Fly Ash Moisture

Essential Production Implications

Maintaining the necessary correct fly ash moisture levels has become a critical component during processing. The MoistTech sensor will monitor the fly ash process in both wet and dry applications to reduce dust and to provide dryer control. As an embankment or fill material, fly ash is used as a substitute for natural soils. Fly ash in this application must be stockpiled and conditioned to its optimum moisture content to ensure that the material is not too dry and dusty or too wet and unmanageable. When fly ash is at or near its optimum moisture content, it can be compacted to its maximum density and will perform in an equivalent manner to well-compacted soil.

The water content of the fly ash stabilized soil mixture affects the strength. The maximum strength realized in soil-fly ash mixtures generally occurs at moisture contents below optimum moisture content for density. For silt and clay soils the optimum moisture content for strength is generally four to eight percent below optimum for maximum density. For granular soils the optimum moisture content for maximum strength is generally one to three percent below optimum moisture for density. Therefore, it is crucial that moisture content be controlled during construction.

Optimize Quality Control Now

Are You Measuring Moisture?

In the presence of moisture, fly ash reacts with lime at ordinary temperature and forms a compound possessing cement like properties. After reactions between lime and fly ash, calcium silicate hydrates are produced which are responsible for the high strength of the compound.

Conditioned: In this method, water is added to the fly ash to facilitate compaction and handling. The amount of water added being determined by the end use of the fly ash. Conditioned fly ash is widely used in aerated concrete blocks, grout and specialist fill applications.

The MoistTech staff is very experienced with the requirements in the production of fly ash. Our sensor calibrations, measurement wavelengths, algorithms and sensor optical requirements are pre-set at the factory. Typical accuracy is about ±0.1% moisture. Typical analog range is 0-10% moisture and up to as much as 40%, subject to application. The outputs can be adjusted to optimize PLC or recording requirements.


Unsurpassed in performance, our sensors can accurately measure  moisture within tenths of a percent of most applications


MoistTech sensors withstand the test of time and are low to zero maintenance


Rely on MoistTech’s NIR moisture sensors to never drift or need re-calibration


A moisture measurement system is essential for the production process and in some cases will pay for itself in less than 30 days

Dryer Control

Efficiency is a top of the line priority for manufacturers and the dryer can drain a lot of that. Measuring the moisture before and after the dryer allows the user to optimize the dryer settings to save time and money. A proper moisture control system will pay for itself with the energy savings from the dryer in less than 30 days. Efficiently controlling the dryer within the facility can drastically change the productivity levels.

Fly Ash Solutions

Installing the CCS3000 fly ash moisture sensor directly over the material being conveyed allows any manufacturer can continuously monitor the process. In addition, MoistTech’s state-of-the-art sensor can control the fly ash moisture content instantly, either manually or automatically.

Dust from the product is not normally a problem. However, in extreme dusty environments, we recommend the installation of an Air Purge System to prevent the accumulation of material on the sensor’s window.


Locate the point in the production process in which measuring moisture will be the most crucial and beneficial. Identify how you will use the moisture measurement data for improvements and if it will tie into your PLC.

Remember this could involve more than one installation point!


A closed loop process is achieved by incorporating a moisture measurement system into the manufacturing process. Developing a proactive solution to moisture control will avoid costly downfalls. 


MoistTech’s experts will assess your specific application with lab tests, calibrations and accuracy results to ensure our equipment will peform for you. All of our sensors are pre-calibrated prior to being shipped to create a plug-and-play operation for the end-user.


We offer service and support throughout the world for our moisture measurement sensors and would be happy to connect you with a rep in your area. Contact us today for more information!

Understand the Process

Using the IR-3000 drastically cuts production costs. It is energy efficient, low maintenance, and decreases startup and down times. Over dried product causes waste; so does product that is too moist. With the IR-3000, these problems will no longer be an issue.

Mineral manufacturing requires proper amounts of moisture and MoistTech Corp’s IR3000 series sensor provides state of the art near-infrared technology to provide quality moisture control.