrete output.

 

For Remote And Labour-Constrained Projects

 

Self-loading mixers are the top candidates for job sites which are set in remote areas or locations where labour may be limited.

 

The Why

 

These mixers offer automated loading, mixing and transportation which conveniently allows a single person to be able to manage the whole process from start to finish. This is beneficial as it significantly reduces labour costs whilst offering a great solution to what could pose as a challenging work environment.

 

 

Getting The Right Mixer For The Job With BS Power

 

In the above article we have discussed the best protocol for selecting the right concrete mixers and how, depending on the unique demands of the specific project, either a drum, pan or continuous mixer is appropriate. For example, small scale builds will do well with a compact, portable drum mixer whereas precast, complex builds would do better with a pan mixer and continuous mixers and self-loading mixers are best for large-scale infrastructural projects.

 

Moreover, this article also outlined how a concrete mixer works and the recommended selection of mixers for optimal efficiency with BS Power.