Online Sand Moisture Sensor and Probe — Seztec SONO VARIO®
The SONO VARIO® is an online sand moisture sensor and probe for continuous moisture measurement in fine sand. Used in concrete batching and ready-mix plants.
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Description
Online Sand Moisture Sensor and Probe — Seztec SONO VARIO®
A fixed online TDR sand moisture probe for continuous moisture measurement in fine sand and aggregates. Used in concrete batching, ready-mix, and precast plants. Sold and supported in the US by Seztec USA, Houston, TX.
Looking for a portable handheld solution? See the Seztec HD2® Aggregate Moisture Content Meter. For coarse aggregates, gravel, and RAP up to 1.25 inches, see the SONO Xtrem®.
Fixed online installation
15 factory calibrations
Continuous real-time measurement
SCADA and PLC compatible
Made in Germany
Our Houston-based application engineers will confirm the right installation configuration for your sand and recommend the correct calibration for your material.
What is an online sand moisture sensor?
An online sand moisture sensor is a fixed probe installed permanently in your production line. It sits inside a silo, hopper, or mixer, or mounts above a conveyor belt, and measures the moisture content of your sand continuously without any manual intervention.
The difference between an online sensor and a portable handheld meter comes down to how your batching system uses the data. A portable meter gives you a reading when you take one. An online sand moisture sensor feeds real-time moisture data directly into your PLC or batching controller on every single batch, automatically.
In concrete batching and ready-mix production, sand moisture is one of the most variable inputs in the mix. Depending on weather, storage conditions, and supplier, the sand arriving at your plant can range from 2% to 8% moisture. If your batching system is not reading actual moisture on every batch, your water-to-cement ratio is drifting. That affects strength, consistency, and cost.
The SONO VARIO® online sand moisture sensor and probe
The SONO VARIO® is a fixed online sand moisture probe built for continuous installation in concrete batching plants, ready-mix operations, and precast manufacturing facilities. It measures moisture content (%), temperature, and electrical conductivity in fine sand and aggregates and outputs that data continuously into your production system.
It is part of the SONO® sensor family from IMKO, distributed and supported in the United States by Seztec USA.
Sensor type
Fixed online probe
Accuracy
Better than 0.1%
Max particle size
Fine aggregates up to 4mm
Measurement technology
TRIME® TDR
Factory calibrations
15 material types
Parameters measured
Moisture %, temp, conductivity
Output options
0–20mA, RS485, IMP-Bus
Probe body
Stainless steel + ceramic
Conductivity range
Up to 12 dS/m
Origin
Made in Germany
How the SONO VARIO® sand moisture probe works
The SONO VARIO® uses patented TRIME® Time Domain Reflectometry (TDR) technology. Once installed in your production line, the probe continuously sends an electromagnetic pulse through the surrounding sand and measures the response across a significant depth of material.
That depth matters. Surface moisture in a sand silo or on a conveyor varies constantly. Material near the walls or the top of a bin can be wetter or drier than the bulk. A surface-reading sensor gives you one data point at one location. The SONO VARIO® measures through a representative volume of material and gives you the actual moisture content of what is entering your mixer.
The probe outputs moisture (%), temperature, and electrical conductivity continuously via 0–20mA analog signal or RS485 and IMP-Bus digital interface. Your batching controller receives real moisture data in real time and adjusts water addition automatically on every batch.
No manual readings. No periodic checks. No drift between measurements.
Why concrete plants use the SONO VARIO® sand moisture sensor
Continuous online measurement
Installed permanently in your line. Measures every batch automatically without manual intervention or production stops.
Direct PLC and SCADA integration
Outputs moisture data via 0–20mA analog or RS485 digital interface directly into your batching controller or plant automation system.
Better than 0.1% accuracy
TRIME® TDR technology penetrates deep into the material volume for highly accurate and repeatable moisture readings regardless of surface variation.
Consistent w/c ratio control
Real-time sand moisture data fed into your mix design system keeps your water-to-cement ratio within specification on every batch.
Ready out of the box
Pre-loaded with 15 factory calibrations for common sand and fine aggregate types. Custom calibrations available for specific materials.
Long service life
Stainless steel body with ceramic measurement window. Automatic correction for probe head abrasion without requiring recalibration.
Online sand moisture sensor vs periodic manual testing
Manual moisture checks and portable spot measurements have their place. But they both have the same limitation. The reading you get reflects the material at one point in time and one location in the stockpile. By the time that data reaches your batching system, conditions may have already changed.
An online sand moisture sensor removes that gap entirely.
| Method | Measurement frequency | PLC integration | w/c ratio control | Accuracy |
|---|---|---|---|---|
| Manual spot check | Periodic | Not possible | Inconsistent | Variable |
| Portable handheld meter | On demand | Not possible | Improved | High |
| SONO VARIO® online sensor | Continuous | Yes | Automatic | Better than 0.1% |
Sand moisture probe installation options
Under silo flap
Measures sand moisture as material exits the silo before entering the weigh belt or mixer. The most common installation for ready-mix plants.
Inside mixer
Installed directly in the concrete mixer for real-time measurement during the mixing cycle. Used in precast and high-specification ready-mix operations.
On conveyor belt
Mounted above or below a conveyor for continuous measurement of sand passing through. Suitable for high-volume aggregate processing operations.
In hopper or bin
Installed in the wall of a storage hopper or weigh bin. Measures moisture content of material at rest before it enters the batching sequence.
Sand moisture sensor applications by industry
Ready-mix concrete
Continuous sand moisture measurement before batching to maintain w/c ratio specification on every truck load throughout the day.
Precast concrete
Tight moisture control for consistent precast product quality. Sensor installed in mixer or silo for real-time batch adjustment on every pour.
Asphalt production
Fine sand moisture measurement before heating and mixing. Reduces energy consumption and improves mix consistency in asphalt batching operations.
Sand processing
Quartz sand, granite rock fines, mineral powders, and granulates up to 4mm. Online measurement in processing, drying, and screening operations.
Compatible materials
The SONO VARIO® sand moisture probe works with fine sand and granular materials up to 4mm particle size. Typical materials include washed concrete sand, quartz sand, granite rock fines, gravel fines, foundry return sand, pozzolan grains, clay, fly ash, lime, and sewage sludge.
If you are working with coarse aggregates, crushed stone, gravel, or RAP up to 1.25 inches, the SONO VARIO Xtrem® is the right sensor for your application. Contact Seztec USA and we will confirm which probe fits your material before you order.
What’s included with the SONO VARIO® sand moisture sensor
Who uses an online sand moisture sensor
Concrete plant managers who need w/c ratio control on every batch without relying on manual checks. Ready-mix supervisors managing multiple aggregate silos simultaneously. Precast manufacturers with tight mix specifications. Asphalt plant operators measuring fine sand moisture before heating. QC engineers integrating moisture data into plant automation and SCADA systems.
If your batching system is currently working from assumed or periodically checked moisture values, an online sand moisture sensor is worth evaluating.
SONO VARIO® sand moisture sensor and probe — frequently asked questions
What is the difference between an online sand moisture sensor and a portable sand moisture meter? The SONO VARIO® is a fixed probe installed permanently in your production line. It measures sand moisture continuously and sends data directly to your PLC or batching controller without any manual steps. A portable meter is a handheld device you use for manual spot checks at a stockpile. If you need a portable solution, the HD2® Aggregate Moisture Content Meter is the right product.
What particle sizes does the SONO VARIO® handle? The SONO VARIO® works with fine sand and granular materials up to 4mm. For coarse aggregates, crushed stone, gravel, and RAP up to 1.25 inches, the SONO VARIO Xtrem® is the appropriate probe.
How accurate is the SONO VARIO® sand moisture probe? The SONO VARIO® delivers better than 0.1% accuracy using TRIME® TDR technology. That level of precision is sufficient for automatic water correction in concrete batching and ready-mix production.
How does the moisture probe for sand connect to my batching system? The probe outputs data via two analog outputs at 0–20mA or RS485 and IMP-Bus digital interfaces. It works with most batching controllers and SCADA systems. Seztec USA application engineers can confirm compatibility with your specific system before you order.
Can I connect multiple sand moisture probes to one system? Yes. Multiple SONO® probes can be networked in a bus configuration via IMP-Bus interface and connected to a single SCADA or control system. This is practical for plants with multiple sand silos or aggregate storage bins on the same production line.
What is the SONO-VIEW display? The SONO-VIEW is an optional field display unit that connects directly to the SONO VARIO® probe. It lets you view moisture readings on-site, adjust parameters, and run manual calibrations without a laptop or external device. Ask Seztec USA about adding SONO-VIEW to your order.
Is this the same sensor as the IMKO SONO VARIO? Yes. The Seztec SONO VARIO® sand moisture sensor is the IMKO SONO VARIO® probe. Seztec USA is the authorized US distributor for IMKO moisture measurement products and provides full US-based sales, application engineering, and lifetime support.
Request a quote for the SONO VARIO® online sand moisture sensor
Our Houston-based application engineers will confirm the right installation configuration for your plant, recommend the correct calibration for your sand, and provide pricing. Most quote requests receive a response within one business day.
Elevate your sand moisture measurement capabilities with the SONO-VARIO Sand Moisture Sensor. Precision, versatility, and ease of use—experience it all today. For detailed information about our range of sand and aggregate moisture probes, please review our complete product guide.
› Highly reliable when measuring complex materials like minerals, powders, granules, quartz sand, food and sludge
› Thanks to TRIME technology it is unaffected by steam or changing particle sizes of sand and gravel
› The additionally measured radar-based conductance up to 12dS/m allows conclusions on other parameters of the material recipe
› Simple installation in containers, shafts, silos and conveyor belts
› Probe head made of stainless steel with rectangular ceramic window
› In case of abrasion at probe head an automatic correction of the measuring value happens – without re-calibration