Both mortar and concrete are made by mixing water, cement, and granular aggregates, which eventually harden into a solid, stable substance. However, while mortar and concrete have essentially the same ingredients, their consistencies are very different, and this difference means that the machines used to mix them require different designs to achieve the best results. If you are doing a DIY masonry project, don’t confuse mortar with cement. Cement has a stone component added to it, which changes its effect after hardening. When wet, they may look the same from a distance, but using cement in a masonry project that requires mortar can cause trouble. Once you have determined whether you need to use mortar or cement, it is time to consider the mixer. Since the two are different, they require different mixers to achieve and maintain the right consistency.
In construction projects, using the right mixer is essential to ensure the quality and longevity of the final project. Two common mixers used in construction are mortar mixers and cement concrete mixers. Although they look similar, they are designed for different purposes and suitable materials. The terms "mortar mixer" and "cement mixer" are often used interchangeably. However, the two machines are used for different purposes and handle different materials and applications. Below, we’ll dive into each blender’s features, their unique applications, blending mechanisms, ideal projects, capacity, portability, maintenance, and more.
What is a cement mixer?
Cement mixers, also known as concrete mixers, are used to mix concrete, which is a mixture of cement, sand, gravel, and water. They are often used to build foundations, floor slabs, and other large structural components. Concrete mixers are designed to mix these heavier materials efficiently and are usually larger in size. Cement mixers are shaped differently than mortar mixers. They usually consist of a round barrel that rotates on a diagonal or horizontal axis. Inside the barrel (also known as a drum) are paddles. These paddles spin through the concrete or cement mixture as the drum rotates. Concrete or cement mixers are powered by gas or electricity. They are usually tilted upward when not pouring. To use a cement mixer, cement ingredients are placed into the mixer while the mixing drum slowly rotates. The paddles push the ingredients and mix them into a slurry of the desired composition and consistency. The cement mixer continues to rotate until the concrete is ready to be poured; otherwise, the concrete hardens and cannot be mixed.
Working Principle of Cement Mixer
A concrete cement mixer is essentially a construction machine used to efficiently mix cement, aggregates, and water to make concrete or other slurry mixtures. The main components of a cement mixer include:
- Drum: This component is a large rotating container where the ingredients of the concrete are mixed.
- Paddles or blades: These components are attached to the inside of the drum and are responsible for mixing the cement and other materials together.
- Motor: The motor powers the rotation of the drum and paddles or blades.
- Wheels: Most cement mixers have wheels for easier maneuvering.
- Frame: The frame holds all the components together and keeps them stable during use.
The mixing process begins with loading the required amount of cement, mortar or other mixture and water into a rotating drum. As the drum rotates, the materials are mixed and stirred into a uniform mixture. The rotation of the drum is powered by an electric motor, a gasoline engine, or in some cases, manually. The speed and duration of rotation are critical to ensure that the concrete is mixed evenly and reaches the desired consistency. Once the mixing process is complete, the mixer pours the mixture out and is ready for use in various construction applications.
Cement mixing process
After placing raw materials such as cement, water, sand and gravel into the mixer, the drum rotates slowly. During the mixing process, the paddles push the raw materials up and down, eventually mixing them into mud.
The mixer rotates continuously and the paddles operate to prevent the concrete from hardening. If it is stationary for too long, the cement slurry will harden and cannot be used.
Main features of cement mixer
The cement mixer has protruding fins inside the drum that produce a tumbling action to mix the raw materials smoothly. The drum does not allow foreign matter to enter the raw materials during the mixing process. The speed of the cement mixer is improved and it is suitable for ingredients with large pieces of debris such as cement and sand. Specifically, it has the following features:
- Rotating drum: Concrete mixers have a rotating drum that tilts to dump the mixed concrete. The rotation helps to thoroughly mix the material and keep aggregates, such as gravel, suspended in the mix.
- Tilted drum: The tilted drum design combined with internal blades or fins creates a tumbling action that is ideal for mixing coarser aggregates in concrete.
- Larger capacity: Concrete mixers are designed to handle larger volumes of material and are suitable for large construction projects. They are often used on sites that require large quantities of concrete.
What is a Mortar Mixer?
The structure of a mortar mixer is different from that of a cement mixer. It has a horizontal trough. In the middle of the trough is a rod with a small paddle on it. The motor drives the stirring rod to rotate, which drives the stirring paddle to rotate continuously to mix the mortar to the right consistency. Some mortar mixers are vertical, but horizontal mixing tanks driven by gas or electric motors are more common. A mortar mixer is a special machine used to mix fine-grained materials such as mortar, plaster and cement paste to achieve a uniform and consistent mixture. Such mixers are usually equipped with paddles or spiral blades to effectively mix fine ingredients. They are mainly used in masonry projects, including brickwork, blockwork and stonework. Mortar mixers are specially designed to mix mortar, which is a mixture of cement, sand and water. Mortar is usually used for bonding bricks, blocks and stones in masonry. Mortar mixers are characterized by their rotating paddles or blades scraping the sides of the fixed drum. This design can mix the mortar thoroughly and evenly, ensuring that all ingredients are fully mixed.
Working principle of mortar mixer
A mortar mixer consists of a stationary barrel and an internal mixing paddle with a rubber strip. The paddle rotates as it mixes the mortar and scrapes against the edge of the barrel to prevent the sticky mortar from sticking to the sides. These heavy-duty mixers are suitable for a variety of applications, including stucco, plaster, epoxy, terrazzo, drywall mud, paint, and grout. They perform well on mortar mixes, but should never be used for cement or concrete mixes. Coarser mixes, such as concrete, will wear out the rubber strip, while rock or gravel particles may clog the mixing paddle.
Mortar mixing process
When the mortar mixture is poured into the mixer, the paddles stir the mixture into mortar.
To pour the mortar, the user simply turns off the motor and turns the mixer tank on its side. Large industrial mortar mixers are sometimes equipped with a side door to facilitate pouring the mortar.
Main features of mortar mixer
Mortar mixers are suitable for various construction jobs such as terrazzo, cement slurry, drywall mud and plaster. They are very suitable for smooth mortar mixtures rather than mixtures with large aggregates, which will cause wear on the paddles and rubber strips. Its mixing speed is fast; therefore, it has low noise when working, and its unique structure can provide road construction services for a long time without damage. It has the following specific features:
- Fixed drum: Unlike concrete mixers, mortar mixers have a fixed drum with paddles that rotate inside. This structure is ideal for mixing thicker materials such as mortar, plaster, stucco, and cement paste.
- Horizontal paddles: Horizontal paddles are more effective for mixing thicker mortars. This design ensures that all ingredients are thoroughly mixed, reducing the possibility of dry spots or lumps.
- Smaller capacity: Mortar mixers typically have a smaller capacity than concrete mixers. This is because mortar is used in smaller quantities and does not require large-scale mixing like concrete.
What is the difference between a mortar mixer and a cement mixer?
Mixing mechanism differences
The mixing mechanisms of mortar mixers and cement mixers differ greatly due to the nature of the materials they process. Read on to learn the differences:
- Mortar Mixer Mixing Mechanism: Mortar mixers operate at lower speeds to facilitate precise mixing of fine materials. They are equipped with paddles or spiral blades to ensure thorough mixing of the mortar for a consistent texture.
- Cement Mixer Mixing Mechanism: Cement mixers use faster speeds to efficiently mix coarser materials such as aggregates and cement. These mixers typically feature a tumbling or tilting drum design to achieve the desired concrete consistency.
Ideal Applications
- Mortar Mixer Applications: Mortar mixers are essential tools for masonry projects, including brickwork, blockwork, and stonework, where precise mixing is essential. In addition, using mortar mixers in plastering and stucco projects ensures consistent texture and quality.
- Cement Mixer Applications: Cement mixers are widely used in concrete projects such as foundations, floor slabs, sidewalks, and driveways. These mixers are essential for large-scale construction and infrastructure projects that require large quantities of concrete.
Mixing capacity and volume
Mortar mixers and cement mixers vary in capacity to suit their specific material requirements:
- Mortar Mixer Capacity: Mortar mixers typically have a smaller capacity (less than 10 cubic feet) and are suitable for handling mortar and plaster. They are ideal for small to medium-sized construction projects where precision is critical.
- Cement Mixer Capacity: Cement mixers have a larger capacity (12 cubic feet or more of material) and can hold both aggregates and cement, making them suitable for medium to large projects. These mixers are preferred for projects that require large volumes of concrete.
Portability and design
- Mortar mixer design: Mortar mixers are usually compact and lightweight, making them easy to transport to different construction sites. Their small footprint improves maneuverability on the construction site.
- Cement mixer truck design: Cement mixer trucks are designed to be more rugged and durable, making them easy to handle heavy-duty jobs. Many cement mixer trucks are equipped with wheels or a tow bar to facilitate moving between construction sites.
Mixing efficiency and yield
- Mortar mixer efficiency: Mortar mixers mix mortar stably and evenly, ensuring quality and precision. Construction projects that require higher mixing precision should choose this type of mixer.
- Cement mixer efficiency: Cement mixers efficiently mix aggregates and cement to produce concrete required for large-scale applications. They are ideal for construction projects that focus on production efficiency.
Maintenance and Cleaning
- Maintenance of mortar mixers: Mortar mixers are fairly easy to clean. Maintenance involves washing the mixing container, paddles or spiral blades with water to prevent lumps in the mortar. Clean thoroughly, using a scraper if necessary, but always use water to break up the mortar.
- Maintenance of cement mixer trucks: Cement mixers require more thorough cleaning. Regular maintenance may include using a pressure washer to remove residue from the machine. Because cement mixers use coarse aggregates, they require more frequent maintenance and care of the mechanical parts.
The main difference between mortar mixer and concrete mixer
- Material consistency: The most notable difference between the two types of mixers is the consistency of the materials they are designed to handle. Mortar mixers are used to mix materials with higher viscosity, such as mortar and plaster, while concrete mixers are used to mix more fluid, higher aggregate content concrete.
- Mixing mechanism: Mortar mixers use a stationary drum and rotating paddles to mix the material, which is ideal for mixing thick, sticky materials. In contrast, concrete mixers use a rotating drum that uses gravity to mix the material and evenly distribute the aggregates.
- Size and capacity: Concrete mixers generally have a larger capacity than mortar mixers, as structural projects often require large quantities of concrete. Mortar mixers are smaller in size and are designed to mix small batches of mortar or plaster for masonry and renovation projects.
- Project type: Mortar mixers are generally used for projects that require a finer, smoother mixture, such as bricklaying, plastering, and paving. Concrete mixers, on the other hand, are used for projects that require a durable, strong mixture, such as building foundations, driveways, and large concrete slabs.
Choose the right mixer for your project
When choosing between a mortar mixer and a concrete mixer, consider the specific requirements of your project:
- Masonry and finishing: If your project involves brickwork, stonework, or plastering, a mortar mixer is a better choice. Its design is optimized to produce a smooth, uniform mixture and is easy to operate for such applications.
- Large structural projects: If your project requires large amounts of concrete, such as foundations, driveways, or patios, a concrete mixer is the ideal tool. Its larger capacity and efficient mixing mechanism ensure that the concrete is fully mixed and can be used for larger construction projects.
Frequently Asked Questions about Mortar Mixers and Concrete Mixers
Some cement mixers can also mix mortar because the mixing process is the same. Mortar just doesn't contain the gravel component, but all other steps in the mixing process are similar.
While some cement mixers can make mortar, the reverse is not true. Mortar mixers are generally unable to make cement because their paddles are smaller and their motors are generally less powerful.
The gravel component in cement puts more stress on the mixer, and the mixing paddles may break or snap. It is also more difficult for a mortar mixer to maintain the right paste consistency in concrete, so the mixture is more likely to harden inside the mixer before use.
For small projects, mortar and cement can usually be mixed manually in a small mixing tank. Medium-sized projects can be handled with the conventional mixers we introduce in this article. However, large projects require large mixers that can handle large amounts of mortar and cement. This usually means that a mixer with a barrel or drum is needed.
The drum of a large mortar mixer does not rotate like a cement mixer, but the drum is stationary and the paddles inside rotate. Since mortar does not contain stone aggregates, mortar mixers can be equipped with rubber tips on the paddles to ensure that all the mortar mixture is scraped off the mixer walls. This means that you can use more mix on the project and the mixer is easier to clean. Again, do not try to mix cement into the mortar mixture. The broken stones in the mixture will damage the paddles and drum walls.
Some mixer models come with paddles or vertical shaft agitators. They use gravity to assist the mixing process, completing the mixing of mortar or cement faster.
The vertical mixing motion is ideal for thin mixtures such as mortar as well as thicker concrete mixtures. Again, you must read the instructions and make sure you use the right mixture in the right mixer to avoid damaging the mixer.
Choosing steel or plastic troughs and buckets is also an important decision. Steel ones are more durable and last longer. However, they are also more expensive. Plastic is less prone to corrosion and doesn’t require as much meticulous cleaning. How often you use your blender should determine your choice.
