In our modern age, the concrete mixer has been used to construct remarkable buildings all around the world. Modern mixers can mix consistently high-quality concrete that is strong and dependable, thus allowing architects and engineers alike to explore more complex building structures. Concrete is an incredibly versatile construction medium, and for this reason, the distribution of concrete mixers has become a huge industry, valued at around 450 billion US dollars in the year 2024, according to LinkedIn.

 

However, this enormous industry has garnered attention from conservation groups and governments alike, who worry about the environmental impact of the ever-growing concrete and cement market. To avoid harsh restrictions and public backlash, the concrete industry has had to adapt in order to lessen its environmental footprint.

 

Many strategies have been implemented to improve the “greenness” of both concrete and mixers and in this article, we will explore a number of these. At BS Power, we care about how our tools are used and how they can impact the environment. We believe that through education and supporting greener concrete mixing processes, we can contribute to more responsible use of our premium concrete mixers.

 

The Use Of Alternative Materials

 

One area that has needed to change dramatically over the last few years is the way that we create concrete. The makeup of concrete, as we know it today, has been around since as early as 1835. Although this type of concrete is dependable and has seen widespread use all over the world, it can’t be classified as environmentally friendly. Especially since the formula for this kind of concrete came about during a period when environmental concerns were not a priority by any means.

 

It’s important to note that the concrete mixer was constructed parallel to the use of concrete and has been critical in allowing for the large-scale use of concrete in building projects. These mixers have also been engineered to tolerate the use of a traditional concrete mixture.

 

Therefore, changing the concrete formulation could have dire consequences for mixers, as they may not be able to operate as effectively if the mixture changes too dramatically. This poses a real challenge to scientists trying to formulate a greener form of concrete.

 

The Makeup Of Concrete

 

When we think about the traditional concrete formulation, as mentioned in the introduction to this section, it is generally agreed that it is made up of three parts, including:

 

• Aggregate: This part of concrete is used to add strength to the mixture. Aggregates are generally made up of crushed rock, sand, or even gravel. Aggregate is also the differentiating factor between simple cement and concrete.
• Cement: This is the binding agent in concrete. The most commonly used form of cement is called Portland cement and is made up of a few ingredients that include limestone, clay, iron ore (or mill scale), and gypsum.
• Water: When added to the cement and aggregate, it allows for the chemical process of hydration to occur, which solidifies the mixture.

 

One way that this traditional formulation has been altered in our modern era while allowing it to remain compatible with concrete mixers, is by targeting the aggregate portion of the mixture. It has been discovered that by using alternative aggregate materials we can drastically decrease our environmental impact while making concrete.

 

Recycled Aggregates

 

Alternative aggregates are a great way to reduce our environmental footprint when making concrete. However, the materials we substitute must be able to provide the same bulk and strength as traditional materials like gravel or crushed stone. Numerous alternatives have already been adopted by construction projects around the world, which have shown promising signs, let us look at some of them here:

 

Fly Ash:

 

Luckily, this material is not made up of cremated flies, as the name might suggest, but rather is a term referring to a byproduct that is found after the combustion of coal in industrial power plants. This material is found as a fine powder and contains both silica and alumina. Fly ash is a pozzolanic material, meaning that it can contribute to the strength of concrete when exposed to the hydration chemical reaction.

 

Although the quality of fly ash is highly dependent on the quality of the coal and the combustion process used, it has many benefits including the ability to make concrete easier to pump while also reducing the heat of the hydration reaction.

 

Slag:

 

Slag is yet another byproduct from an industrial process, but this time it is found during the forging of iron. Unlike fly ash, slag is generally composed of calcium, silicon, and aluminium, and like fly ash, it is also a type of pozzolanic material.

 

Slag may alter the amount of time it takes for your concrete mixture to set and could negatively impact the early strength of concrete once laid. But in the long run, it makes concrete more workable, increases the concrete’s resistance to sulphate and chlorides, and enhances long-term strength.

 

The Benefits Of Alternative Materials

 

As you can see, both fly ash and slag are byproducts, which means as recycled products, they are not only helping to reduce the environmental impact of the concrete industry, but also that of the fossil fuel and iron industries respectively. However, this is not the only benefit of utilising alternative aggregates, other benefits include:

 

• Both fly ash and slag can decrease carbon emissions by reducing the need for Portland cement, which is well known to produce large amounts of carbon dioxide during the concrete mixing process.
• Using recycled materials like fly ash and slag also helps prevent the over-extraction of natural resources, like limestone or silica, that are generally found in the production process of cement, as these byproducts perform the same function, making them usable alternatives.
• Fly ash is made from coal combustion, as seen above, and when released into the environment can negatively impact the surrounding air quality. By collecting it in a flue glass and using it in concrete production instead, it will have a drastically positive impact on the air quality surrounding coal power plants.

 

 

Energy Efficiency And Modern Concrete Mixers

 

So far, we have looked at the most important ways that the concrete and cement industry has sought to reduce its environmental footprint, using aggregate alternatives. However, there is yet more that can be done if we want to see a meaningful improvement to the environment.

 

In the section above, we noted that the formulation of concrete could not be changed too drastically for fear that it may prevent the use of concrete mixers. However, in this section, we now turn our attention to concrete mixers, and how they too can contribute to reducing the environmental impact of the concrete industry.

 

In this section let us focus our attention on green technological advancements in the modern concrete mixer:

 

Technological Advancements

 

We have been lucky enough to experience technological advancements in almost every facet of our lives. The same is true for mixers, which in recent years have been reworked in several ways to make them more effective, efficient, and smarter. Let’s review them here:

 

Variable Speed Drives: Also known as VSDs these drives allow modern mixers to be able to accurately change the speed at which the motor spins, depending on the mixture requirements. By tailoring the speed of the concrete mixer to the exact requirements of the current load you can improve energy efficiency.

 

Better Mixing Equipment: Another improvement made to the concrete mixer is in the blades responsible for mixing the concrete. Some areas in the mixer that have seen major reworks are the blades of the mixer, which have been better optimised to generate less friction. When combined with an improvement to the geometrics of the spinning drum, which has made these mixers more effective in mixing the materials well, it enables huge savings in the energy department.

 

Better Insulation: The mixing of concrete for large construction projects is an art, and many variable factors must be kept in check. One of these factors is the temperature at which concrete is mixed. For concrete to be at its optimal strength, the temperature during the mix should remain consistent. Newer concrete mixers are manufactured with insulation material installed around the mixer’s drum and hoppers.

 

Additionally, high-end models even have heat recovery systems that capture heat lost during mixing and divert it towards the preheating of materials or water, reducing the overall energy required to mix concrete at the correct temperature.

 

Renewable Energy Technologies: Due to the improvement in renewable energy technologies, making them more compact and even more efficient, some concrete mixer manufacturers have been trying to figure out ways to integrate renewable energy into their machines. One of the most popular integration methods currently on the market is the use of solar panels, which are installed onto mixers, providing them with renewable sources of energy to run on.

 

Waste Reduction

 

So far, we have examined how the concrete and cement industry has made improvements to both their concrete formulations and the concrete mixers, in order to reduce their environmental impact and contribute towards a greener tomorrow. However, at this point we should also look at ourselves, many of us use concrete for several reasons, from DIY projects around the house to garden projects.

 

What are we able to do when using concrete and a concrete mixer to help reduce their environmental impact? Well, the answer is simple, and that is to practise waste reduction when using these machines. Many waste reduction strategies are already being employed by construction companies to remain compliant with environmental regulations. So here are a few ways we can prevent waste when mixing concrete:

 

Strategies To Minimise Waste

 

Be Precise: One way we can reduce waste is simply by paying more attention to the amount of concrete we use. By following the instructions provided on the packaging and by understanding how much concrete you need for a project, you can adjust your mixture to match that size, ensuring you don’t make more concrete than is necessary.

 

Equipment Maintenance: Another way you can contribute to waste reduction is by making sure that you keep your concrete mixer in good condition. Machines that are not well kept may not mix concrete as effectively or may even lead to a loss in total batch quantity due to concrete leaking out. By making sure your drum has no holes and that the machine is kept clean you can avoid wastage.

 

Recycle: When making multiple batches, make sure to reuse concrete that was not used in previous batches. This way you can reduce the amount of concrete needed, and even save money on material costs.

 

 

BS Power: A Greener Tomorrow

 

In this article, we examined several ways that we can all be more environmentally conscious when using concrete. From the way concrete is made to the modern concrete mixer, all these developments have contributed towards a greener tomorrow.

 

If you would like to find out more about our machines at BS Power and how green they are, don’t hesitate to contact us and one of our friendly, professionally trained assistants will be happy to go over all the details with you.