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ABRASIVE BLASTING & PAINTING

EQUIPMENT & SUPPLIES

BLAST
ROOMS
Service Defines Our Reputation AUTHORIZED DISTRIBUTOR
TABLE OF CONTENTS

MECHANICAL RECOVERY BLAST ROOMS...... 4

DIAGRAM OF COMPONENTS...................................... 5
BLAST ENCLOSURE..................................................... 6-9
RECLAIM FLOOR SYSTEMS................................... 10-13
ABRASIVE RECOVERY............................................. 14-17
DUST COLLECTION................................................. 18-20

PNEUMATIC RECOVERY BLAST ROOMS....... 22

BLAST ENCLOSURE....................................................... 23
RECLAIM FLOOR SYSTEMS................................... 24-25
ABRASIVE RECOVERY................................................... 26
DUST COLLECTION....................................................... 27

ABRASIVE BLAST POTS.. ......................... 28-31

SUPPORT / USER EQUIPMENT................ 32-33

SUPPORT SERVICES..................................... 34

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 INTRODUCTION
Thank you for your interest in an IDS Blast® abrasive blast room solution. This brochure will provide an overview
of the types of blast rooms available and to their configuration options. Blast rooms are a complex subject, but
remember, the IDS Blast experts are just a phone call away.

THE ADVANTAGES OF BLAST ROOM OWNERSHIP

Compared to open air blasting, the controlled environment of a blast room has many advantages that justify the
investment. Confining abrasive blast operations to a controlled, clean environment enables efficient abrasive
recycling which has huge cost savings over using single-use abrasive. Blasting doesn’t have to wait for good
weather so your production will increase. Well planned abrasive blast room designs include details such as
an amply lit work area, an abrasive reclaim floor, an abrasive/trash separation system and a dust collector for
keeping the environment clean and contaminant free. The bottom line is blast rooms are a more efficient and
productive way to blast.

THE IDS BLAST APPROACH TO BLAST ROOM DESIGN

GUIDANCE The decision to invest in a blast room is a major one in which proper guidance and expertise
will make the difference between a profitable success and a potential disaster. IDS Blast takes the time to
understand your objectives and will design a solution with you that is best for your needs, highly efficient, and
within budget. We will explain what you can expect from blast room ownership and what the true ongoing
costs will be so there are no surprises.

DESIGN Anybody can throw together a blast room, but will it be the right solution for your needs? With
our many years of experience, the veteran team at IDS Blast have the up-to-date knowledge and real-world
exposure necessary to build the right solution for you. Under-engineering or over-engineering a blast room
solution can have disastrous results, we dial it in just right.

IMPLEMENTATION Installation of a blast room can be a complex process but we make it as painless as
possible. From planning the physical location of the blast room all the way through final assembly and start-up,
we stay involved to ensure the everything goes according to plan. We see the implementation of a blast room
at your facility as the beginning of our relationship, not the end.

SUPPORT When you get a blast room from IDS Blast, you get more than just a piece of equipment, you get
ongoing support that is second to none. Of course, this all starts during initial start-up when we make sure
your new blast room is running efficiently and explain the systems to you and your staff. We also provide
ongoing services such as abrasive sales, replacement parts & consumables sales, repair services, training &
efficiency evaluations.

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 MECHANICAL RECOVERY BLAST ROOMS
Nobody can offer you more complete guidance and a better selection of
mechanical blast room systems than IDS Blast. Mechanical blast rooms
are typically preferred because they can handle more volume, use any
type of media, slowly convey the abrasive resulting in less equipment
wear, and are generally the more heavy duty option.

When you choose to pursue a mechanical blast room with IDS Blast, you
receive individualized attention and we work to save you every possible
dollar without cutting quality or production efficiency. It is our cost
effective, common sense, personalized approach that has allowed us to
be at the top of the blast room industry for over 2 decades.

Learn more about the specific systems that make up a mechanical

recovery blast room on the following pages.

WHEN IS A MECHANICAL BLAST ROOM THE RIGHT CHOICE?

Mechanical recovery blast rooms use augers and lift buckets to physically move used
abrasive from the blast room to the abrasive recovery system. The slower speed of
abrasive through the recovery system results in less wear and tear. They are typically the
right choice for medium to heavy production facilities.

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DIAGRAM OF SYSTEM COMPONENTS

BLAST ENCLOSURE The blast room enclosure is the structure which encloses the area in which
blasting will take place. (See pages 6-9)

RECLAIM FLOOR SYSTEM The reclaim floor system is a mechanical system that moves debris and
abrasive away from the blast room enclosure. (See pages 10-13)

ABRASIVE RECOVERY The abrasive recovery system separates reusable abrasive from the broken
down abrasive and debris produced during blasting. (See pages 14-17)

DUST COLLECTION The dust collector is a filtration system that is responsible for cleaning airborne
dust from the blast room enclosure to ensure good visibility. (See pages 18-21)

ABRASIVE BLAST POTS An abrasive blast pot is the pressurized tank that contains abrasive and uses
several valves to start and stop the flow of abrasive. (See pages 28-31)

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 BLAST ENCLOSURE
(MECHANICAL RECOVERY BLAST ROOMS)

Blast enclosures are very customizable and have many

options that can make your operation more efficient. They
are engineered to ensure you have adequate space to blast,
lighting, and ventilation for dust removal. By getting to
know your operation and goals, IDS Blast will be able to
recommend the enclosure and options that will make your
operation the most efficient and keep your costs down.

The engineered panels, doors and other components that

make up our blast room enclosures are made of high quality
materials designed to stand up to the punishing environment
of abrasive blasting. Calling these enclosures “high quality”
or “heavy duty” is really understating their ruggedness.
These are not “bolt” together booths, but are engineered
systems specifically designed for abrasive blasting.

INCLUDED FEATURES (TYPICAL ENCLOSURE)

• 10 gauge roof and wall panels
• Baffled air exhaust plenums
• Baffled air inlet plenums
• Panic type OSHA approved man escape doors with vision window and shield
• Dimmable LED lights (277 volt)
• OSHA approved LED exit light assemblies with battery backup

Large blast room enclosure. Smaller blast room enclosure.

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 BLAST ENCLOSURE
(MECHANICAL RECOVERY BLAST ROOMS)

ROOM SIZE
The right room size is dependent on the size of the largest piece you are trying to blast. The blast room should be
large enough to accommodate the largest work piece and provide ample room for the blasting personnel to work.
We recommend 3’ - 5’ of workspace around the object being blasted.

Typical blast room sizes range from a small single operator booth to massive enclosures several stories high
capable of enclosing huge objects. There is nothing too small or large for us to engineer.

DOORS
In addition to one or more personnel entrance/exit doors, the main doors where the objects to be blasted enter
and exit the blast enclosure are an important consideration. Typically two methods are used. The first is a single
“in/out” door that is used as both and entrance and exit. The second is a flow-through design with doors on both
ends of the blast room where objects enter from one end, and exit through the other. Depending on your type of
operation, flow-through designs can be a major improvement on work flow.

Single Door Flow Through

Other door systems can be incorporated when necessary for production efficiency such as a pneumatic side door.
The style of the door is also an option. Door styles include:

• Swing Manual Doors • Rubber Roll-Up Doors • Custom Doors

Blast room with rubber roll-up door.

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 BLAST ENCLOSURE
(MECHANICAL RECOVERY BLAST ROOMS)

MATERIAL HANDLING
One of the most important considerations when designing a blast room is how the objects being blasted are
going to be moved in and out of the blast room. When it comes to material handling, there are several options
that can speed up moving objects in and out of the enclosure.

Monorail - Monorail systems can be installed inside the blast room or outside with a brush seal providing
containment of abrasive within the room. Monorails allow objects to be hung below them and moved in and out
of the room and can be motorized.

Overhead Crane - When blasting heavier items, an overhead crane is a great option for material handling. The
crane is installed above the blast room and uses a brush seal to keep abrasive from escaping during blasting.

Work Cart (rails in the floor) - Rolling work carts are also a great solution for heavier items. The object to be
blasted is placed on the work cart outside of the room and rolled in to be blasted. The wheeled work cart stays in
the room during blasting and can be mounted on tracks or rails when required.

ACCESSIBILITY
Accessing all sides of an object can start to be an issue when it is very large. There are options available that are
far superior and safer than using ladders.

Catwalks - Catwalks can be installed in taller blast rooms to allow access to taller items from a stable platform.
They can run the entire length of the blast room or only a portion of it. They can be installed on one side of the
enclosure or more.

3-Axis Man-Lift - When you need to get at an object from both sides and different heights, we can configure a
blast enclosure with a 3-axis man-lift that can place the operator virtually anywhere in the blast room.

LIGHTING
Poor visibility results in poor blasting personnel performance and missed spots that are hidden in shadow. The
lighting in our blast enclosures is both ample and durable. A typical lighting set-up in one of our blast rooms
includes fixtures in both the ceiling and walls. Lights are protected from abrasive impact using replaceable 1/4”
thick polycarbonate lenses.

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 BLAST ENCLOSURE
(MECHANICAL RECOVERY BLAST ROOMS)

Blast room with monorail material handling system. Work cart on rails in a blast room.

Blast room with dual catwalks and a tank ventilation hoses. Blast room with dual 3-axis man-lifts.

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 RECLAIM FLOOR SYSTEMS
(MECHANICAL RECOVERY BLAST ROOMS)

The purpose of the reclaim floor system is to collect

abrasive and debris, such as removed paint/rust, from the
floor of the blast room and transport it to the abrasive
recovery system. These systems are installed below the
floor in the abrasive blast room and are covered with
grates.

The basic rule of a reclaim floor system is the more floor

space that is occupied by the reclaim system, the less
manual labor required to move all abrasive into the system.
There are five basic types of reclaim systems that vary in
the amount of floor space they occupy from only a small
corner to the entire floor.

It is important to know your production goals and budget

when considering the type of recovery floor you will need.
We will help you understand the “true” cost of processing
the abrasive through the recovery system.

All our mechanical reclaim floor systems feature 1-1/4” floor grating rated at 500# per sq. ft. All of the floor
systems, except for corner sweep-in systems, use heavy duty 9” diameter return augers with 3/8” thick flighting to
move abrasive to the abrasive recovery system. The augers are protected from overload by metering shed plates
resulting in a highly reliable system.

Shed Plate

Grate and shed plate removed showing abrasive return auger.

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 RECLAIM FLOOR SYSTEMS
(MECHANICAL RECOVERY BLAST ROOMS)

FULL FLOOR RECLAIM SYSTEM

Full floor reclaim systems recover more of the abrasive automatically
than any other reclaim system because the entire floor space acts as
one big collector. Anywhere abrasive falls, it goes through the grates
and is transported to the abrasive recovery system via augers below the
floor. These systems are best suited for high production operations and
save cost by eliminating the need for additional “clean up” time.

Full floor systems require material handling of the work piece to be

designed into the configuration of the room as the standard floor grates
cannot support heavy loads. Options include a work car/track system,
an overhead monorail crane, an overhead bridge crane, or heavy duty
floor grating and support steel to allow a forklift to drive onto the
reclaim floor.

H-SHAPED PARTIAL RECLAIM SYSTEM

H-Shaped partial reclaim systems are similar to U-Shaped systems
except they run along 2 of the 4 sides of the blast room are typically
used with 2 door flow-through setups. Heavy work pieces can be moved
in one end of the blast room and out the other never needing to travel
over the reclaim system floor grates.

Since the majority of the abrasive falls along the walls of the blast room,
the H-Shaped system (like the U-Shaped system) requires only minimal
“clean up” to push the abrasive in the center of the room to the edges.
Augers below the floor grates are used to move abrasive to the abrasive
recovery system. Abrasive from the far side of the room travels under
the floor using an auger covered by heavy steel plates.

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 RECLAIM FLOOR SYSTEMS
(MECHANICAL RECOVERY BLAST ROOMS)

U-SHAPED PARTIAL RECLAIM SYSTEM

U-Shaped partial reclaim systems run along 3 of the 4 sides of the blast
room are typically used with single door (in/out) setups. Heavy work
pieces can be moved in and out of the room never needing to travel
over the reclaim system floor grates.

Since the majority of the abrasive falls along the walls of the blast room,
the U-Shaped system requires only minimal “clean up” to push the
abrasive in the center of the room to the edges. Augers below the floor
grates are used to move abrasive to the abrasive recovery system.

SINGLE SCREW PARTIAL RECLAIM SYSTEM

Single screw partial reclaim systems typical run along the end of a single
door blast room setup. This way, heavy work pieces can be moved in
and out of the room never needing to travel over the reclaim system
floor grates. If necessary, single screw reclaim systems can be installed in
positions other than the back wall.

More “clean up” time is required to push the abrasive to the floor
grates. A single auger below the floor grates is used to move abrasive
to the abrasive recovery system. For this reason, this type of system is
appropriate for low to medium production.

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 RECLAIM FLOOR SYSTEMS
(MECHANICAL RECOVERY BLAST ROOMS)

SWEEP/SHOVEL IN RECLAIM SYSTEM

Sweep in systems are the most economical abrasive reclaim system but
are only appropriate for low production operations. Almost all abrasive
must be manually moved to the corner of the blast room where a chute
directs the abrasive to the recovery system.

This is the simplest reclaim system available but can increase operating
costs due to the time needed for “clean up.”

Also available in a shovel in version located entirely above the floor

requiring no concrete work.

Shovel-in above floor reclaim system.

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 ABRASIVE RECOVERY
(MECHANICAL RECOVERY BLAST ROOMS)

The purpose of the abrasive recovery system is

to separate usable abrasive from debris, dust
and broken down abrasive returning from the
blast room. Usable abrasive is collected and
stored in an abrasive hopper while trash is
moved to a drum/bin. The abrasive recovery
system is custom engineered based on your
production goals.

Abrasive separation is achieved using a rotating

drum and an air wash separator ensuring only
good clean abrasive makes it through to the
abrasive hopper. This system is very efficient for
both ferrous and non-ferrous dry abrasives, and
ensures the maximum recycles of the abrasive.

Magnetic separators are available for removing

wire welding pig tales from non-ferrous
abrasives or for separating abrasives in dual
systems that would use, for example, steel grit &
glass bead.

Good abrasive is stored in an abrasive hopper

which feeds it directly to the abrasive blast pots
located below.

STANDARD FEATURES
• Bucket elevator assembly, including cast ductile iron buckets, 1/2” thick belting
• Gravity type air wash separator with perforated plate rotary drum assembly
(a.k.a. scalping drum)
• “Free standing” abrasive hopper with required support steel and shut off gates
• Caged ladder and access work platform with hand railing for abrasive storage hopper
• Easy and safe access to air wash separator and elevator head section
• Pre-wired and interlocked NEMA 12 electrical control panel

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 ABRASIVE RECOVERY
(MECHANICAL RECOVERY BLAST ROOMS)

STEP 1: RECLAIM FLOOR / BUCKET ELEVATOR

Abrasive and other debris
collected by the reclaim
floor system arrives at the
Abrasive base of a mechanical bucket
Separator elevator where it is moved
to the top of the abrasive
recovery tower. At the top,
the abrasive/debris mixture
is moved with an auger
horizontally to the trash
separation step.
Hopper
Waste
Drums

Blast
Pot

Blast Room
Reclaim Floor

STEP 2: TRASH SEPARATION

Using a perforated plate rotary drum assembly
(a.k.a. scalping drum), larger trash is separated from
the abrasive/dust mixture and is delivered to a trash
drum/bin. The abrasive/dust mix then proceeds to
the air wash.

Abrasive recovery perforated plate rotary drum assembly.

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 ABRASIVE RECOVERY
(MECHANICAL RECOVERY BLAST ROOMS)

STEP 3: AIR WASH

At this point in the recovery process,
reusable abrasive is still contaminated with
dust, broken down/undersized abrasive
particles, and material that was removed
during blasting like paint and rust particles.
This mixture is fed through an air wash
where it falls in a precisely metered curtain
while a controlled volume of air is drawn
through it separating it into the following 3
classifications:

I) Dust: Super fine debris is separated out

and carried away by duct to the blast room
dust collector.

Curtain of abrasive falling through the air wash.

II) Undersized Abrasive: Abrasive that
has broken down enough to no longer be
productive (typically 100 grit or finer) is
separated out and falls down a chute to
a receptacle. This spent abrasive is then
available to be sold as scrap, recycled or
disposed of.

III) Reusable Abrasive: After the dust

and undersized abrasive is separated out,
what’s left is good abrasive that is ready to be
used again. It is deposited into the abrasive
storage hopper located below the air wash.

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 ABRASIVE RECOVERY
(MECHANICAL RECOVERY BLAST ROOMS)

STEP 4: ABRASIVE IS REUSED

Once the reusable abrasive falls from through
the air wash into the abrasive hopper, it is
stored there until needed. The abrasive
hopper is located above the abrasive blast
pots and delivers clean abrasive directly to
them during their refill cycle.

Air wash/magnetic separator/abrasive hopper feeding two abrasive

blast pots with trash & undersized abrasive collection drums.

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 DUST COLLECTION
(MECHANICAL RECOVERY BLAST ROOMS)

The dust collector provides several crucial functions in a blast

room system which include:

1. Ventilate and move dust out of the blast enclosure to

maintain visibility.

2. Filter/collect airborne dust produced in the abrasive

recovery process.

To do the job properly, a dust collection system must

be sized properly for the blast room it will serve. An
inadequately sized dust collector will have a devastating
effect on your productivity and operating costs. IDS Blast
has the know-how and experience to ensure your blast room
is equipped with a properly matched dust collector.

STANDARD FEATURES
• Cartridge style dust collector
• 99.999% efficiency filters down to particle size of .5 micron; Merv-15 rating
• Abrasive inlet plenums, fan, and premium efficiency motors
• All required duct work to tie the full system together
• Exhaust fan silencer (if required)
• Return air duct work (if required)
• Interlocked into the supplied control panel
• Slide gates for dust/waste drums

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 DUST COLLECTION
(MECHANICAL RECOVERY BLAST ROOMS)

PROPER SIZE - CFM REQUIREMENT

The preferred method of moving air through a blast room is cross-draft ventilation. Air is drawn in through
intake plenums, moves across the entire room, and is drawn out at the other end. This method provides the best
visibility and dust evacuation for a blast room because the sweeping motion ensures the entire volume of the blast
enclosure is well ventilated and there are no “dead spots” for dust to collect in.

To achieve optimal results, cross-draft ventilated blast rooms require air to move at a certain speed through the
room. This is referred to as “Cross Sectional Air-Speed Feet Per Minute” and depends on the type of blasting
being performed. The following chart shows the optimal flow rates for common types of blasting.

Min. Required Cross Sectional Air Speed For Abrasive Blast Rooms

Non-steel abrasives such as

Steel Shot/Steel Grit
Aluminum Oxide, Garnet, Etc.

60 (FPM) 50 (FPM)

Dust collectors are rated in terms of the air CFM (Cubic Feet per Minute) they can move. To calculate the CFM
required from the cross sectional air-speed and room size, the following formula is used:

Room Width (ft) x Room Height (ft) x Cross Sectional Air-Speed (FPM) + 600 = CFM

So for example, the minimum dust collector CFM for a blast room that is 20’ wide x 16’ high x any length using
Aluminum-Oxide calculates as follows:

20(ft) x 16(ft) x 60(FPM) + 600 = 19,800 CFM required

*The length of the blast room does not affect the CFM requirement. The 600 is added to account for the dust
collection requirement for the abrasive air wash. In certain cases where the material/coating that is being blasted
creates excessive dust, higher cross sectional air speeds may be necessary.

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 DUST COLLECTION
(MECHANICAL RECOVERY BLAST ROOMS)

FILTRATION
The dust collectors we provide feature cartridge filters with a high efficiency rating of 99.999% to particle size of
.5 micron (Merv-15 rating). These collectors meet the most stringent guidelines for particle emissions and ensure
the discharged air is clean and virtually dust free.

Keeping the filters clean is important to maintaining air flow. The pulse jet cleaning system automatically cleans
the filter elements while the dust collector is in operation, eliminating any production down time for a filter
cleaning cycle. The cartridge filters are easily accessed from outside the dust collector by removing a single wing
nut per row of two elements. Ease of maintenance means increased productivity.

One common mistake in sizing dust collectors is trying to force too much CFM of air through too few filter
cartridges. The intent is to save money by purchasing a smaller dust collector but forcing too much air through
the filter cartridges has a detrimental effect. A proper “air-to-cloth” ratio is necessary to maintain filter cartridge
efficiency and filter cartridge life. IDS Blast sizes all blast room dust collectors to be within the recommended “air-
to-cloth” range of 1.7 to 2.0 meters per minute ensuring proper dust collector performance.

EXHAUST / RETURN AIR

Blast room dust collectors can be very large and take up significant space when CFM requirements are high. The
good news is dust collectors can be constructed either inside your facility or outside near an exterior wall saving
valuable interior floor space.

Your dust collector can be engineered to exhaust the filtered air outside your facility or back into your facility
creating a closed loop system. Returning the air back to your facility can help save of facility HVAC costs. Optional
HEPA filters are available for returned air.

Dust collector with custom paint color.

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 DUST COLLECTION
(MECHANICAL RECOVERY BLAST ROOMS)

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 PNEUMATIC RECOVERY BLAST ROOMS
In addition to mechanical blast rooms, IDS Blast has vast experience in supplying pneumatic recovery blast
rooms tailored to your exact needs. While mechanical blast rooms physically move abrasive using augers
and bucket elevators, pneumatic recovery blast rooms covey media through the system using controlled
high velocity air flow and ducting.

Mechanical recovery blast rooms will often be the better choice for heavy duty, full day production &
heavy abrasive blasting. IDS Blast will guide you through the choice between pneumatic and mechanical
recovery blast rooms.

WHEN IS A PNEUMATIC BLAST ROOM THE RIGHT CHOICE?

Pneumatic recovery blast rooms use ducting to physically move used abrasive from the
blast room to the abrasive recovery system. The faster speed of abrasive through the
recovery system results in more wear and tear than in mechanical recovery blast rooms.
Pneumatic recovery blast rooms are typically an appropriate choice for light to medium
production facilities when using lighter abrasives such as glass beads, plastic media,
aluminum oxide, etc. They are a lower cost alternative to a mechanical recovery blast
rooms and typically require less concrete work to install.

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 BLAST ENCLOSURE
(PNEUMATIC RECOVERY BLAST ROOMS)

BLAST ENCLOSURE
The pneumatic blast room enclosures we supply are specially ventilated and illuminated for abrasive blasting.
They are fully sealed, and an all steel structure. The highly engineered components are prefabricated for simple
bolt-together assembly with little or no welding required.

These enclosures stand by their own structural support without connections to the surrounding facilities. Length,
width, height, lighting, entry/exit doors & man doors are customizable and will be configured specifically for your
application. We can fully explain and guide you through all the options available so you end up with exactly what
you need.

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 RECLAIM FLOOR SYSTEMS
(PNEUMATIC RECOVERY BLAST ROOMS)

The reclaim floor system captures spent abrasive and conveys it

through ducts away from the blast room to the blast media cleaning
and classification system. The system consists of modular recovery
channels and can be installed either above the floor or into the floor
(requires concrete work). There are several configurations available
which are outlined below.

FULL FLOOR RECLAIM SYSTEM

Full floor reclaim systems
recover more of the
abrasive automatically
than any other reclaim
system because the entire
floor space acts as one
big collector. Anywhere
abrasive falls, it goes
through the grates and is
transported to the abrasive
recovery system below the
floor without the need to
manually sweep abrasive
into it. Each modular
section of the floor is cycled Full floor reclaim system being installed with tracks for
work car material handling (floor grates removed).
on and off one-at-a-time to
maintain the efficiency of
the recovery system.

Full floor systems require material handling of the work piece to be designed into the
configuration of the room as the standard floor grates cannot support heavy loads.
Options include a work car/track system, an overhead monorail crane, an overhead
bridge crane, or heavy duty floor grating and support steel to allow a forklift to drive
onto the reclaim floor. “In-Floor” and “Above-Floor” systems are available.

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 RECLAIM FLOOR SYSTEMS
(PNEUMATIC RECOVERY BLAST ROOMS)

TWO WALL RECLAIM SYSTEM

Two Wall partial reclaim systems
run along the two longest walls
of the blast room. Since the
majority of the abrasive falls along
the walls of the blast room, the
two wall reclaim system requires
only minimal “clean up” to push
the abrasive in the center of the
room to the edges. “In-Floor”
and “Above-Floor” systems are
available.
Two wall “above-floor” recovery system.

SINGLE WALL RECLAIM SYSTEM

Single Wall partial reclaim systems
run along one wall of the blast
room (typically the back wall.)
More time is required for “clean up”
and to sweep the abrasive to the
collection point than with full floor
or two wall reclaim systems. “In-
Floor” and “Above-Floor” systems
are available.

Single wall “above-floor” recovery system.

SWEEP/SHOVEL IN RECLAIM SYSTEM

Sweep in partial reclaim systems
provide a single point of abrasive
recovery on the blast room floor.
The most time is required for “clean
up” since all the abrasive that must
be moved to the collection point.
“In-Floor” and “Above-Floor”
systems are available.

Sweep in pneumatic recovery system.

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 ABRASIVE RECOVERY
(PNEUMATIC RECOVERY BLAST ROOMS)

ABRASIVE RECOVERY
Simply put, the abrasive recovery system
cleans the used abrasive prior to being
recycled back into the blasting system. Proper
reclamation and classification of the recovered
abrasive is important to the efficiency and
repeatability of the blasting operation. The
pneumatic reclaim and classification systems
we provide have been developed over many
years of research and field experience. They
efficiently recover reusable media and separate
out broken-down media, dust & debris.

Step 1: Abrasive, dust & debris are carried

from the collection points in the blast room
floor through ducting and reach the reclaimer
inlet.

Step 2: The abrasive, dust & debris are spun

at high speeds inside the reclaimer separating
the heavier materials from the dust an fines.
The dust and fines are carried away to a
dust collector while the heavier materials fall
through to the next step. When set correctly,
only 1% to 3% of usable abrasive is lost.

Step 3: The remaining abrasive and debris

mixture fall through a screen to separate out
larger pieces of trash and debris.

Step 4: The reusable media is now clean

and is stored in a hopper. From the hopper, Pneumatic abrasive recovery system.
it flows into the abrasive blast pot(s) and is
reused providing savings over using media
once and throwing it away.

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 DUST COLLECTION
(PNEUMATIC RECOVERY BLAST ROOMS)

DUST COLLECTION
To maintain visibility in the blast room
enclosure and collect the dust/fines
from the abrasive recovery system, every
pneumatic recovery blast room is equipped
with a cartridge type dust collector. The
filters are kept clean by an automatic pulse
jet cleaning system. Collected dust and
other fines are deposited into collection
drum for easy disposal.

Dust collectors are a key component in the

blast room as they contribute greatly to
the overall productivity and efficiency of
Dust collector shown left of Waste Collection
the blasting operation. IDS Blast has the abrasive recovery unit. Drum.
knowledge and experience to ensure you get
a properly sized dust collector for your room.

Dust Collector Sizing: To achieve optimal results, cross-draft ventilated blast rooms require air to move at a certain
speed through the room. This is referred to as “Cross Sectional Air-Speed Feet Per Minute” and depends on the
type of blasting being performed. The following chart shows the optimal flow rates for common types of blasting.

Min. Required Cross Sectional Air Speed For Abrasive Blast Rooms

Non-steel abrasives such as

Steel Shot/Steel Grit
Aluminum Oxide, Garnet, Etc.

60 (FPM) 50 (FPM)

Dust collectors are rated in terms of the air CFM (Cubic Feet per Minute) they can move. To calculate the CFM
required from the cross sectional air-speed and room size, the following formula is used:

Room Width (ft) x Room Height (ft) x Cross Sectional Air-Speed (FPM) = CFM

So for example, the minimum dust collector CFM for a blast room that is 20’ wide x 16’ high x any length using
Aluminum-Oxide calculates as follows:

20(ft) x 16(ft) x 60(FPM) = 19,200 CFM required

*The length of the blast room does not affect the CFM requirement. While steel grit is not the typical abrasive
media used in pneumatic recovery blast rooms, pneumatic rooms optimized for steel grit capability are available.

800 - 800 - 0665 27

 ABRASIVE BLAST POTS
Blast pots may be the smallest component of a blast room
but they affect the productivity of your room greatly. We
understand the importance of supplying the right blast pot
setup to prevent a production bottleneck.

All blast rooms include one or more abrasive blast pots

which provide the actual abrasive blasting capability. In
simplest terms, the abrasive blast pot is the pressurized
vessel which contains the abrasive and mixes it with
compressed air. That mixture is sent out through a blast
hose where it is accelerated through a venturi blast nozzle
at the other end.

Blast pots are highly customizable and we will make

recommendations for cost saving options and accessories
based on your specific needs.

CAPACITY / BLAST TIME

How much abrasive your blast pot holds determines how long you can blast before stopping to refill. The standard
blast pot capacities we recommend for most blast rooms will be 6.5 or 10 cu. ft. but we can go far beyond that for
when longer blast sessions are necessary. When extra high capacity is needed, 120 and 160 cu. ft. bulk blast pots
are an option. Plan accordingly and spend more time blasting and less time filling.

6.5 cu. ft.

10 cu. ft.

8.0 cu. ft.

Dual
Chamber

start 1 hour 2 hours 3 hours 4 hours

Blasting Blow-Down Filling

/ Pressurize

Chart data and percentages above based on real-world observations when blasting with a single #8 or dual #6 nozzles.
Data represents the “best case” scenario as the total filling time may actually be longer if the operator starts blasting
before the vessel is full or is idle for a time after it is full. To put it another way, 20% is a very low estimate of how much
time is wasted on filling in a real-world environment. Times may vary depending on type of abrasive, nozzle & PSI.

28 W W W. IDSBL A ST .C OM
 ABRASIVE BLAST POTS
DUAL-CHAMBER BLAST POTS
The ultimate in abrasive capacity. When it comes to productivity dual-
chamber blast pots are the top-of-the-line. They continuously refill while
under pressure so your operation never has to stop blasting to wait for more
abrasive. What makes this possible is a second pressure chamber above the
primary chamber which cycles between a unpressurized state where it refills
from the abrasive hopper, and a pressurized state where it moves abrasive
into the primary chamber. They are less expensive and take up less space
than a high capacity bulk pot.

Level
Sensor

LOWER CHAMBER ABRASIVE REFILL UPPER

OFF / STARTUP
EMPTIES TRANSFER CHAMBER

HOW MANY OUTLETS DO YOU NEED?

Blast rooms can be equipped with a single blast pot with
a single blasting outlet or multiple blast pots with multiple
outlets each. Multiple blast outlets are used when more than
one operator is blasting simultaneously or in larger blast
rooms where different areas of the room have dedicated
outlets. The chart below shows available outlet options
based on blast pot capacities.

Available Outlet Configurations Per Blast Pot

Blast Pot Capacity Standard Outlets Maximum Outlets

6.5 ft 3
1 1
10 ft3 1-2 3
6.5 cu. ft.
blast pot with 8 ft3 Dual Chamber 1-2 3
single outlet 10 cu. ft. blast
pot with two
120/160 ft3 Dual Chamber 2-4 16
outlets

800 - 800 - 0665 29

 ABRASIVE BLAST POTS
BIG-GUN™ FULL FLOW SYSTEM
We use Pirate Brand® blast pots that feature the BIG-GUN™ full
flow system. These blast pots are designed with high productivity
in mind. The more air and abrasive you can flow, the less time
it takes to complete the job. BIG GUN blasters are designed to
have the lowest restriction possible to achieve higher blasting
rates. They feature 1-1/2” ID piping, full port blast hose
connections, lower restriction moisture separators, and larger air
valves for blast pots with abrasive cut-off systems

The complete BIG-GUN™ system also includes blast hose with

larger ID, full port couplings, and faster accelerating nozzles.

All of this adds up to less pressure drop throughout the system

and significant performance gains resulting in the best possible
productivity.

Comparison between Big-Gun™ and

Standard Components

SHORT-CYCLE™ SYSTEM SAVER

Short-Cycle™ Blasters are designed to withstand the punishing
effects of quick on-off blasting while retaining the convenience
of a pressure release system. Standard pressure release (SPR)
blasters are great for blast rooms because when paired with an
overhead abrasive hopper, they can be refilled by simply releasing
the control handle and allowing the blaster to depressurize and
automatically fill. Unfortunately, when blasting frequently for
less than 10 minutes at a time with an SPR system, abrasive can
overfill the blaster, damaging the pop-up and causing it to not seal
properly. This causes abrasive to “burp” from around the pop-up
and eventually ruin the metering valve.

Avoid damage
Pirate Brand® Short-Cycle™ blasters overcome this issue by like this caused by
remaining pressurized when the control handle is released but short blast cycles.
feature a remote blow-down button to allow you to depressurize/
refill your blaster without leaving the blast room.
Remote
blow-down
Note: Dual-Chamber abrasive blast pots are inherently short-cycle button.
proof by design.

30 W W W. IDSBL A ST .C OM
 ABRASIVE BLAST POTS
ABRASIVE CUT-OFF
Adding the abrasive cut-off option to your blast pot(s) allows the operator to switch off just the abrasive flow and
clean off the object being blasted with compressed air. Abrasive cut-off systems are available for blast pots with
either pneumatic or electric controls. The switch can be mounted on the blast hose near the blast nozzle and
deadman control handle or wall mounted.

REGULATOR OPTION
Regulating the pressure of the compressed where it enters the
blast pot is an often overlooked option that greatly effects blast
pot performance. There are 2 important reasons to regulate the air
pressure at the blast pot.

1. Better functionality: The more consistent the air supply pressure

is, the smoother and better the abrasive blast pot will function. Swings
up and down in supplied pressure will diminish productivity and can
even result in premature wear of several blast pot components. This is
especially important for dual-chamber systems. Big-Gun regulator kit commonly recommended
with large bore or multiple nozzle systems.

2. Profile control: By adjusting the blasting pressure with the regulator, you have total control over the level of
profile created during abrasive blasting. When you can control both the abrasive flow and the air flow precisely,
the quality and repeatability of your work will be much better.

5 YEAR / 10 YEAR WARRANTY

Pirate Brand® abrasive blast pots include a standard 5 year warranty on the complete abrasive blast pot and a 10
year warranty on the pressure vessel. See the complete warranty documentation for details.

IDS Blast relies on Pirate Brand® abrasive blast pots

for the blast rooms we design. They are reliable,
efficient, and offer the flexibility needed to build
a blast room that is designed for your operation.
Many hundreds have been deployed to the field
and their operational record is outstanding.
In addition, their warranty is unbeatable.

800 - 800 - 0665 31

 SUPPORT / USER EQUIPMENT
In addition to the blast room there are several pieces of support and personal protective equipment that will be
necessary for a successful and productive blasting operation.

ABRASIVES BLAST HOSE & COUPLINGS

It is important to understand all your abrasive options. There are several varieties of blast hose that
We want to be sure to educate you on the cost of are available in many sizes. IDS Blast® can make
the abrasive versus the recyclability of the abrasive. recommendations that will help you get the best
We are a stocking distributor of all commonly performance and life from your blast hose as well as
used abrasives and maintain a large warehouse of some suggestions for how to minimize user fatigue.
inventory. IDS Blast® is your connection for abrasives. We also supply all the necessary couplings and nozzle
holders you will need.

BLAST NOZZLES REPLACEMENT PARTS

Straight bore, venturi, high performance big-gun, With our massive inventory, the distance between
urethane jacket, aluminum jacket, tungsten-carbide, you and the replacement part you need is never far.
boron-carbide, SiAION... When it comes to blast IDS Blast® stocks everything from filter cartridges, to
nozzles, there are hundreds of options. Let IDS Blast® valves, to control handles, to fittings and everything
be your guide and make recommendations for your in between. Keeping you up and running at peak
operation. Compressed air HP and CFM determines the performance is our priority and commitment.
size of the nozzle to use in your blast room.

32 W W W. IDSBL A ST .C OM
 SUPPORT / USER EQUIPMENT
IDS Blast® is a stocking distributor of abrasives, parts & supplies and is here to support all of your needs from air
compressors to replacement parts.

RESPIRATORS BREATHING AIR FILTERS

& CO MONITORS
To protect the operator from airborne dust and flying Your respirators must be supplied with clean/safe air
abrasive, you will need a protective respirator for each for your operators to breathe. Airline filters remove
operator. We stock a complete line of respirators for moisture, particulates & odor providing clean air to
the abrasive blasting industry as well as accessories, the respirator. Carbon monoxide is a serious concern
like climate control tubes, that keep the operator when it comes to operator safety/health. CO monitors
comfortable and productive. are available and highly recommended.

PERSONAL PROTECTIVE EQUIP. COMPRESSORS & AIR PREP.

Rely on IDS Blast® to stock all the personal protective IDS Blast® has the knowledge & experience to supply
equipment you will need to operate you blast room. you with properly sized and reliable air compressor(s)
From durable protective blast suits, to hearing for your abrasive blasting setup. Cool, clean & dry
protection, to comfortable protective gloves, we compressed air is the key to better abrasive blasting.
literally have you covered. We take blasting safety IDS Blast® supplies air dryers and filtration systems to
seriously and can advise you on what you will need. minimize compressed air quality related down time.

800 - 800 - 0665 33

 SUPPORT SERVICES
PROFESSIONAL MAINTENANCE SERVICE
YOUR RELATIONSHIP WITH IDS BLAST® ISN’T OVER ONCE YOUR BLAST ROOM IS INSTALLED, IT’S ONLY
BEGINNING. Our trained technicians are ready to serve you from initial startup, through proper maintenance and
repairs. We are here to support your blasting operation in every way and make sure your investment continues to
perform at its peak year after year. Blast room services we commonly perform include:

• INITIAL STARTUP INSPECTION & CHECK OUT.

• EXPLANATION AND PROPER USE OF SYSTEMS.
• EFFICIENCY EVALUATIONS / OPTIMIZATION.
• EQUIPMENT REPAIR / REPLACEMENT PARTS.
• FUTURE UPGRADES & EXPANSION.

PREVENTATIVE MAINTENANCE PROGRAM

To get the best productivity and long term reliability, we highly suggest setting up a preventative maintenance
program for your blast room. Improperly maintained blast equipment costs you money due to lower productivity
and break downs. Let IDS Blast® maintain your equipment for you. Our factory trained technicians will come to
your location on a regularly scheduled basis to make sure your blast equipment is running at peak performance!

AVAILABLE PREVENTATIVE MAINTENANCE PLANS

Yearly Inspection & Maintenance

Semi-Annual Inspection & Maintenance

Quarterly Inspection & Maintenance

Monthly Inspection & Maintenance

34 W W W. IDSBL A ST .C OM
 CFM / PSI / ABRASIVE REQUIREMENTS
NOZZLE PRESSURE
NOZZLE# 50 PSI 60 PSI 70 PSI 80 PSI 90 PSI 100 PSI* 125 PSI 140 PSI
AIR & ABRASIVE RATES
ORIFICE SIZE (3.5 BAR) (4.1 BAR) (4.8 BAR) (5.5 BAR) (6.2 BAR) (6.9 BAR) (8.6 BAR) (9.7 BAR)
(cu ft/min) 12 13 15 18 19 21 26
#2
1/8 inch
AIR
(cu m/min) .34 .37 .42 .51 .54 .59 .74
(lb/hr) 70 80 90 100 110 120 135
(3.2 mm) ABRASIVE
(kg/hr) 32 36 41 45 50 54 61
(cu ft/min) 25 30 35 40 43 45 60
#3
3/16 inch
AIR
(cu m/min) 0.71 0.85 0.99 1.13 1.22 1.27 1.70
(lb/hr) 150 170 200 215 240 260 320
(4.8 mm) ABRASIVE
(kg/hr) 68 77 91 98 109 118 145
(cu ft/min) 50 55 60 70 75 80 95
#4
1/4 inch
AIR
(cu m/min) 1.42 1.56 1.70 1.98 2.12 2.27 2.69
(lb/hr) 270 300 350 400 450 500 675
(6.35 mm) ABRASIVE
(kg/hr) 122 136 159 181 204 227 306
(cu ft/min) 80 90 100 115 125 140 190 230
#5
5/16 inch
AIR
(cu m/min) 2.27 2.55 2.83 3.26 3.54 3.96 5.38 6.51
(lb/hr) 470 530 600 675 750 825 1000 1125
(8 mm) ABRASIVE
(kg/hr) 213 240 272 306 340 374 454 510
(cu ft/min) 110 125 145 160 175 200 275 315
#6
1/8 inch
AIR
(cu m/min) 3.12 3.54 4.11 4.53 4.96 5.66 7.79 8.91
(lb/hr) 675 775 875 975 1060 1100 1350 1840
(9.5 mm) ABRASIVE
(kg/hr) 306 352 397 442 481 499 612 835
(cu ft/min) 150 170 200 215 240 255 315 405
#7
7/16 inch
AIR
(cu m/min) 4.25 4.81 5.66 6.09 6.80 7.22 8.92 11.46
(lb/hr) 900 1000 1200 1300 1400 1510 1800 2540
(11.1 mm) ABRASIVE
(kg/hr) 408 454 544 590 635 703 816 1152
(cu ft/min) 200 225 250 275 300 340 430 540
#8
1/2 inch
AIR
(cu m/min) 5.66 6.37 7.08 7.79 8.50 9.63 12.18 15.28
(lb/hr) 1200 1350 1500 17010 1850 2025 2525 3240
(12.7 mm) ABRASIVE
(kg/hr) 544 612 680 771 839 919 1145 1470
(cu ft/min) 300 350 400 450 500 550 700 880
#10
5/8 inch
AIR
(cu m/min) 8.50 9.91 11.33 12.74 14.16 15.58 19.82 24.90
(lb/hr) 1900 2200 2400 2700 3000 3300 4000 5200
(16 mm) ABRASIVE
(kg/hr) 862 998 1089 1225 1361 1497 1814 2359
(cu ft/min) 430 500 575 650 700 800 1100 1255

#12
3/4 inch
AIR
(cu m/min) 12.18 14.16 16.28 18.41 19.82 22.66 31.15 35.52
(lb/hr) 2700 3100 3500 3900 4300 4700 5700 7375
(19 mm) ABRASIVE
(kg/hr) 1225 1406 1588 1769 1950 2132 2586 3345
This table is to be used as reference only. Actual results may vary depending on specific abrasive media used. This table is based on abrasive with a bulk density of 100 pounds per cubic foot.

*100 PSI MIN/REDUCE CFM REQUIRED RESPIRATOR REQUIREMENTS

Most abrasive blast equipment requires a minimum When calculating your CFM requirements, the
pressure of 100 PSI in order for the control system to air used by each respirator must be taken into
function properly. To maintain the 100 PSI minimum account. A general rule is each respirator will
and lower the CFM requirement of blasting, a require an additional 6-16 CFM. PSI and type of
pressure regulator can be installed downstream of control device will affect the CFM used. Consult
the control air connection. Example: if blasting with a the owners manual for your respirator for more
#5 nozzle, the CFM requirement can be lowered from on specific PSI and CFM requirements.
140 to 115 by regulating the pressure to 80 PSI.

800 - 800 - 0665 35

 IDSBLAST.COM
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