16 WAYS TO IMPROVE YOUR

ABRASIVE BLASTING SYSTEM

SPECIAL REPORT

1800 190 190 www.BlastOne.com

 1 INTRODUCTION

2 INSTALL A MICROVALVE

3 TAKE OFF YOUR OLD MOISTURE TRAP

4 USE A BULL HOSE TO SUPPLY AIR TO YOUR POT

5 CHECK YOUR NOZZLE PRESSURE REGULARLY

6 BLAST WITH A LOW DUST ABRASIVE

7 USE A LIGHTWEIGHT, COMFORTABLE HELMET

8 ENSURE YOUR COMPRESSOR IS BIG ENOUGH

9 FIT A LARGE BORE FLEXIBLE WHIP HOSE

10 SCREW IN A LIGHTWEIGHT, LONG LIFE BLAST NOZZLE

11 DEADMAN CONTROLS

12 LET’S LOOK AT YOUR BLAST POT

13 KEEP YOUR COOL WITH A HELMET AIR COOLER

14 WIND UP YOUR PRESSURE

15 MONITOR AND PURIFY YOUR BREATHING AIR

16 USE A COMMUNICATION SYSTEM

17 RECYCLE YOUR ABRASIVE

18 TECHNICAL DATA

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INTRODUCTION
TO BLAST CLEANING
EFFICIENCY
This booklet has been written to assist you to identify ways to make your life easier as a blaster and more
efficient. Some of the items explained here may seem common sense to you. In fact, you may have used
them for some years. Unfortunately, many blasters haven’t ever had any specialist training.

Who trains the blaster?

The old blaster.
Who trained him?
The blaster before him.

Did any of them investigate new techniques? New equipment? New ways of working more efficiently?
No. (It’s sad but true).
Fortunately, this is now changing. By just using a few of the ideas in this booklet, you should be able to
improve your production and efficiency. It means decreasing your costs and dramatically improving your
profits.
The majority of this booklet summarized in one sentence: Increase your nozzle pressure and decrease
your abrasive consumption. It makes all the difference to your efficiency.

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1
USE A VALVE WITH
PRECISION CONTROL
MANY BLASTERS HAVE FOUND THEIR BLAST
POT LASTS UP TO 3 TIMES LONGER BETWEEN
REFILLS USING THE MICROVALVE, WITHOUT
ANY DOWNTURN IN BLASTING SPEED!

The abrasive metering valve on the bottom of your

Very accurate
blast pot can make or break your profits. If you metering of abrasive
have it open too wide, you use too much abrasive
and have to refill the pot sooner. Too much
abrasive can also mean slower, dustier blasting.
The problem is, it is very hard to accurately adjust
Easy attachment
metering valves to get the perfect mix of air and to blast pot
abrasive.
The MicroValve III is a new valve from BlastOne
which makes “fine tuning” your abrasive mix easy.
Install one onto your blast pot instead of your old
metering valve, and you’ll immediately notice a
big difference!
Very simply designed for operation, it only takes
two bolts and two minutes to pull it down for
maintenance.
For blast pots with two or more outlets, upgrade
to the Thompson Valve.

CAUTION
This valve is becoming so popular that cheap copy valves are
appearing. Beware, they may be made of inferior metals and
wear out fast. Insist on genuine BlastOne MicroValves. Heavy duty and long
lasting nipple

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2
TAKE OFF YOUR OLD
MOISTURE TRAP
IT COULD BE SUCKING THE LIFE OUT OF
YOUR BLASTING PRESSURE

Are you using a ⅜” (no. 6) nozzle or bigger? Have

you got one of these moisture traps (as shown)
on the side of your blast pot? Rip it off now if you
want to improve production.
These moisture traps may work well when they
are new. However, they have a fine filter element Old style moisture trap
inside that very quickly becomes clogged with any (too restrictive for
bigger nozzles)
dust, oil and foreign matter.
And then they become a big cause of pressure
drop! You may have 100psi coming in from the
compressor, but going out of the little moisture
trap may be only 90psi! This is a very common
problem.
Instead, you should install a high volume moisture
separator, which operates without this pressure
loss problem and removes more moisture. The
MS H800 (shown right), works by allowing the air
High volume
to expand and drop out the water, then stainless moisture separator
steel coalescing pads remove this moisture from Reduces pressure loss
and removes more water
the air.
Simply put, the MS H800 works very effectively. It
was built for rugged site use and it doesn’t drink
up your pressure.

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3
USE A BULL HOSE TO
SUPPLY AIR TO YOUR POT
INCREASING YOUR PRESSURE – INCREASES
YOUR PROFITS
Do you use a big nozzle to blast with, but only
supply your blast pot with air from a jackhammer
hose? Or you may have two jackhammer hoses?
This is no good.
But, we do have good news! Overnight, you can
double your blasting rate. Big nozzles need big
hoses.
For any bigger than a 7/16” (no. 7) nozzle, you
need a 2 inch (50mm) ID bull hose to supply air to
your blast pot. Any smaller air delivery hose will
simply be choking the air supply. And you lose
valuable air pressure.
Important note: Watch your hose fittings. It’s no good fitting
a nice big bull hose to the pot if you’ve still got hose fittings
or pipe fittings that are smaller in the bore than your hose
size. A 2” bull hose should be connected to a 2” outlet on the
compressor and use large bore fittings right through.

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4
CHECK YOUR NOZZLE
PRESSURE REGULARLY
THIS CRITICAL CHECK SHOULD BE DONE AT
LEAST WEEKLY
KEEP A GAUGE IN YOUR TOOL KIT CH
EC
The nozzle pressure gauge is unarguably the K
most important testing instrument in your whole
kit! Did you know that if your nozzle pressure
drops from 100psi to 90psi, you’ll take 15%
longer to blast anything?
For every 1psi under 100psi, you lose 1.5% of
your production efficiency. Check your system
right through with this pressure testing gauge
and find where the pressure losses are. Test the
pressure at both ends of a long length of hose –
you’ll be amazed to see how much the pressure
can drop!
We recommend getting two pressure test kits,
to test both air pressure into your blast pot,
versus the air pressure out in your blast hose,
simultaneously. It can tell you a story.

CHECK

CHE
CK

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5
BLAST WITH A LOW DUST
ABRASIVE
WHY GMA GARNET WILL WORK BETTER FOR YOU

The largest cause of complaints about blasting

is the DUST. It’s amazing how much difference
blasting with GMA Garnet makes. First of all, let’s
have a look at exactly what it is.
GMA Garnet is a silica-free abrasive made up of
small garnet crystals. Each crystal is heavy, sharp
and hard. When it slams into the steel at 500mph,
it doesn’t smash up and break into tiny pieces like
other abrasives. This makes it very low dusting.
Each small crystal carries tremendous cleaning
energy. You blast faster and cleaner than with
grits twice or three times its size, using half as
DUST CLOUD
much abrasive! from blasting with conventional abrasives

GMA GARNET
GMA Garnet is dense (heavy), and hard so it doesn’t create dust clouds

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6
USE A LIGHTWEIGHT,
COMFORTABLE HELMET
USE THE INDUSTRY LEADING HELMET
THE RPB NOVA 3

An air-fed helmet is designed to protect your life. This helmet has an excellent wide vision,
It should prevent you breathing any dust, protect combined with less weight on the head and neck.
your face from flying particles and offer some By using pillow foam as head support (instead of
hard hat protection. But, wearing a helmet on the old ‘hard hat’ suspension), these are the most
your head for hours, can give you a headache! comfortable and quietest helmets ever used.
Leading blasters are now using the extra You’ll find operators blast for longer and don’t feel
comfortable Nova 3 helmet. so worn out, when they wear RPB Nova air-fed
blast helmets.

STREAMLINED AIR SYSTEM

REPLACEABLE AIR
INLET FITTING
MOULDED HEAD LINER
PADDING
REFLECTIVE AND
HIGHLY VISIBLE
SUPER-PROTECTIVE
HELMET SHELL

DUST SEAL HAND STRAP

COMFORT-FIT SIDE
REMOVABLE VISOR PADDING

LARGE VIEWING WINDOW

RATCHET FIT STRAP

“10 SECOND SWAP”

INNER LENS SYSTEM HEX LOCK
“ALL-IN-ONE” KEY

LARGE GLOVE SIZED LATCH

HELMET HYGIENE
TEAR-OFF LENS SYSTEM

SECURELY ATTACHED CAPE

CLIP-ON CAPE SEAL

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7
ENSURE YOUR COMPRESSOR
IS BIG ENOUGH
HOW MUCH AIR DO YOU NEED TO RUN A
BLAST MACHINE?

The table above shows the amount of air each air-fed helmet PLUS a 50% reserve to allow for
nozzle size needs when the nozzle is new. nozzle wear.
But what happens when the nozzle starts to wear (Example: A new No.7 nozzle needs 312cfm PLUS
a bit? You are going to need more and more air to 20cfm for helmet PLUS 50% reserve of 155cfm:
maintain the same pressure at the nozzle. (i.e. after
Minimum compressor size required = 490cfm).
2-3 weeks).
Many blasters have said – “I could blast a lot
When you buy an air compressor for your blast
faster when my nozzle was new – but now I’ve lost
package, you should allow sufficient volume for the
pressure…”
nozzle (from the table below) plus 20cfm for your

Air consumption (CFM) per blast nozzle using garnet abrasive.

NOZZLE SIZE NOZZLE PRESSURE

50 psi 60 psi 70 psi 80 psi 90 psi 100 psi 120 psi* 140 psi*
No. 2 1/8” 14 17 19 21 24 26 30 34
No. 3 3/16” 32 37 42 47 52 57 67 77
No. 4 1/4” 57 66 75 84 93 103 119 136
No. 5 5/16” 89 103 117 131 145 158 186 214
No. 6 3/8” 129 149 169 189 209 229 269 309
No. 7 7/16” 176 203 230 258 285 312 367 422
No. 8 1/2” 229 265 300 336 371 407 478 549
No. 10 5/8” 356 412 468 524 580 632 744 856
No. 12 3/4” 516 596 676 756 836 916 1076 1236
EFFICIENCY 47% 55% 64% 74% 86% 100% 130% 165%
*Ensure equipment is rated for these pressures.

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8
FIT A LARGE BORE FLEXIBLE
WHIP HOSE
DON’T USE A SMALLER SIZE BLAST HOSE AS A
WHIP HOSE, YOU’LL JUST CHOKE THE SYSTEM UP

You need to be a mighty big man of muscle to This special hose is made of high-quality rubber
continually hang onto some of those blast hoses to maintain life, but with thinner walls to make it
these days. lightweight and flexible. ‘SupaLife’ whip hose has
a large bore, so you don’t lose pressure to the
By ensuring the blast hose is four times the
nozzle.
diameter of the nozzle sure helps keep the
pressure up, but it becomes very hard to Your operator will find it easier to blast, much
continually hold. We recommend you fit a 20ft less tiring on the back and easier to get into
(6m) SupaLife whip hose between your blast tough spots.
hose and nozzle.

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9
SCREW IN A LIGHTWEIGHT,
LONG LIFE BLAST NOZZLE
THE BUSINESS END OF YOUR BLAST HOSE

The blast nozzle at the end of your hose has to

do a lot of work. It takes air and abrasive and
accelerates it to about 500mph.
For the last 20 or so years, we have used tungsten
carbide long venturi nozzles. These work fine
and will normally last around 300 hours but they
are heavy and tend to crack easily if dropped or
hit against the steel. (Many blasters tend to think
nozzles are hammers!)
The superhard ULTRA-TUFF nozzles are made
from new technology silicon nitride and weigh half
that of tungsten nozzles and will last for about 800
hours!
You’ll notice a big difference hanging onto an
ULTRA-TUFF nozzle.

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10
DEADMAN CONTROLS
DOES YOURS ACT FAST ENOUGH?

All blast machines must have remote controls For FASTER and SAFER control, many blasters
(sometimes called dead man controls) which are now fitting:
quickly stop the blasting when the control handle
a. COMBO VALVE
is released. (Many people have been injured in
For single outlet blasters for normal blasting
this Industry from poorly designed or even non-
operations. This is a revolutionary fast-
existent deadman systems.)
depressurization remote control valve that
What have you got fitted onto your blast pot? is safer and trouble-free. It has a very large
Does it start and stop very quickly when you want exhaust port which rapidly shuts down
it to? On some systems the deadman DELAY blasting when you release the deadman
time is around 15-20 seconds before the pot handle.
stops blasting out grit (That seems like about 15
b. THOMPSON VALVE SYSTEM
minutes if you’ve got trouble.)
For spot blasting operations or multiple
Safety is not the only advantage of a FAST remote outlet blasters. This system offers almost
control system. instantaneous on/off by immediately shutting
off the abrasive and air flow, leaving the blast
• It saves you time waiting for shut-down and
pot pressurized. It saves a lot of time and
start-up
money (and by fitting your ‘Thompson Valve’
• It can save you a lot of abrasive with the optional ‘remote abrasive cut-off
• It will save you over-blasting or blasting switch’ installed at the nozzle, you can cut off
inappropriate areas the abrasive and blow down the workplace
with air only at the simple flick of a switch,
anytime)
The Combo Valve and the Thompson Valve
are both fail-safe valves, which automatically
shut off if there is an air supply problem.
Very important feature on a blast pot! If you
are working over 100 feet away from your
blast machine, you should seriously consider
installing 12-volt electric remote controls to
reduce the distance delay time.

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11
LET’S LOOK AT YOUR
BLAST POT
DOES YOUR POT HAVE ANY RESTRICTIONS?

The heart of your blasting system is your blast DOES IT HAVE AN ERGONOMIC DESIGN AND
pot. You should carefully consider the following COMFORTABLE LOADING HEIGHT?
points because a lot of blast pots that have When you want to shift your blast pot around, you
been sold have been poorly engineered and can sure don’t want to end up with it on top of you or
cost you more money to run. How a blast pot is end up in the hospital with back problems. Well
manufactured can affect your profitability. engineered pots are designed to balance on their
wheels to aid movement. They also should be the
HAS IT GOT UNRESTRICTED PIPING? right height to load comfortably.
OK, so we now have air delivered into the pot
In this leading design, the pot doesn’t put any
with 2-inch bull hose and the air abrasive
weight on its wheels when being used. The
mixture goes out in a 1-¼ blast hose. But what
wheels only touch the ground when it is tilted
size pipe fittings have you got on your blast pot?
slightly.
Do you choke your air supply by trying to make
it go through ¾ or 1-inch fittings or pipes? A
good blast pot has large bore pipe fittings with a
minimum of elbows and bends.
Get a needle pressure gauge and compare
the air pressure just before the pot and then
just after. You should have a maximum of 3 psi
pressure drop across the pot.
Warning: Some manufacturers’ blast pots come
new with a 10 psi drop because of complicated
pipe and valve configurations.
** Remember, 1 psi = 1.5% performance drop
*** This 10 psi drop is immediately making your
blasting efficiency drop by 15%!
(eg: If you could blast at 300 ft²/hr at 100 psi,
your production would drop to 250 ft²/hr at 90 psi.)
Fit valves and pipework that do not restrict the LOW RESTRICTION POT
makes a faster blaster
air flow.

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12
KEEP YOUR COOL WITH
A HELMET AIR COOLER
DO ALL YOUR BLASTERS HAVE THEIR OWN
AIR-CONDITIONER?

Air compressors dramatically heat the air upon

compression. Nice warm air coming into your
blast helmet on a chilly cold morning may be
very comfortable.
However, during hot months, warm to hot
breathing air in your blast helmet is very
uncomfortable and greatly reduces your ability to
work efficiently.
A Helmet Air Cooler (normally worn on the belt)
can be placed in the airline immediately before
the helmet and is engineered to reduce the
temperature of the incoming air by up to 30°C
(50°F).
A small feature with big benefits.

RPB C40 CLIMATE CONTROL DEVICE

Work in comfort year round

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13
WIND UP YOUR
PRESSURE
YOU WILL BE SURPRISED AT THE INCREASE
IN PRODUCTION

What if you now take our standard, time-tested RULE OF THUMB

level of 100 psi blasting and increase it to 125 psi? 1 psi = 1.5% Blasting Efficiency
What will it do to our blasting speed? You may
increase your efficiency by 38%! Important: Before increasing the pressure in your blasting
system, ensure all equipment – compressor, blast pot, hoses
What does this 38% mean? It means that you can and fittings are pressure rated to the working pressure
blast a lot more in four days than you used to do required. Operators may need additional training to move the
in five days! Or, it’s like having a second blaster nozzle faster and hold the hose in such a way to minimize
back thrust effect.
two days a week for free! It also means that you
can make a lot more profit.

APPROXIMATE BLASTING SPEED AT ELEVATED PRESSURES

m² per hour

100 psi 110 psi 120 psi 130 psi

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14
MONITOR AND PURIFY
YOUR BREATHING AIR
MANY BLASTERS USE DIESEL AIR COMPRESSORS
TO SUPPLY BLASTING AND BREATHING AIR TO THE
AIR-FED HELMET

Many blasters use diesel air compressors to purification system will remove oils, water,
supply blasting and breathing air to the air-fed particles, tastes, odors and toxic gases from the
helmet. breathing air.
That same air compressor that is sucking air for Not only will it be safer for your blasters, but it’ll
breathing is pumping out carbon monoxide in also keep OSHA very happy!
large volumes from the diesel engine exhaust.
If the carbon monoxide is drawn back into the air
intake of the compressor, you can poison your
blaster (You can also poison your blaster if the
compressor overheats. Overheated compressor
oil can produce carbon monoxide gas. Carbon
monoxide is an odorless, deadly gas).
Now, OSHA’s Standard 1910.134 (i) (7) requires us
to do something about this...
“For oil-lubricated compressors, the employer
shall use a high-temperature or carbon monoxide
alarm, or both, to monitor carbon monoxide
levels.
If only high-temperature alarms are used, the air
supply shall be monitored at intervals sufficient
to prevent carbon monoxide in the breathing air
from exceeding 10ppm.”
For safety’s sake, we recommend the installation
of a carbon monoxide alarm and purification
system. RPB GX4 GAS MONITOR
Monitor up to 4 gases simultaneously
These systems will continuously monitor the
breathing air for carbon monoxide while the

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15
USE A COMMUNICATION
SYSTEM
A GOOD COMMUNICATION SYSTEM CAN IMPROVE
NOT ONLY EFFICIENCY BUT ALSO SAFETY

When we are blasting or painting, whether it be

on a site, in a blasting yard or in a blast room,
having a “pot attendant or spotter” to fill, adjust
and control the machine means actual time spent
blasting or spraying is increased. The problem
is that on a site where there are many workers
but communication between the site personnel
is poor, we may never actually realise our full
productive potential.
Communication difficulties on blasting and
painting sites are nothing new. Many blasters
carry a hammer in their pocket and hit it on the
steel (or hit the nozzle on the steel!) to give you a
message (i.e. 1 hit = more abrasive, 2 hits = less
abrasive, 3 hits = turn the machine off!). This can
be very inaccurate.
Using a communication system is a much safer
and quicker way to work. There are many types of
communication systems available.
The RPB Nova Talk communication system can
be integrated into your Nova helmet and attach
to your existing radio which means workers can
communicate effectively.

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16
RECYCLE YOUR
ABRASIVE
USE YOUR ABRASIVE OVER AND
OVER AGAIN
What do you do with all that spent abrasive at the
end of the day? Do you go and dump it and go to
buy some more?
Why not try recycling? If you are using a
recyclable abrasive such as GMA Garnet, you
could save thousands of dollars each month.
To recycle your GMA Garnet, you must remove
all rubbish, stones, paint flakes, dust and fine
particles from it and you then have “like new
garnet.”
Special recycling machines have been developed
which simply and efficiently recycle GMA Garnet.
Put your dirty GMA Garnet on one side and
cleaned GMA Garnet comes out the other!
High-performance vacuum systems are also
useful to remove spent GMA Garnet from tanks
and confined spaces etc. and convey it to your
recycling station.

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TECHNICAL DATA

AIR CONSUMPTION (CFM) PER BLAST NOZZLE USING GARNET ABRASIVE

NOZZLE SIZE NOZZLE PRESSURE
50 psi 60 psi 70 psi 80 psi 90 psi 100 psi 120 psi* 140 psi*
No. 2 1/8” 14 17 19 21 24 26 30 34
No. 3 3/16” 32 37 42 47 52 57 67 77
No. 4 1/4” 57 66 75 84 93 103 119 136
No. 5 5/16” 89 103 117 131 145 158 186 214
No. 6 3/8” 129 149 169 189 209 229 269 309
No. 7 7/16” 176 203 230 258 285 312 367 422
No. 8 1/2” 229 265 300 336 371 407 478 549
No. 10 5/8” 356 412 468 524 580 632 744 856
No. 12 3/4” 516 596 676 756 836 916 1076 1236
EFFICIENCY 47% 55% 64% 74% 86% 100% 130% 165%
* Ensure equipment is rated for these pressures

NOZZLE PRESSURE VS EFFICIENCY

BLAST NOZZLE PRESSURE APPROXIMATE ABRASIVE VELOCITY APPROXIMATE EFFICIENCY FACTOR
100 psi 425 mph 100%
95 psi 400 mph 93%
90 psi 365 mph 86%
85 psi 330 mph 80%
80 psi 270 mph 74%
75 psi 200 mph 69%
70 psi 185 mph 64%

HOSE SELECTION GUIDE FOR BLASTING AT 100 PSI NOZZLE PRESSURE

NOZZLE NUMBER NO. 4 NO. 5 NO. 6 NO. 7 NO. 8
Nozzle Size ¼” (6mm) (8mm) ⅜” (10mm) ” (11mm) ½” (13mm)
CFM at 100 psi 103 158 229 312 407
Air Hose ID – minimum 1” (25mm) 1 ½” (38mm) 1 ½” (38mm) 2” (50mm) 2” (50mm)
Blast Hose ID – minimum ¾” (20mm) 1” (25mm) 1 ¼” (32mm) 1 ¼” (32mm) 1 ½” (38mm)

18 [email protected] 1800 190 190

TYPICAL ID – OD RELATIONSHIP IN COMMON BLAST HOSE
STANDARD HOSE SUPALIFE WHIP HOSE

ID OD ID OD
mm inch mm inch mm inch mm inch

13 ½” 33 1 13 ½” 30 1

19 ¾” 40 1 ½” 19 ¾” 33 1

25 1 48 1 ⅞” 25 1 40 1 ½”

32 1 ¼” 55 1 32 1 ¼” 48 1 ⅞”

38 1 ½” 60 2 ⅜” 38 1 ½” 55 2

ENGLISH USA UNITS/METRIC CONVERSION CHART

INCH MM INCH MM

5mm 1 ¼” 32mm

¼” 6mm 1 33mm

8mm 1½” 38mm

⅜” 10mm 1 40mm

11mm 1 ¾” 44mm

½” 13mm 1 ⅞” 48mm

⅝” 16mm 2” 51mm

¾” 19mm 2 55mm

1” 25mm 2 ⅜” 60mm

1 30mm 2 ½” 64mm

DISCLAIMER: The performance characteristics provided in this brochure only serves as a guide and that the results can vary widely on every project. Let BlastOne
assist you on using the right abrasive and the right equipment for every project.
While care has been taken in compiling these notes, no responsibility is accepted by the compiler for any damage or loss, caused to anyone or any company accepting
the advice or suggestion contained herein. It is your responsibility to be aware of regulations which Local, State, or Federal Government authority may impose.

©Copyright BlastOne 2017. All rights reserved.

The entire contents of this booklet are copyright. Photocopying, scanning, duplications or copying of pictures or information (except as permitted under the Copyright
Act) is a breach of copyright and may result in legal action.
No part of this booklet may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior
written permission of BlastOne.

www.blastone.com 19
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