REVERSING DRUM MIXER

Workhorse - 4/16
A New Spin on Mixers
It is only sand, rock, water, and cement
until you mix it
Without proper mixing, concrete will fail to achieve its desired properties.
Good mixing is critical in promoting hydration, allowing development
of the desired cement paste. Mixing promotes proper dispersion of
the sand and aggregates within the cement paste, ensuring that the
concrete develops the intended workability and strength.

Mixing is at the heart of the concrete

production process
The mixer is the heart of any central mix plant. The mixer governs the
quality and productivity of the concrete plant and directly affects the
profitability of the operation. Tilting, Twin Shaft, Planetary, Pan and
Reversing drum are common concrete mixing technologies. All these
mixing technologies can produce quality concrete, but each technology
has unique advantages and drawbacks. How do you know which
technology is right for you?

Why choose reversing drum mixing?

Leading-edge reversing drum technology can surpass the mixing
performance of the other systems, while eliminating many of the
drawbacks. With reversing drum systems, drum rotation in one direction
mixes the contents while rotation in the opposite direction discharges
the drum. Paddles and rakes mounted inside the drum create high shear
conditions during drum rotation. This simple mixing principle minimizes
the number of moving parts compared to other mixers, resulting in an
efficient, reliable, and low cost mixing solution.

Stephens Workhorse reversing drum mixers

lead the pack
The elegantly simple design of the reversing drum mixer reflects three
decades of research spent developing and refining. This was the first
reversing drum mixer introduced in North America. The mixer is now
Open base frame allows for
owned, marketed and manufactured by Stephens Mfg. as the Workhorse easy cleaning under mixer
Mixer. Our commitment to industry leading technology, quality, and
customer service has made us the right choice.

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A safety fence is standard with each
Workhorse mixer, to guard moving
parts and pinch points.

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 Reversing drum mixer operating principle
A charge chute directs materials into the mixing drum. The creating an efficient and forceful three-dimensional mixing
positive seal between the chute and drum prevents dust escaping action inside the drum.
from the mixer. After mixing is complete, the drum rotates in the opposite
While loading, electric motors coupled with urethane drive direction, allowing proprietary discharge shovels to empty the
wheels rotate the drum. Drum rotation causes the drum contents drum’s contents into the discharge chute. Specially designed
to pass over and through an array of wear resistant paddles while discharge cones ensure smooth, pulse, and splatter free concrete
longitudinal rakes promote lateral motion of drum contents, flow into the downstream process.

charging sequence

Drum Rotation

Cement Aggregate
Dust

Dust

Water

discharge sequence

Drum Rotation

Concrete

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Benefits of the reversing drum mixer
fast, clean mixing
■ The fully enclosed charge and discharge points control dust and minimize splatter. The optimized
mixing paddle and rake configuration promote rapid homogenization of the drum contents.

■ Reversed drum rotation causes the paddles to discharge a smooth stream of concrete from the mixer,
allowing fast delivery of the concrete to the trucks or downstream process.
■ The reversing action also promotes cleaning the back side of racks and paddles.

energy efficient mixing

■ Proprietary paddle and rake features create high shear action in the mixer drum at low rotational
speeds, resulting in less energy consumption during moving.
■ The paddles and rakes promote both radial and lateral mixing of the drum contents to achieve fast,
thorough mixing.

■ Variable frequency drives control the drum motors, reducing in rush current, peak power demand and
reducing the cost of peak charges imposed by utility companies.

quiet operation
■ Many features of the mixer combine to create a quiet mixing process. The reversing drum system does
away with the noisy ring gear drive and hydraulic motors used by other systems for tilting or discharge.

■ The drum is mounted and driven with urethane drive wheels, eliminating metal-on-metal noise while
the urethane wheels absorb the vibration from drum rotation and material charging processes.
■ The sealed inlet and outlet ports provide sound baffling, further reducing mixer noise, resulting in one
of the quietest mixing processes on the market.

lower maintenance costs

■ The design of the Stephens Workhorse reversing drum mixer has significantly fewer moving parts than
other mixing systems, meaning fewer things to go wrong.

■ Replaceable, wear resistant liners and paddles extend mixer life, allowing easy replacement of worn
components.

■ A hinged charge chute and removable mixer-drum sections provide unrestricted access inside the
drum, improving maintainability.

■ The mixer employs proven, off-the-shelf bearings, gearboxes, and motors to improve serviceability,
reliability, and availability of replacement parts.

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Standard Mixer Features
Drive System Features
The Stephens Workhorse mixer employs proven drive technology to ensure operational reliability, energy efficiency, and durability.

emergency 2
motors

3 electric motors

polyurethane 1
drive wheels
5 hubs
gearboxes 4

1 Polyurethane Drive Wheels 5 Hubs

The mixer drum mounts on urethane drive wheels, eliminating A simple, robust wheel hub design can easily withstand forces
metal on metal wear and reducing noise and vibration caused from the motors and the mixer drum, making service and
by the mixing process. Replacement of competitor’s ring gear is adjustment of tires simple.
a major shutdown both in lost production, to do the work, and
costly to buy and warehouse. VFD Control System
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Motor control allows adjustment of mixing speed for both
2 Electric Motors
directions. Regulation of discharge speeds allows optimal rates of
The drive motors are high efficiency, totally enclosed, fan concrete transfer from the drum. When holding mixed materials
cooled units well suited for this heavy-duty application. Motor in the drum, a low speed (idle) feature slows drum rotation,
specifications ensure enough torque and horsepower is available keeping the concrete mixed while slowing the hydration process.
to handle all scenarios.

3 Emergency Motors 7 Maintenance Control Panel

3 phase auxiliary electric motors can discharge the mixer contents A panel mounted near the mixer gives maintenance workers
in the event of power failure. Generator by customer or optional. control over drum rotation, allowing them to rotate the drum as
needed to facilitate maintenance.
4 Gearboxes
The oversized gearbox can withstand the largest drum loads.
The gearbox connects to motor and hub drive shafts allowing for
easy servicing.

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Drum and Mixing Tools
Innovative mixing features inside the drum promote thorough rapid concrete mixing, while discharge features achieve rapid emptying
of mixed concrete from the drum.

1 drum

4 belly paddles
discharge shovels 5

3 rubber
charge seal

rakes 2

1 Drum 4 Belly Paddles

Drum construction features 3/8” plate steel, with 1” plate on Mounted on the inside drum surface is a series of 1/2” steel
drive lanes. 1” thick polyurethane liner inside drum reduces drum paddles with 3/8” bases and 1” polyurethane liner covering wear
wear. The non-stick properties of the wear liner improves drum prone surfaces. The paddle design and orientation within the
cleaning. drum creates high shear mixing of the concrete.

Rakes 5 Discharge Shovels

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Internal rakes, spanning the length of the drum, move concrete Designed to force concrete from the drum, the shovels promote
end-to-end inside the drum, promoting three-dimensional rapid, uniform discharge of drum contents. Innovative shovel
material mixing. The rakes are lined with 1” thick polyurethane. designs are compatible with a range of concrete types. Shovels
are lined with 3/8” 400 Brinnell A/R liners.

3 Rubber Charge Seal

The Rubber seal provides a flexible joint between the charge
chute and the drum. The seal minimizes spillage and facilitates
dust capture.

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 Swinging Charge Chute PATENTED
The charge chute mounts on a hinged joint, allowing it to pivot away from the mixer to give easy maintenance access to the inside of
the drum.

1 hinge adjustment

6
wear ring

4 cement
chute

7 charge end
scraper

2 locking mechanism

3 pneumatic open and close

*cement chute engagement mechanism
not show on diagram

1 Fine and Coarse Hinge Adjustment Cement Chute Engagement (Optional)

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Adjustment plates allow precise special adjustments to the A simple compression fit coupling prevents cement leakage
charge chute position, allowing proper seal between drum and while allowing easy manual disengagement of the cement chute
charge chute. Ability to reposition the chute compensates for to decouple it from the charge chute (not shown).
charge seal wear, maintaining the positive seal.

2 Locking Mechanism 6 Sacrificial Wear Ring

Mechanism ensures the charge chute remains fixed in position A ring feature at the end of the mix drum accepts the frictional
and prevents unintentional chute opening. wear caused by drum rotation. The simple bolt-on configuration
allows easy replacement of worn rings.

3 Pneumatic Open and Close Mechanism

A cylinder affects opening and closing of the charge chute and 7 Charge End Scraper
ensures proper sealing between the chute, seal, and drum. A urethane blade coupled to the mixer frame provides continuous
cleaning of the charge side of the mixer, reducing clean up at the
end of the day.
4 Cement Chute
A dedicated rigid pipe inside the charge chute delivers cement
into the mixer. The chute helps keep the cement dry prior to 8 Charging Chute
Charging chute wear surfaces are lined with 1” thick polyurethane.
entering the mixer, aids in minimizing process dust, and creates a
better charging sequence.

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Discharge Chute
The discharge chute and related components promote clean transfer of the mixed concrete to the downstream process while helping
to control dust and minimize noise.

dust collection port 3

service access doors 2

urethane dust seal 1

reversible wear liner in 4

discharge tube

1 Urethane Dust Seal 4 Reversible Wear Liner in Discharge Tube

The seal mates the discharge chute to the rotating drum, The discharge tube has a 4-way reversable wear liner,
capturing dust and controlling spillage. maximizing wear plate life before replacement.

2 Service Access Doors 5 Discharge Chute

A wide double door provides clear access inside the discharge The discharge chute wear surface is lined with 1” thick
chute and into the discharge side of the mixer. polyurethane liner.

3 Dust Collection Port

An integrated 012” flanged connection point provides an
optimal method for coupling dust systems to the mixer.

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Optional Mixer Features +
In addition to the standard features, Stephens offers anumber of optional features to tailor the mixer to your specific requirements.

High Shear Belly Paddles PATENT PENDING

An alternate belly paddle design incorporates additional shear promoting
features to achieve improved mixing. The high shear paddles are suitable
for use with certain mixers where slump is 6” or higher.

Camera/Temperature Probe Hatch

A hatch port provides cameras and non-invasive temperature probes
access to inside the mixer discharge. Streaming data back to the batch
computer allows automatic batch-to-batch recipe adjustment. Camera
ports include an air curtain to protect the camera lens from dust.

High Durability Charge Chute Liners

Polyurethane liners with embedded ceramic tiles or Chrome Carbide liners
are available to provide improved abrasion resistance. These liners are well
suited for use with abrasive aggregates or in high volume applications.

Cr3C2
Chromium Carbide Paddle and Rake Liners
The hardness of these liners provides additional wear resistance compared
to our standard polyurethane liners.

Hydraulic Emergency Drive

In the event of a power loss, a hydraulic back-up drive system can discharge
the drum contents, preventing the concrete from setting in the mixing
drum. Systems can also be provided to use a loader or mixer truck to
provide the hydraulic pressure required to power the drive.

Mixer Moisture Meter

A moisture probe embedded in the drum provides continuous monitoring
of the moisture content.

Individual Disconnects
individual disconnects are recommended on each 50hp motor.

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Specifications

CAPACITY DRUM DRIVE OVERALL DIMENSIONS WEIGHT

DIAMETER MOTORS A B C D
m3 mm kW mm kg
y3 in hp in lbs

3 2500 2 x 22 4500 2400 400 1700 12000

4 99 2 x 30 177 96 16 66 26000

4.5 2800 4 x 18 5000 2700 350 1800 15000

6 4 x 24 198 108 14 72 33000
111

6.0 3150 4 x 22 6000 2900 350 2000 18000

8 14
123 4 x 30 235 114 78 40000

7.5 3150 4 x 30 6300 2900 350 2000 19000

10 14
126 4 x 40 247 114 78 41800

9.5 3350 4 x 37 6500 3100 300 2100 21000

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132 4 x 50 256 123 12 84 46000

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New Heavy
Portable Falcon
• Standard frame supports up to two 1000 bbl
Why a Stephens?
silos/200 ton agg bins and optional 400 ton
• Plant• can be designed
Owned with 36” family
by Stephens belt, since 1957
water batcher and holding tank for 200 yds/hr
• Reputation of honest, reliable and second to none sales and service
production
• Space saving, mountable
• In-house central dust
CNC/Machine shop
collector available
• Can• beCertified
designed in-house
for Zone 1 -scales to keep load cell size and quantity down
Zone • 4Simple and easy to service and maintain, features standard off the shelf parts
seismic calcuations

• Each plant is designed for your seismic requirements

New Low-Profile
Mustang Proud
• 400 bbl in truss silo Members of
• 70 ton agg bin
• 30” transfer belt
• Two-10” screws Proud Supporter

• Optional in truss central dust collector

• Standard frame designed to typical Zone
2A calculations

Stephens Manufacturing
www.stephensmfg.com
800-626-0200
P.O. BOX 488 • TOMPKINSVILLE , KY 42167
MADE IN
THE USA
Find us on: PHONE: 800-626-0200 • OUTSIDE the USA 270-487-6774
www.stephensmfg.com
FAX: 270-487-8368
www.stephensmfg.com
facebook.com/stephensmfg
twitter.com/stephensmfg

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