Smart Batch® Technology

The Machine,
The Record,
The Difference

The only Smart Batch®-equipped applicator in the Pacific Northwest, and a Formulated Materials partner.

The Smart Batch® GC-1

A trailer-mounted, computer-controlled batch plant built in the USA by Smart Batch Systems. It weighs every ingredient of every batch (gypsum, sand, water) and mixes to the programmed spec for your job, with no bag counts and no eyeballed water.

One weighed batch every 75 seconds: 13–20 cu yd/hr, capable of up to 40,000 sq ft per day
Setup in under 10 minutes on hydraulic jacks, with 7–13 hours of runtime per fueling
Bulk supersacks + bulk sand: enclosed batching, no bag-breaking position on the crew
Programmable per job-site spec: mix designs and limits locked in before the first pour

Every Batch Becomes a Document

The Smart Batch® GC-1 records the weights, measures, and mix duration of every single batch and archives it to a cloud server. QC reports are generated and emailed automatically, a batch-by-batch record for the GC’s closeout file.

Months or years later, the answer to any floor question is already in your closeout file.

BATCH QC REPORT Sample — illustrative

Project: [Multifamily — Podium Deck] Mix: per project spec

BatchGypsumSandWaterMix

#041✓ wt✓ wt✓ wt✓

#042✓ wt✓ wt✓ wt✓

#043✓ wt✓ wt✓ wt✓

#044✓ wt✓ wt✓ wt✓

ARCHIVED TO CLOUD Auto-emailed to project file

Educate First

Computerized Batching Overcomes Common Challenges

Consistent Pours

Hand-batching by bag count and eyeballed water makes PSI vary batch to batch. Computerized weighing delivers a consistent pour every time and eliminates over-watering and over-sanding, the leading cause of weak gypsum concrete.
Specification Compliance

UL and acoustic assemblies are specified around minimum PSI and thickness. Our per-batch cloud log documents compliance and puts the proof in the GC’s closeout file.
Nuisance Dust & Safety

Gypsum concrete is gypsum-based, not Portland cement, so its dust is nuisance dust with no measurable respirable silica. Enclosed bulk batching still cuts airborne dust ~94% (per Smart Batch Systems). Our crew’s safety is elevated by eliminating the bag-breaking position, and less dust leaves a cleaner jobsite.
Schedule Confidence

Up to 40,000 sq ft/day capability, setup in under 10 minutes. Precise water content in every batch means predictable dry times before finished flooring.

The Old Way vs.
The Sound Floors Way

Batching

The Old Way
Bag counts and eyeballed water.

The Sound Floors Way
Every ingredient weighed, every batch.
Proof

The Old Way
A cube sample from the first batch.

The Sound Floors Way
Cloud-archived QC report, emailed.
Dry Times

The Old Way
Human-controlled water input. Over-watering extends dry times and lowers compressive strength.

The Sound Floors Way
Precise water content maintains predictable dry times.
Dust

The Old Way
Human bag-breaking creates dust clouds and safety risks.

The Sound Floors Way
Enclosed bulk batching reduces airborne dust by 94%.*

*Per Smart Batch Systems.

Why Batching Is the Whole Ballgame

Gypsum concrete strength is a direct function of the water-to-gypsum ratio and the sand loading. Hand-batching runs on bag counts, scooped sand, and water adjusted by feel, so those ratios drift from batch to batch. Computerized weighing holds every batch to the programmed mix design, which is how a floor gets consistent strength, a hard surface, and predictable dry times.

One Trailer, One Computer, Zero Guesswork

The Smart Batch® GC-1 is a trailer-mounted, computer-controlled batch plant built in the USA by Smart Batch Systems (Norman, Oklahoma), sister company of gypsum manufacturer Formulated Materials. We bring the batch plant to your site.

How it works on your job:

Arrival and setup. The Smart Batch® GC-1 is a 25-foot, 18,000-pound trailer that levels itself on hydraulic jacks and is batching in under 10 minutes. No staging yard, no plant convoy, no waiting on ready-mix windows.
Loading. Gypsum cement loads from 3,000-pound supersacks and sand loads in bulk, both feeding an enclosed 51-cubic-foot hopper.
The mix design goes into the computer. Your spec (PSI target, mix proportions, water limits) is programmed as the job’s recipe. The machine will not drift from it, because it cannot. There is only the scale.
Weighed batching. Every ingredient of every batch (gypsum, sand, water) is weighed. A half-ton batch is produced every 75 seconds, sustaining 13–20 cubic yards per hour and supporting pours up to 40,000 square feet in a day.
The record. The machine logs weights, measures, and mix duration for every batch and archives everything to a cloud server. QC reports are generated and emailed automatically.

A 110HP Tier 4 diesel runs the whole plant for 7–13 hours, a full pour day without refueling.

Weights, Timestamps, Proof

Every batch report records, for every single batch poured on your job:

Ingredient weights: actual pounds of gypsum, sand, and water dispensed, batch by batch, against the programmed mix design
Mix duration: how long each batch was mixed
Timestamps and sequence: when each batch was produced, in order, across the pour day
Job and location data: which site, which crew

UL fire-rated assemblies and tested acoustic assemblies are specified around a minimum compressive strength at a specified thickness. A per-batch log documents that every batch matched the mix design, so any future question about the floor is answered by the record, not by memory.

The Documentation Package

What the closeout package looks like on a typical multifamily pour:

Submittal set (pre-pour): product data for the specified gypsum underlayment, the UL assembly references your architect called out, and the programmed mix design for the job.
Per-pour batch reports: the cloud-archived QC report for each pour day, every batch’s weights, measures, and mix duration, compiled per building or per pour area.
Pour log: dates, areas, thicknesses, and square footage placed, mapped to your unit and building numbering.
Field QC: slump-ring checks and cast compressive-strength samples per ASTM C472 practice, tied to the batch record for the same pour.

Enclosed Batching, Cleaner Jobsites

Gypsum concrete is gypsum-based, not Portland cement-based, so there is no measurable respirable silica in the mix; what traditional bag-breaking kicks up is nuisance dust. The GC-1 batches from enclosed bulk supersacks inside a contained hopper, and Smart Batch Systems measures the result at roughly a 94% reduction in airborne dust versus bag-batching. Our crew’s safety is elevated by eliminating the bag-breaking position, and less dust leaves a cleaner jobsite for every trade on it.

Fast Setup, Big Days, Predictable Dry Times

Under 10 minutes from parked to pouring. No plant assembly, no ready-mix scheduling conflicts.
Up to 40,000 sq ft per day. One weighed batch every 75 seconds means the pump never waits on the mix. Fewer pour days, fewer trade conflicts, faster turnover to flooring.
Precise water content means predictable dry times. Because water is weighed, the slab dries toward flooring-ready moisture levels on a consistent, plannable curve, at the water content the manufacturer specified.