Train the Inspector: Abrasive Blast Cleaning

Introduction

© Copyright 2016 Fitz-Coatings Ltd

 General Overview

Objective:
The objective of this training unit is to gain an understanding in the many applications of abrasive blast
cleaning and the various uses of preparation. Also to appreciate the role of the abrasive blast cleaning
operator for industrial applications.

Abrasive blast cleaning is one of the most effective methods of surface preparation used for cleaning
surfaces prior to application of industrial coatings.

Abrasive Blast Cleaning

Abrasive blast cleaning is a method of surface preparation that

has been used for well over 100 years.

The basic principle of abrasive blast cleaning has remained

unchanged since the initial concept.

The abrasive blast cleaning process can be used in numerous

applications.

Abrasive Blast cleaning is widely used in shipyards, fabrication

and construction industry and maintenance such as bridges etc.

Surface Preparation

Abrasive Blast Cleaning is the most popular and economical

(productive) method of preparation for removing rust, millscale,
scale and old coatings.

Abrasive blast cleaning is a superior method of surface

preparation compared to mechanical forms of surface preparation
such as wire brush, needle gun etc.

There is no better method of surface preparation where a high

level of surface preparation is required.

Abrasive Blast Cleaning

This video demonstrates the use of abrasive blast cleaning in a

purpose made abrasive blast chamber.

Metallic abrasives are use in the blast chamber, as this abrasive

can be recycled.

You will be able to see the speed of coatings removal down to a

bright cleaned substrate.

Abrasive Blast Cleaning on Site

This video demonstrates the use of abrasive blast cleaning on a

typical construction site.

Abrasives are generally the 'use once-expendable' type as it is

difficult to collect the spent abrasives from temporary locations
such as scaffolding.
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 It is difficult to keep the abrasives dry which makes recycling
abrasives virtually impossible in many environments and
locations.

This process is however always under review due to the high

disposal costs.

Spent abrasives can be classified as hazardous material,

depending upon the substrate coating being removed.

Note: If the environment can be kept dry then the use of recycled
abrasives (such as chilled iron grit) is more economical than
expandable abrasives.

Hand Wire Brushing

This video demonstrates the use of a hand held wire brush being
used as a method of surface preparation.

The process is labour intensive and does not allow a good surface
for coating application with regards to service life.

A polished substrate is also a potential problem with mechanical

wire brushing and not a good base for coatings.

Certain coatings have been specifically developed for such

substrates, however always check with the coating supplier for
technical advice.

Abrasive blast cleaning as a method of surface preparation

can extend the life of a coating considerably compared to
hand wire brush preparation.

Mechanical Preparation

Mechanical preparation methods such as needle gunning, disking,

wire brushing and abrading are used for surface preparation.

The life expectancy of a coating is, however, reduced

considerably with this method of surface preparation, compared to
abrasive blast cleaning.

There will also be a higher level of labour required for this process
as they are relatively slow.

Abrasive Blast Cleaning - Shot

This animation demonstrates the use of abrasive blast cleaning

with the use of shot as the abrasive.

Shot will give a low surface profile and is often used within
automatic equipment such as wheelabrators etc.

The use of coarse chilled iron grit for example, would wear the
equipment out very fast.

The shot abrasive will break down and 'topping up' with new shot
abrasive should be conducted on a regular basis.

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 Abrasive (shot)
This is a close up picture of shot abrasive. The shot is generally a
metallic abrasive and used in automated equipment such as
wheelabrators and tumble blast equipment.

The shot abrasive gives a smaller surface profile than grit and
breaks up during the blasting process.

Some forms of equipment use a mixture of shot and grit to

achieve the desired surface profile.

Abrasive Blast Cleaning - Grit

This animation demonstrates the use of abrasive blast cleaning

with grit abrasive.

Grit will give a larger surface profile than shot and is used for
most mobile operations.

Grit is generally specified for most industrial abrasive blast

cleaning contracts.

The grit size can be varied to achieve a specific surface profile.

Always check the surface profile requirements in the coating

specification and product data sheets.

Grit (abrasive)
This is a close-up view of grit abrasive. The abrasive has various
edges and angles which impacts the surface removing coatings,
rust, scale, etc leaving a roughened surface finish (profile).

The surface profile may be important for certain coatings,

especially high build coatings and thermal metal spray.

Various sizes of abrasive are available.

Galvanised Surfaces

Galvanised surfaces are generally painted to extend the life of the

galvanising and offer a colour or decorative finish to the zinc
coated structure.

Abrasive blast cleaning can be used to 'etch' or 'key' the surface

ready for paint application.

Low pressures should be used to ensure the galvanising is not

removed from the steel surface it is protecting.

It can sometimes be quite difficult to get paint to adhere to a

galvanised substrate and some form of preparation is usually
required.

A test piece is always recommended.

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 Flash Blasting

This animation demonstrates the use of abrasive blast cleaning

lightly over the surface to achieve a key.

The process is commonly used on galvanised surfaces which are

to be over-painted.

Usually a soft abrasive is used otherwise there is a danger of

removing the zinc coating from the underlying surface.

Low pressures are also recommended during the flash blasting

operation.

Reference Documents: SSPC-SP 7/NACE NO. 4, Brush-off blast

cleaning

Concrete Surfaces

Abrasive blast cleaning can be used on concrete surfaces to

remove laitance which is a weak surface found on the surface of
the concrete.

The abrasive blast cleaning provides a 'key' for paint application.

The abrasive blast cleaning also exposes blowholes etc. often

found on concrete surfaces.

A test piece is always recommended to see the quality of surface

finish and the extent of exposed blowholes etc.

Concrete Surface

This animation gives a close up side view of a typical concrete

surface.

The concrete surface is generally porous and therefore difficult to

paint.

Pinholes in the coating applied over concrete are common.

There is always a danger of exposing a rough surface on the

concrete after abrasive blast cleaning.

As always, a test piece is strongly recommended.

Concrete Surface -Preparation

This animation demonstrates one of the methods used as surface

preparation technique on concrete.

Light abrasive blast cleaning will open all the fine holes in the
concrete.

Automated blast machine are often used on concrete floors.

These machines used metallic shot which is recycled within the
body the machine.

Floor coatings, including non slip etc. are often applied to the
concrete floors after the blast cleaning has been conducted.

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 Stainless and Exotic Metals

In certain environments stainless steels and other exotic metals

are coated.

Abrasive blast cleaning can be used to 'key' the surface of the

stainless steel and other similar metals.

Specialised non-metallic abrasives are used for this process.

The stainless steel has a very hard tenacious substrate and

achieving any surface profile is very difficult.

Types of Abrasive Medium

There are a number of abrasives used to suit the requirements of

the process:

Metallic abrasives such as grit and shot.

Expendable abrasives such as copper slag.
Natural abrasives such as walnut shells.
Glass which is a recycled product.
Specialised products such as sponge, egg shell, nuts etc.

Garnet is also popular and can be recycled a number of times.

Metallic Abrasive Blast Cleaning

This video demonstrates the use of metallic abrasive being used

in the abrasive blast cleaning process.

The abrasive blast cleaning assistant is refilling the blast unit with
fresh abrasive.

The use of metallic abrasive has a number of advantages, one

being that the abrasive can be recycled.

Metallic abrasives have an increased role in site blasting due to

improved containment etc

Dry Ice Abrasive Blast Cleaning Process

This animation demonstrates the use of dry ice to remove grime

and debris from a coating.

The existing coating should remain in place during this operation.

Overpainting can then be conducted.

The process has limited market use for industrial coatings but
popular where there may be a risk with the use of abrasives
around machinery and moving parts.

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 Abrasive Blast Cleaning Process

The abrasive blast cleaning process is used for different surfaces

such as:

Corrosion and coating removal from steel surfaces.

Abrading surfaces such as stainless steel, concrete,
galvanizing and exotic metals.

Portable equipment such as abrasive blast pots and compressors

make abrasive blast cleaning a mobile process so its use is
possible in most locations providing you take all Health, Safety
and Environmental precautions.

Wet Abrasive Blast Cleaning

Abrasive blast cleaning can be used in conjunction with water.

The process creates considerably less dust than dry abrasive

blast cleaning and is gaining popularity.

Coating manufacturers have, or are developing coatings, for damp

surfaces.

This process will continue to grow in popularity due to

environmental issues with dusts etc.

You will, however have to assess the possible waste water

issues.

Wet Abrasive Blast Cleaning

This video simply demonstrates the use of abrasive blast cleaning

with the use of water.

Wet abrasive blast cleaning has a number of advantages including

reducing dusts etc.

The process is used extensively in the marine industry where

paints and coatings have been developed for damp or gingered
(oxidized) surfaces.

The level of oxidation has to be agreed in advance of the coating

application.

General Overview - Abrasive Blast Cleaning

The process consists of:

Having the correct equipment such as abrasive blast units

and associated equipment.
Use of labour, both direct such as abrasive blast cleaners
and indirect such as cleaners etc.
Power from compressed air.
Location of work such as abrasive blast chamber or site
works such as a ship, rig or bridges etc.

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 Abrasive Blast Cleaning Equipment

This diagram illustrates the equipment necessary to operate an

abrasive blast unit.

The process is relatively simple with the air compressor and

abrasive blast unit being the two main items.

Associated items, hoses and PPE and RPE are also essential.

The equipment can easily be containerised and shipped anywhere

around the globe.Training of local labour would be necessary due
to the skill required and Health and Safety requirements.

Direct Pressure Blast Units

A range of direct pressure units are available to suit the

requirements of the project.

The abrasive blast pot size can vary, as illustrated.

All direct pressure units are operated by an abrasive blast

cleaning operator and, in most cases, an abrasive blast cleaning
assistant commonly known as the pot man.

All abrasive blast cleaning equipment is pressurised and pressure

testing must be conducted and certificated to a specific pressure
prior to use. This process is usually conducted annually.

Portable Blast Unit

An example of a portable blast unit that is used for flat surfaces.

The abrasive, which is usually metallic shot, is recycled within the

body of the equipment.

Labour is still necessary to operate the equipment, however it is

more economical than the open type blast cleaning process as
containment would be required along with the collection of the
spent abrasive.

These portable blast units are commonly used for concrete floors
which are also to be coated.

Portable Blast Unit

The equipment is well suited for flat surfaces such as ship decks
and large flat floors etc.

The abrasive is recycled and the spent abrasive, debris etc. is

separated and vacuumed away down a disposal tube.

No spent abrasive is exposed to the atmosphere.

Power is still required for the equipment along with a trained

operative to work with the equipment.

Portable Abrasive Blast Unit

This video demonstrates the use of a portable abrasive blast unit

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 on a flat steel plated structure.

The process is ideal for flat surfaces such as decks.

The abrasive is recycled within the machine and should not

exposed to the atmosphere.

The process is a dust free process and safe to use around other
trades.

The equipment should make the process economical also.

Vertical Blast Cleaning

Vertical blast cleaning is similar to portable blast units, however

the process is used for vertical locations such as; tank walls,
sides of ships etc.

No spent grit or dust is exposed to the atmosphere.

The process is very economical, however a crane is usually

required, as illustrated.

Some areas will still require some form of open blasting or other
preparation method, as this equipment will not reach to all areas
such as close to edges and openings.

Vertical Blast Unit

Vertical Blast units usually use metallic abrasives which are

recycled within the body of the equipment.

Vertical Blast Units can give high productivity rates which makes
them economical for large flat areas.

High standards of blast cleaning can be achieved with this type of

equipment.

There will be a large capital cost for equipment, however some

equipment can be hired from specialized organizations.

Vacuum Blast Unit

A vacuum blast unit is a semi-automatic form of equipment.

Metallic abrasives are used and recycled with the blast unit.

This type of equipment is only generally used for small areas or

localised repairs.

The process is, however, slow compared to other forms of

abrasive blast cleaning equipment.

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 Wheelabrator

A "Wheelabrator"™ is abrasive blast cleaning equipment which

uses centrifugal blast wheels to project grit or shot onto a surface
as it passes through the equipment.

The process is ideal for flat plates, structural steel members,

pipes etc.

A wheelabrator is typically a factory process and generally used in

paint shops and fabrication facilities, however mobile site
equipment is available for large contracts.

Abrasive Blast Cleaning - Pipe Mill

This video demonstrates the use of an automatic abrasive blast

cleaning unit - wheelabrator.

A pipe section has been abrasive blast cleaned to a high standard

ready for coating application.

There will be a large capital cost for this type of equipment.

Large size units are also available for large bore pipe work, steel
plates, etc.

The equipment is capable of running 24/7, excluding maintenance

time, and can therefore blast clean large volumes of steel ready
for coating application.

Automated Blast Cabinets

Automated blast cabinets are used for abrasive blast cleaning

such as engineering parts.

The equipment is generally designed to meet the customer

requirements such as the shape and size of the items to be
abrasive blast cleaned.

The equipment is generally a factory installed unit and used for

small items.

Automated Tumble Blast Cabinet

Items are placed in a rotating basket inside the tumble blast

cabinet.

Abrasive blast cleaning is conducted with the use of jet nozzles.

The tumble blast cabinet is simply loaded and the abrasive blast
cleaning process is automatic.

An operator is needed to load and unload the cabinet with the

items to be prepared.

There is a risk of damage to steel items during the use of the

tumble blast if the steel items are not robust enough.

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 Specialist Blast Equipment

Specialised blast equipment and associated equipment are

available for a variety of situations.

Examples include internal pipe cleaning, as illustrated. Various

tools are available to suit the pipe diameters.

Internal spray equipment is also available to coat the prepared

surfaces.

Other bespoke items of equipment are also available.

Abrasive Blast Cleaning - Spin Blast

This video demonstrates the use of abrasive blast cleaning

equipment being used to clean the inside surface of a pipe.

Various sizes are available to suit the task and diameter, etc.

Cameras can be used to inspect the surface preparation if visual

inspection can not be easily conducted.

Life Expectancy

If maintenance painting was conducted to steelwork in a hostile

environment, such as an offshore platform (splash zone), the life
expectancy can be as little as 1-2 years using mechanical tool
preparation techniques.

If abrasive blast cleaning was chosen as the method of surface

preparation, an 8-10 year life can be expected providing a good
coating system was suitably applied.

Summary
This training unit is a overall review of abrasive blast cleaning and
the wide spread use of the abrasive blast cleaning process and
the different forms of equipment and types of equipment etc.

The remaining training units for abrasive blast cleaning will go into
much more detail on specific areas of the abrasive blast cleaning
process.

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 Basic Corrosion

Objective:
The objective to this training unit is to gain a basic understanding of the corrosion process relating to steel
structures. Also gain an appreciation of how corrosion can be controlled by abrasive blast cleaning and
coating application. Some basic chemistry will be used.

In every form of life where steel is used, you will generally see evidence of corrosion, which is more
evident when little maintenance is conducted

Basic Corrosion

In dictionary terms, corrosion is defined as 'wearing away or

gradual destruction from the surface inwards'.

The word corrosion, in fact originates from the Latin 'corrodere' - to

gnaw away.

Corrosion is all around us. You won't have to look far to find some
rusty steel.

The rust will be at various levels due to location and protection

from the environment i.e. paint.

The closer the marine environment, the more the rust or corrosion
due to the salt laden environment.

A Single Piece of Metal

This animation demonstrates a single piece of metal showing the

anodic and cathodic sites.

Corrosion occurs at the anodic sites. Therefore if we made the

steel all cathodic, we could stop corrosion.

If you were to magnify a piece of steel you may find thousands of

anodic and cathodic sites.

It is however, unusual to find them uniform as various factors

such as contaminants will cause different types of corrosion rates
on a single piece of metal.

Corrosion Process

This animation demonstrates how corrosion can be accelerated in

general:

Higher humidity - increases corrosion rates

Higher temperature -increases corrosion rates
Higher pollution - increases corrosion rates

It is clear from the above that there is more corrosion near

chemical plants and marine environments.

Corrosion of Iron and Steel

Corrosion is an electrochemical process that occurs in stages,

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 primarily on the surface:

Ferrous ions go into solution at anodic sites.

Electrons are released from the anodic sites and pass
through the metal to the cathodic sites.

This illustration demonstrates the anodic and cathodic sites.

Corrosion of Iron and Steel

Corrosion is an electrochemical process that occurs in stages,

primarily on the surface:

Combine with water and oxygen to form hydroxyl ions.

Ferrous and hydroxyl ions react to form ferrous hydroxide.
Ferrous hydroxyl further oxidises to produce hydrated ferric
oxide. commonly referred too as red rust

Corrosion - General Rules

Moist air is more corrosive than dry air.

Corrosion rates increase with temperature.
Corrosion rate depends on specific species present.
Polluted air is more corrosive than clean air.
Salt water is more corrosive than fresh water.
Corrosion does not occur in a vacuum.

Methods of Corrosion Control

Design - corrosion allowance, etc.

Materials - corrosion resistant materials, etc.
Modification of environment - corrosion inhibitors, etc.
Electrochemical techniques - cathodic protection, etc.
Protective coatings - paint, etc.

This is an illustration of a large vessel which has aluminium

anodes attached to the underwater section to prevent corrosion.

Corrosion Reaction

This illustration demonstrates the combined reaction of rust.

Steel
Oxygen
Water
Rust

Remember this illustration, as removal of the oxygen or water will

result in the elimination of corrosion.

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 Anodic and Cathodic Sites

Close-up view of a corroded steel surface showing anodic and

cathodic sites on a steel surface.

Not all steel surfaces result in uniform corrosion.

There are various forms of corrosion including pitting etc. Some

pitting can result in perforation of the steel leading to leakages of
products.

Corrosion can form in many ways depending upon the storage and
usage of the steel and the location and environment.

Corrosion

Corrosion animation demonstrating the current flow between the

anodic and cathodic sites within an electrolyte.

The electrolyte can be water or soil.

The resistivity will change between the different types of medium

i.e. dry soil will have a different resistivity from damp soil and sea
water will have a different resistivity from fresh water.

Corrosive Environments

Most environments contain oxygen, some of which contain

corrosive contaminants, such as sodium chlorides.

Corrosion is more aggressive in coastal locations due to the salt

laden environment.

Corrosion control is therefore essential in the marine and offshore

environments.

High performance coating systems are often used in marine and

offshore environments to give a long life.

The Electrolyte

The electrolyte is the solution, which is in contact with the metal.

Different electrolytes have different levels of conductivity.

An example of an electrolyte is the sea water around an offshore

platform, as illustrated.

This electrolyte is more conductive than other electrolytes as it

contains chlorides.

The level of chloride salt also varies between different waters

around the globe. Some seas and oceans have very high
concentrations of chloride salts and therefore are very corrosive
environments.

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 The Metallic Path

The corrosion process requires a metallic material that provides a

pathway for the flow of electrons.

Iron and steel provide an ideal metallic path.

A metallic path can be a single structure, such as a bridge,

platform, pipe, etc.

Steel will always be used due to its high strength and cost
compared to other metals.

Corrosion Experiment

For corrosion to occur it is necessary to have the simultaneous

presence of oxygen and water.

If either is removed corrosion will cease.

In this experiment, the steel plates in tubes 1 and 2 do not rust

while the steel plate in tube 3 will corrode.

Understanding this principal will help you understand the corrosion

control process.

Oxygen

Most environments contain oxygen, some of which contain

corrosive contaminants.

Electrolyte

The electrolyte is the solution, which is in contact with the metal.

Different electrolytes have different levels of conductivity.

Metallic Path

The corrosion process requires a metallic path and this can be

supplied on a single piece of steel.

Chlorides

Chlorides are present in marine environments such as coastal and

offshore.

Chlorides can accelerate the corrosion process and should be

removed, whenever possible.

Chlorides can be removed from a surface by fresh ( potable )

water washing.

In certain environments you may need to wash between coats,

also during paint programs to ensure there will be no trapped
salts.

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 Sulphates

The burning of fossil fuels, such as coal or oil produces sulphur

dioxide.

The sulphur dioxide then combines with water in the atmosphere

to form sulphurous and sulphuric acids.

These acids increase corrosion rates.

There are many industrial locations around the globe where you
will find high levels of sulphates.

Corrosion

The driving force that causes metals to corrode is a natural

consequence of their temporary existence in metallic form.

To reach this metallic state it is necessary for them to absorb

energy.

Different materials absorb energy in different amounts.

The more the energy the more the reactivity of the steel.

Magnesium and potassium for example are very reactive and top
the galvanic series.

General Galvanic Series

The galvanic series is a table used to demonstrate the reactivity

of different metals.

When two metals are in contact with each other, the more reactive
metal will corrode in preference to the less reactive metal.

Aluminium will therefore corrode in preference to iron when the two

are connected.

The galvanic series is important when considering design with

different materials.

Thermal Coatings

If two metals are in contact, the metal which requires the most
energy will corrode first.

For this reason, aluminium is used for corrosion protection on

steel surfaces as aluminium is more reactive than steel.

Aluminium is used in thermal spray coatings on steel for corrosion

protection as demonstrated in this picture of arc spray thermal
metal coating. Aluminium anodes use the same principal in
cathodic protection.

Zinc in the galvanized process also uses the same principal.

Thermal Metal Spray

This video demonstrates the use of thermal spray to apply

aluminium wire onto a prepared steel structure.

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 The aluminium will offer the corrosion protection.

The metal coating can be overpainted for additional protection and

aesthetic properties.

The use and benefits of painting over metal spray, the number of
coats and thickness is under constant discussion and
specifications vary widely.

Thermal Spray Application

This animation demonstrates the use of a thermal spray gun to

apply a melted wire onto a prepared steel surface.

The wire, which is supplied in coil form, is fed into the gun and
mixed with gas and air which melts the wire before being thrown
onto the surface.

The application of metals such as aluminium with suitable sealers

have been very successful on high temperature structures such
as flarebooms and other high temperature surfaces.

Anodes

Aluminium and zinc anodes are used for galvanic corrosion

protection.

Anodes are attached to steel surfaces on buried or immersed

surfaces such as oil rig legs, jackets and pipelines.

The more reactive metal (aluminium) will corrode in preference to

underlying steel substrate.

Anodes are available in various shapes and sizes to suit the

structure and location.

These anodes should never be over painted!

Galvanic Series

More examples of the use of the galvanic series.

When mixing two dissimilar metals it is important to get the

correct ratio.

The steel is the anode, however it is used in a bigger surface

area so corrosion will be slow.

Always consider the galvanic series when mixing different metals.

Galvanic Series

This diagram represents how we can see rapid corrosion by using

two different metals with the incorrect mix ratio.

The steel is the anode and will corrode first and rapid corrosion
will happen due to the size ratio.

Severe galvanic corrosion could occur when the design does not
consider the implications of the galvanic series.

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 Surface Preparation and Coating Application

Coatings applied to cleaned steel act as physical barriers and will

reduce atmospheric attack, moisture penetration etc.

Anti-corrosive layers such as zinc primers act sacrificially and will

'corrode' in preference to the steel substrate. High build coatings
will slow down the passage of moisture and general contaminants.

Correctly specified and applied coatings have a tremendous track

record in combating corrosion on an economical basis.

It is imperative to ensure the coating specification is written

correctly.

Abrasive Blast Cleaning Steelwork

The role of the abrasive blast cleaning operator can not be

overlooked.

It is important that they understand the basic corrosion process

along with the general requirements of the task.

The abrasive blast cleaning operative does not need to

understand the chemical reaction of corrosion, only that correctly
cleaned surfaces with suitable coatings applied can give long life
and predicted performance.

Summary
This training unit reviewed the corrosion process and gave an
overview of how complex corrosion can be when discussing the
chemistry.

The unit discussed how corrosion occurs and the various

environments and how the corrosion process can be slowed down
or stopped when using coatings and cathodic protection.

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 Mill Scale

Objective:
The objective to this training unit is to gain a basic understanding of how mill scale is formed and the
importance of its removal during abrasive blast cleaning.

The abrasive blast cleaning operator will undoubtedly see mill scale during their duties.
The most effective method to mechanically remove mill scale is with abrasive blast cleaning.

Mill Scale

Structural steel is hot rolled.

As the steel leaves the last rolling section, the temperature on the
surface is approx. 1200°C. (2200o F)

As the steel cools, it reacts with oxygen to produce millscale.

This is an illustration of intact new mill scale.

The mill scale is typically blue in colour from new, then turns
black over time.

Steel Manufacture
Steel is composed of iron and carbon. The iron is extracted from
iron ores, mined and then refined.

Part of the refining process is to remove oxygen from these ores

by heating them with coke and limestone to a temperature of
about 1600°C (2900o F) in a blast furnace.

There are two types of metals, ferrous and non-ferrous. Ferrous

comes from, or contains iron, while Non-Ferrous does not contain
iron.

Examples of non-ferrous metals would be copper, aluminum,

magnesium, titanium, etc.

Mill Scale
Typically the production of the steel plates is followed by storage
and ultimate delivery to the fabricator. The steel will initially have
tight mill scale attached, however this scale will fall away from the
surface.

Some steel plates can be stored for many months and some in
corrosive (salt laden) environment.

The mill scale will not break away evenly and you may get some
pitting in areas and tight mill scale in others.

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 Mill Scale

The thickness of the mill scale is dependent upon the steel

section.

Lighter shapes of structural steel have thin scale while heavy

steel sections can have as much as 250 microns (10 mil) of mill
scale attached.

Mill scale is not a protection for the underlying surface and will
begin to fall away from a substrate.

The adhesion of the mill scale will vary depending upon thickness,
location and age.

Mill Scale

Mill scale is a complex oxide which is unstable and needs to be

removed.

As the steel is exposed to the atmosphere, water penetrates the

scale, the mill scale then loses adhesion and falls away from the
substrate.

Anything attached to the scale will also fall away from the
surface, this will include any coatings applied to the mill scale.

Mill Scale

Mill scale that is formed on steel is not uniform.

There are also a number of layers.

The scale is complex and has different levels of oxygen.

The colour of mill scale can vary over a small area as illustrated.

Mill Scale

Mill scale is generally brittle.

Mill scale has a lower thermal expansion than steel and cracks on
cooling

The cracks allow the moisture and oxygen to penetrate the scale.

This illustration demonstrates the different levels within the scale

and the amount of oxygen in each layer.

Mill Scale and Temperature Changes

This animation demonstrates how mill scale cracks as it has a

lower thermal expansion than steel.

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 As the temperature changes the scale breaks away from the
surface over time.

This can be a slow process over many months or even years,

depending upon the location.

Pitting of the underlying substrate may be found as the scale falls

away from the surface.

Mill Scale

Mill scale is cathodic and the steel anodic.

As previously discussed, if the steel was stored for a period of

time, especially in marine or corrosive environments, you may
find pitting underneath the mill scale.

This is an illustration of a pitted substrate underneath a scaled

surface.

This pitting can be very dangerous in corrosion terms and may

even cause penetration of the steel surface.

Mill Scale

Illustration

Virtually intact mill scale.

Found on new steelwork.
Very difficult to remove.

Abrasive blast cleaning is generally the only option available for

removal of the mill scale, certainly for site use. The new mill scale
can have good initial adhesion and extremely difficult to remove.

Mechanical wire brush will certainly not remove scale of this

nature.

Mill Scale

Untreated mill scale after 12 months exposure.

The condition will vary, depending upon the location of the
steel.
The scale is beginning to crack and fall away from the
surface and staining will become evident, especially in damp
or wet and corrosive environments.

© Copyright 2016 Fitz-Coatings Ltd Page 20

 Mill Scale

Untreated mill scale after 36 months exposure.

The condition of the steel will vary depending upon the
location of the steel ie if the steel is stored in a corrosive
environment the steel condition may be a lot worse.
It is unlikely you will find this form of uniform corrosion unless
it is stored indoors etc.
Pitting may also be found behind the layer of rust.

Mill Scale

Untreated mill scale after 8 years exposure.

Metal loss and pitting of the steel may be possible.
The condition could be considerably worse in corrosive
environments such as coastal or marine locations.
Chipping or needle gunning may be required to expose the
steel before any general preparation is conducted.

Abrasive Blast Cleaning

It is widely recognised that the best method of mill scale removal

is to abrasive blast clean.

Abrasive blast cleaning will remove mill scale at all levels.

The harder the scale the longer the abrasive blast cleaning will
take.

Acid cleaning is sometimes conducted for certain factory uses,

such as pre-galvanizing.

Abrasive Blast Cleaning

This video demonstrates the use of abrasive blast cleaning with
the use of chilled iron abrasive to remove mill scale on a new
steel structure.

Abrasive blast cleaning is the most effective and efficient method

of scale removal.

The video illustrates the speed of the abrasives and pressures

used in the blast cleaning process.

© Copyright 2016 Fitz-Coatings Ltd Page 21

 Coating system

Applying coatings directly over mill scale is a short term solution.

Both the mill scale and the applied coatings will lose adhesion and
flake away from the substrate.

This illustration demonstrates a protective coating (yellow) applied

over mill scale (black).

No surface preparation had been conducted on the mill scale

before the paint was applied therefore coating failure was
inevitable.

Mill Scale under a Coating

This animation demonstrates the outcome if a paint is applied

over a surface which has mill scale still attached.

The mill scale will eventually break away from the underlying
surface bringing the paint with it.

Generally the most economical option for the construction

industry is to remove the scale during steel manufacturing and
apply a primer coat which can be removed or abraded and over
coated at a later date.

Note: A simple test for telling whether steel surface residues of

mill scale (or rust and paint) are tightly adhering or loose is with a
dull putty knife. If the material (Mill Scale, Rust, or Old Coating)
CAN NOT be removed with a dull putty knife then the material is
considered tightly adheared.

Mechanical Preparation

Mechanical preparation such as disking or wire brushing will not

remove mill scale.

Loose flaking can be removed, although some areas will be tight

and intact.

Abrasive blast cleaning is the best and most economical method

of scale removal.

The age of the scale will generally dictate the removal speed and
rate.

Mill Scale Detection - Test Method

To test for mill scale you require a solution of 4% anhydrous
copper sulphate in 1% sulphuric acid with a few drops of wetting
agent and applied to the steel surface suspected of having mill
scale.

Copper will be deposited on areas free from mill scale and any
remaining patches of mill scale will appear as darker areas
against the copper background.

Extreme care must be taken with this test utilizing the correct
PPE and RPE by experienced and qualified personnel.

© Copyright 2016 Fitz-Coatings Ltd Page 22

 Summary
This training unit reviewed the production of steel and how mill
scale is formed and eventually breaks away from a surface.

We also discussed the problems with leaving mill sale on the

surface or over painting the mill scale.

We also discussed the various options for mill scale removal.

© Copyright 2016 Fitz-Coatings Ltd Page 23

 Substrate Materials

Objective:
The objective of this training unit is to gain an understanding of the various substrates that may require
abrasive blast cleaning in some form or another.

The abrasive blast cleaning operator may encounter a number of substrates that require abrasive blast
cleaning as a method of surface preparation.

Substrate Materials

The abrasive blast cleaning operator will spend much of their time
blast cleaning iron and steel.

This process is generally conducted to remove scale, rust and old

paint etc.

There are however, a number of other substrates which are

abrasive blast cleaned as a method of surface preparation.

Examples of Substrates that may need surface

preparation include:
Steel.
Cast Iron.
Aluminium.
Stainless Steel.
Galvanised Steel. (zinc surfaces)
Concrete.
Wood.
Copper and Lead etc.
Plastic and Fibre Glass.

We will briefly look at all these materials in this training unit.

Steelwork

Steelwork is widely used in the construction Industry due to it's

high strength and cost compared to other materials.

The steel is usually prepared and coated prior to site delivery and
erection.

Site touch up and overcoating, if required, can be conducted once

the steel is in place.

© Copyright 2016 Fitz-Coatings Ltd Page 24

 Mill Scale
Mill scale is formed on steel during the initial manufacturing
process.

This mill scale must be removed prior to painting.

This is an illustration of new mill scale found on steel soon after

leaving the mill.

The mill scale can vary in thickness and adhesion depending

upon age and location and storage of the steel.

Mill scale under an applied Coating

Although mill scale can offer some initial protection, it will

eventually break away from a surface.

If the mill scale is not removed and painted over, the outcome will
be mill scale and paint removal detachment as demonstrated.

This process is by no means a quick event, however it will occur

over a period of time.

Painted Steel

If painted steel has to be fully abrasive blast cleaned, it is

generally required due to a coatings failure or a coating
refurbishment. (lack of maintenance)

The type of coating thickness and adhesion, will vary from one
substrate to another.

This photograph demonstrates a coatings failure due to an

inadequate painting specification in a chemical environment.

Total removal will be required due to extent of failure and improper

paint system.

Previously Coated Surfaces

Some surfaces may have been coated many times over a number
of years.

Abrasive blast cleaning trials may be necessary to assess the

best types of abrasive blast cleaning process, abrasive and
pressures etc.

This particular paint sample has over 30 coats of paint.

A paint analysis is usually conducted (recommenced) prior to

surface preparation to assess if any of the coatings contained
hazardous ingredients such as heavy metals etc.

© Copyright 2016 Fitz-Coatings Ltd Page 25

 Pitted and Corroded Steel

There will be times when the abrasive blast cleaning operator has
to abrasive blast clean old steel, which may be pitted or has
layers of rust as illustrated.

Heavy scale may have to be removed by mechanical methods

prior to abrasive blast cleaning.

Pre-surface preparation may consist of chipping or the use of

needle gunning.

Chipping Hammer

This animation demonstrates the use of a chipping hammer to

remove rust and heavy scale from a steel surface.

This tool is often used as a pre-surface treatment technique.

The steel thickness has to be thick enough to ensure the hammer

does not penetrate the material.

A test piece is always recommended with this task.

The hammer head should not be too sharp or pointed which may
cause steel penetration.

Power Chipping Hammer

A simple animation of a power chipping hammer.

In extreme cases if may be possible to use a air driven chipping

hammer.

There is a big risk however of penetrating the steel surface.

A structural review may be necessary on steel structures which

have this amount of old scale on them.

Chipping Hammer

This video demonstrates a chipping hammer being used to

remove paint and rust on a steel substrate.

There is always a risk of penetrating the surface with the force of

the hammer.

The process is very labour intensive and can be destructive in the

wrong hands.

Chipping hammers do not feather edge the existing coating that

maybe left on the surface.

© Copyright 2016 Fitz-Coatings Ltd Page 26

 Pitted Steel

Some steel substrates may have deep pitting.

Different types and sizes of abrasive may be necessary to clean

the bottom of the pits.

The pits may also contain soluble salts etc which will require fresh
water washing to dissolve the salts prior to re-blasting and
coating.

Pit thickness checks may also be necessary to ensure the steel

is not close to penetration.

Soluble Salts

Soluble salts can be generally removed by wet abrasive blast

cleaning or after dry abrasive blast cleaning by fresh water
washing.

Soluble salt detection equipment is available to assess the

prepared surface for the salts, which if left, will cause the coating
to fail prematurely.

The coating specification should stipulate the maximum levels of

soluble salts permitted and the type of test to be conducted.

Soluble Salts

If dry abrasive blast cleaning is conducted alone, the soluble

salts, if present, will not be removed.

These soluble salts can be detrimental to a coating system

especially in a corrosive environment.

The soluble salts are coloured for illustrative purposes here as

soluble salts are virtually invisible to the human eye.

You may, however see black corrosion spots where the soluble
salts are creating severe corrosion and pitting, especially where
the soluble salts have been established on the steel for a period
of time.

Cast Iron Structures

There is still a lot of cast iron structures in service, including a lot

of bridges as illustrated.

Cast iron is a brittle and porous type of material.

The cast iron can have a 'honeycomb' structure which is difficult

to clean and paint.

The cast iron can also be difficult to do any steel repairs on,
especially welding repairs.

© Copyright 2016 Fitz-Coatings Ltd Page 27

 Cast Iron Structures

When cast iron structures are abrasive blast cleaned, the

blowholes can open and be visually exposed as illustrated.

These blowholes may require grinding or filling during the

subsequent painting operations.

Surface preparation trials are always recommended on cast iron

structures. It is not uncommon to grind open a cast iron blowhole
only to find additional blowholes.

The quality of cast iron can also vary from cast to cast. The
quality can vary even on a small single structure.

Aluminium Substrate

Aluminium has a smooth dense surface covered by a thin oxide

film.

Sometimes the surface is coated, generally for aesthetic

purposes.

If painting is a requirement, the surface is usually brush-off

blasted in accordance with SSPC-SP 7/NACE No. 4 to provide
the anchor or surface profile for the coating.

Specialised abrasives may be required for aluminium substrates

to ensure you do not damage or contaminate the surface. Low
pressures should also be used during any form of surface
preparation.

Aluminium Substrates
As aluminium is very light weight it is often found in architectural
uses such as solar panels and lighting.

Sometimes the aluminium has to be prepared prior to coating or in

many circumstance a pre-treatment is used and the aluminium is
painted or powder coated.

Note: Moving the blast nozzle slowly in a downward north to south

motion across the surface reduces the risk of damaging the
aluminum.

Stainless Steel Material

Stainless steels usually contain chromium, nickel and other
alloying elements.

Stainless steel is much more corrosion resistant than standard

steel, however this steel is more expensive than ordinary steel.

Stainless steel may still have to be top coated in certain

environments such as marine, as stress corrosion cracking is
possible at specific temperatures and conditions.

© Copyright 2016 Fitz-Coatings Ltd Page 28

 Stainless Steel
Stainless steels are used extensively in the petrochemical and
offshore industry.

A cost life time analysis will determine if the additional cost of the
stainless steel is worth considering.

The designer will have to consider maintenance and access costs

along with replacement costs when considering stainless.

It is possible to get stress corrosion cracking (SCC) on stainless

if the stainless is in a specific environment.

Note: Stress corrosion cracking is defined as cracking caused by

corrosion, along with stresses in the metal.

Stainless Steel Preparation

When stainless steels are to be painted, the abrasive must be
metallic free to ensure there are no metal fragments left on the
stainless surface which could cause galvanic corrosion at a later
date.

Abrasives must be relatively hard to ensure the tough tenacious

coating on the stainless is removed leaving a form of surface
profile.

There are various coating systems for stainless steel, however

zinc coatings should not be used.

Note: Stainless steel is very hard and high nozzle pressures can
be used.

Zinc Coated Steel

A considerable amount of steel is galvanised prior to erection.

Protective coatings can then be applied to give additional life and

add colour.

Galvanised surfaces are sometimes 'flash blasted' (brush-off

blasted) at low pressure to give a key for coating application.

You will see galvanised steel in every day working in some form
or another from lamp posts to handrails etc.

Reference Document;SSPC-SP 7/NACE NO. 4, Brush-off blast

cleaning

Flash Blasting

Galvanised surfaces can be difficult to coat so a light abrade is a

viable option prior to coating.

One option is to flash blast with abrasives.

This process is usually conducted with soft abrasives at low

pressure.

The use of hard abrasives or high pressures can damage or

remove the soft galvanised coating.

© Copyright 2016 Fitz-Coatings Ltd Page 29

 Reference Document;SSPC-SP 7/NACE NO. 4, Brush-off blast
cleaning

Concrete Surfaces

Many concrete surfaces are coated. This includes floors and

walls.

The coating can be conducted for aesthetics, protection or both.

Abrasive blast cleaning is usually conducted to remove surface

laitance prior to coating application.

Laitance must be removed on concrete surfaces prior to coating

application as this is a weak surface and coatings will fail as the
concrete spalls from the substrate.

Typical Concrete Surface

This animation demonstrates a close up view of a typical concrete

surface.

The surface is usually full of small holes which are difficult to

paint.

The surface could have thousands of these holes which can be

difficult to view with the human eye.

The size of the holes will vary over the surface.

Concrete Surfaces

This animation demonstrates the use of abrasive blast cleaning to

remove the laitance and small holes.

A light abrade should ensure a good surface ready for coating

application.

Acid cleaning is also a option, however this has environmental

issues on waste, etc.

Always conduct a test piece when preparing concrete substrates

for painting. The test piece should also include the coating
application.

Stone Cleaning (blast cleaning)

Abrasive blast cleaning can be used to clean old stone structures
such as buildings etc.

Years of grime, acid rain, previous coatings, bird droppings, algae

etc can be removed by abrasive blast cleaning.

Special abrasives such as walnut shells, egg shells can be used

as they are less aggressive, especially on sand stone.

Building bricks are also blast cleaned in the same way.

© Copyright 2016 Fitz-Coatings Ltd Page 30

 Wood Substrates

Sometimes wood is lightly abraded with soft abrasives to remove

years of paint and coatings.

Too severe blasting will damage the wood and lead to other
problems.

Hand or mechanical methods are also used to remove the old

paint, however this could be labour intensive over large areas.

It is always advisable to conduct a test piece with different

abrasives and different pressures.

Wood Surface Preparation

By carefully selecting abrasives such as sponge etc it is possible
to remove all the coatings from a previously painted wood surface
as illustrated.

The pressures must also be correct as damage to the wood

surface is possible.

Copper Surfaces

Copper has a dense surface covered with a copper oxide film.

Light abrasion prior to coating is a general requirement to achieve
a good key necessary for the paint to adhere. Any abrading
should be followed by a wash etc to remove surface debris and
contaminants.
Copper is predominately used in the water and heating industry
and therefore common to most industries.

Plastic and Fibreglass

Plastic and fibreglass are becoming increasingly popular as these

materials are strong and durable.

The surfaces are smooth, dense and can be difficult to paint.

Abrasive blast cleaning using soft abrasives at low pressures is

usually conducted to give a 'key' for coatings.

Hand abrading or sanding is also possible to use as a method of

surface preparation.

A single coat of urethane acrylic or similar coating is generally

acceptable on plastic and fibreglass.

© Copyright 2016 Fitz-Coatings Ltd Page 31

 Plastic Preparation
Plastic can be abrasive blast cleaned free from previous coatings
and to assist in abrasion of the surface in readiness for a coating.

A test piece with different pressures and abrasives is always

recommended. Wet abrasive blast cleaning is also possible.

Summary
This training unit has reviewed the various substrates that are
abrasive blast cleaned.

Surfaces discussed include steel, cast iron, aluminium, stainless

steel, galvanized steel, concrete, stone/brick, copper and
plastics.

© Copyright 2016 Fitz-Coatings Ltd Page 32

 Pre-Surface Condition

Objective:
The objective of this training unit is to understand the importance of pre-surface condition requirements on
steel surfaces and implications on coating performance.

Coating performance is dependent upon the level of surface preparation.

Abrasive blast cleaning will NOT remove defects in the steel.
Pre-surface preparation is a requirement prior to the abrasive blast cleaning process.

Sharp Edges

Remove sharp edges prior to surface preparation such as

abrasive blast cleaning.

A 2mm edge radii is generally recommended for good painting

practice.

This illustration demonstrates the difference on a sharp angle

before and after grinding.

The coating specification should define the requirements for

edges etc.

Weld Spatter

Remove weld spatter before and after surface preparation such as

abrasive blast cleaning.

The weld spatter is generally removed by scraper or disc grinder.

Abrasive blast cleaning will not remove the weld spatter, even
with high pressures.

Do not tolerate weld spatter. It must be removed prior to coating

operations.

Laminations

Remove all laminations before and after surface preparation.

Laminations may not be exposed until after the surface

preparation, especially abrasive blast cleaning.

A light lamination is sometimes referred to as surface shelling.

A thorough inspection of the prepared surfaces may be required

as some laminations can be difficult to see.

© Copyright 2016 Fitz-Coatings Ltd Page 33

 Undercut

Inspect welds prior to surface preparation for undercutting.

The undercut will be found around the edges of the weld.

Additional welding or filling may be required after the surface

preparation has been conducted.

Check the specification for requirements on undercut.

If undercutting is not treated, then coating failure is possible as

coatings may not necessarily evenly coat this location.

Note: Welds are to be striped to assure these areas are coated.

Inspection Technique

This video demonstrates skip weld, weld spatter and sharp edges
on a typical primed steel structure.

Most of theses items can be visually inspected and addressed

prior to and after surface preparation.

Always check the coating specification requirements.

Hand gloves are always recommended when conducting this type

of test!

Skip Welds
Wherever possible all welds should be continuous. This should be
conducted at the fabrication stage of the build or maintenance.

if welding is not possible it may be an option to apply a sealant

such as an epoxy filler after the primer has been applied.

Ensure you use a compatible sealant or filler.

Check the details with the coating supplier.

Thin gaps may be sealed with a single part sealant or mastic,

such as a polysulphide, before the topcoat has been applied.

As always check with the suppliers about compatibility etc.

Weld Locations (WUSPS)

W = Welds. Should be continuous and free from sharp

projections.
U = Undercutting. Should not be excessive and rough
S = Spatter. All weld spatter should be chipped away
P = Pinholes. Should be filled
S = Slag. Should be removed by chipping so that the underlying
weld may be inspected

© Copyright 2016 Fitz-Coatings Ltd Page 34

 All Areas (LEB)

L = Laminations. The surface should be checked before and after

surface preparation for laminations in the steel. Laminations must
be removed.

E = Edges. Should be radiused to provide a smooth, round

surface to enable the paint to adhere satisfactorily and provide
good protection.

B = Burrs. Should be removed as above. Check bolt holes and

other areas where cutting has been carried out.

Weld Spatter

Weld spatter has to be removed otherwise coating failure is

inevitable.

The weld spatter should ideally be removed prior to the abrasive

blast cleaning, however a post blast inspection is also
recommended.

The identification is purely a visual inspection which is deemed

part of the quality control system.

Weld Spatter
Weld spatter can create premature coating failure due to irregular
dry film thickness as demonstrated in this animation.

The coating will flow away from the roughness of the weld spatter
and you will not get a continuous coating.

The weld spatter itself maybe loose and corrosion can occur on
the sides and underside of the spatter.

Flame Cut Edge

Flame cut edges should be prepared by grinding or disking.

The grinding and disking should be conducted prior to abrasive

blast cleaning.

Specific training may be required for the use of grinders and

disking machines.

This is a picture of severe flame cut edge which has occurred

after preparation and priming.

© Copyright 2016 Fitz-Coatings Ltd Page 35

 Sharp Edges

Sharp edges should be removed by grinding prior to abrasive blast

cleaning.

The sharp edges can clearly be seen on this steel plate.

Paint will run away from a sharp edge leaving a thin film in this
location and the edge will be potentially exposed to the
environment.

Certain coatings are formulated to hold up better on stripe coated

areas, however the sharp edge must still be removed.

Edge Treatment
This is a good example of a fabricated section of steelwork that
has been prepared ready for abrasive blast cleaning.

The edges have been suitably ground to a 2-3 mm radius which is

generally recommended for new works.

The welds and other areas have also be ground to ensure there
are no surface irregularities such as laminations and spatter etc.

Radius Check
Although radius checking is generally conducted by visual
inspection there is a simple method for assessing the radius of a
structure as illustrated in this photograph.

Some coating inspection material suppliers have a 2mm radius

check on the corner of the wet film comb.

The corner is placed against the edge of the structure and will
determine the radius.

Sharp and Rugged Edges

Sharp edges can sometimes be found around 'ratholes' during

steel fabrication.

Ratholes will be found in certain types of fabrication such as

marine and offshore structures.

A small pencil grinder will be required to smooth the edges prior to

abrasive blast cleaning.

Radius of edges is usually conducted by other trades, not

specifically painting operatives.

© Copyright 2016 Fitz-Coatings Ltd Page 36

 Molten Slag

Slag from burning and cutting has to be removed prior to abrasive

blast cleaning.

Disking and grinding is the usual requirement for molten slag.

It should be obvious that this slag is removed prior to surface

preparation.

The slag itself will create additional burning to the surrounding

painted (primed) areas if the process is conducted after initial
coating operations.

Grinding

Disking and grinding can usually be conducted by 110 volt

equipment.

Slight variations on power may be found from country to country.

The operator of the disking and grinding equipment must have:

Training in the use of grinders and disking equipment

Appropriate PPE and RPE

Risk Assessments must be conducted and be in place prior to

conducting the task.

These heated sparks generated by the grinding could cause

damage to any surrounding coatings. This would lead to coating
failure if not identified and treated.

Grease, oil and Contaminaants

Surface contaminants such as grease, oil etc must be removed

prior to abrasive blast cleaning or any form of mechanical
preparation.

If contaminants are left on the surface, the abrasive blast cleaning

may spread the contaminants over the surface.

Solvent cleaning has found to be good for removing grease and oil
etc, however the user should be aware of all the safety
implications when using solvents for cleaning.

Refer to specific standards such as SSPC-SP 1. Sovent cleaning

of steel surfaces.

Solvent Cleaning
Solvent cleaning may be required to remove traces of grease and
oil before you abrasive blast clean. The substrate could be bare
steel or a contaminated coated surface.

The cloths should be changed on a continuous basis to ensure

you are not spreading the contamination around the surface.

It is essential that the operator has the correct PPE and RPE on
and a risk assessment is conducted prior to conducting the task.

© Copyright 2016 Fitz-Coatings Ltd Page 37

 Blow Holes

Illustration of a blow hole in the weld after the steel has been
abrasive blast cleaned. The hole may have previously been filled
prior to abrasive blast cleaning.

Exposed blow holes should be filled during the painting operation.

Filling is usually conducted after the 1st coat or primer coat.

Always check the paint specification requirements for exact

details of the filling as some areas may be critical and additional
welding etc may be required.

Laminations

Illustration of laminations on a coated steel pipe.

These laminations or surface shelling should have been removed

during the original surface preparation.

Check the painting specification requirements on how to treat the

laminations etc.

Grinding or scraping can remove the laminations, although this

may depend upon the depth and size.

Always seek advice prior to grinding out any laminations in the

event that you inadvertently reduce the wall thickness of the steel
beyond the minimum requirements.

Surface Shelling
Small laminations in the steel are referred to as surface shelling.
This shelling may be removed by the abrasive blast cleaning,
otherwise a light scrape or grind may be required.

Additional blast cleaning may then be required to ensure you

achieve the appropriate blast standard and surface profile.

Depending upon the type of coating to be applied, the surface

shelling may be still visible through the coating.

Undercutting

Poor welding practice.

Poor welding can sometimes be identified prior to abrasive blast

cleaning. On other occasions the poor welding is only identified
after the abrasive blast cleaning.

This is an example of poor welding.

Undercutting can cause problems with coating systems leaving

gaps and corrosion around the weld.

Note: Always inform the Supervisor if any grinding is to be

conducted.

© Copyright 2016 Fitz-Coatings Ltd Page 38

 Skip Welds
Animation showing use of filler on skip welds prior to the
application of coatings.

Skip welds can either be fully welded or filled with a suitable

sealant.

The filler or sealant is usually applied after surface preparation

and priming.

Check the compatibility with the coating manufacturers.

Flame cut edges

Rugged edges should be mechanically dressed to a smooth edge.

This illustration is a extreme case of flame cut edges which

should never be painted without adequate surface preparation.

It is important to conduct a pre-surface inspection on fabricated

steel prior to surface preparation.

Poor Welding Techniques

If the weld defect can not be rectified by welding, filling may be

conducted during the painting process.

There are a number of fillers available, however they must be

compatible with the coating system that may be applied later.
Epoxy fillers have been found to give good performance for gaps,
holes etc, however ensure you have compatibility been the filler
and coating. (seek advice from suppliers)

A trial area maybe necessary before the full painting process is

conducted.

Note: Any defects found on a weld may require a

investigation by the Engineer etc, especially on pressure
vessels etc.

Extent of Filling

Poor welding could leave numerous problems for the coating,

including holes, edges, etc.

Filling of the defects may be necessary during coating operations.

Seek the manufacturers advice or coating specification details.

Fillers include two part epoxies and single part elastomeric

coatings and it is therefore essential to check paint compatibility.
Fillers may also be affected by the contents, for example in tank
lining projects.

© Copyright 2016 Fitz-Coatings Ltd Page 39

 Summary
This training unit reviewed the requirements to remove surface
irregularities on the surface prior to abrasive blast cleaning which
includes weld spatter, sharp edges, laminations (shelling), weld
slag etc.

We also discussed the requirement to remove contamination such

as grease, oil etc from bare steel and previously coated surfaces.

© Copyright 2016 Fitz-Coatings Ltd Page 40

 Mechanical Blast Cleaning Equipment

Objective:
The objective to this training unit is to gain an understanding of mechanical surface preparation using
centrifugal blast cleaning equipment.

Centrifugal blast cleaning equipment is widely used to blast clean structural steelwork.
Centrifugal blast cleaning is a method of surface preparation widely used by steel shops, fabrication
facilities, shipyards etc.

Centrifugal Blast Equipment

Centrifugal blast equipment units have been successfully used for
over sixty years.

Note: Centrifugal blast cleaning equipment, both fixed and

portable, is supplied by specialist manufacturers who generally
conduct training courses for operatives.

This illustration demonstrates the use of centrifugal blast cleaning

equipment to external walls on a large storage tank. There will be
minimum dust and no scaffold access required.

Note; The units may not get right to the edge and manual cleaning
will still be necessary.

Advantages over air blast systems

Speed - more productive than air blast cleaning.

Reduced labour - automated system.
Energy - reduced cost.
Less environmental impact - dust, abrasives etc.
Centrifugal blast cleaning is considerably less hazardous than
air blast cleaning.

Wheelabrator in Use

Animation of a typical wheelabrator used to abrasive blast clean

steel sections.

The pre-cleaned steel, which is usually washed and force dried, is

placed on rollers and fed into the blast unit.

The steel is abrasive blast cleaned within the body of the machine
so no abrasive or contaminants escapes.

A high surface preparation standard can be achieved with this

method of surface preparation.

Wheelabrator in Operation

© Copyright 2016 Fitz-Coatings Ltd Page 41

 This video demonstrates the use of a wheelabrator type
equipment use to abrasive blast clean a steel pipe section.

No dust is exposed to the atmosphere and a very high surface

preparation standard is achieved.

The process is effective and efficient.

The equipment is generally a factory type unit.

There will be a high initial cost to set up this equipment, however

it is cost effective over a period of time.

Process

The steel is pre-cleaned and dried as necessary. All surface

contamination such as grease and oils must be removed. Surface
irregularities such as sharp edges, weld spatter must also be
removed.

The dry cleaned steel is placed on rollers, which pushes the steel
plate, beams etc through the blast housing area.

Centrifugal blast wheels throw the abrasives, usually shot or a

mixture of shot and grit, onto the steel surface.

The process is automated, however personnel are used to place

the steel in the machine and also to remove the steel.

Centrifugal blast wheel

The number of blast wheels will depend upon the size and type of
equipment.

Centrifugal blast wheels are generally made from hard wearing

materials such as stainless steel or other hard wearing materials.

This is an illustration of a typical centrifugal blast wheel.

The abrasive is generally fed into the center of the wheel and onto
the curved metal blades and flung onto the surface being
prepared.

Abrasive Blast Cleaning Standards

Centrifugal blast cleaning can produce a high quality standard

finish.

It is possible to achieve an ISO Sa3 ( SSPC SP 5/NACE No.1 )

Standard on a consistent basis. A lower Standard, however is
generally specified.

High production rates, especially on flat plates, can be also be

achieved.

The process is considerably faster than manual blast cleaning.

© Copyright 2016 Fitz-Coatings Ltd Page 42

 Four Wheel Wheelabrator Type Equipment

The number of wheels varies depending upon the size of the

equipment.
The wheels have to be set up to ensure all parts of the
structure will be prepared by the abrasive.
Some types of equipment are developed for specific shapes
of structures such as pipes or plates etc.

Four Wheel Wheelabrator Type System

This animation demonstrates how the wheels are used to throw

the abrasive onto the steel beam.

The wheels are specifically placed for best use.

All the wheels must be working correctly and at the same speed
to ensure you get a consistent blast pattern.

Eight Wheeled Wheelabrator Type Equipment

The number of wheels depends upon the size of the equipment.

This diagram illustrates eight wheels being used on a flat plate.

This type of equipment is very fast and can prepare considerable

areas over a short period of time.

Eight Wheeled Type Wheelabrator in Operation

The process is the same as the four wheel type, however this
operation is more efficient and extremely fast.

The equipment is ideal for large flat page fabrication such as

shipyards or offshore fabrication yards.

Plates are also prepared and primed for steel suppliers.

Abrasives

Steel or Iron is usually used with centrifugal blast cleaning

equipment.

Shot abrasive tends to give a low surface profile and is generally

mixed with grit abrasive to give a suitable surface profile.

The use of grit abrasive alone will wear the machine parts much
faster than steel or iron shot.

This illustration demonstrates shot abrasive which is typically

round when new.

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 Abrasive Recovery System

The abrasives are usually collected within the equipment recovery

system.

The dust, debris and abrasive are separated with the dust and
debris removed from the system.

The abrasive is recycled and 'topped-up' as necessary.

It is important to ensure the additional abrasives give the correct

mix and the surface profile does not change significantly.

Check for specific standards or spefications used such as SSPC

AB 2, Cleanliness of Recycled Ferrous Metallic Abrasives.

Steel Plates

Steel plates are often 'shot blasted' in a fabrication plant.

After the plates are welded together, site touch-up is then

conducted.

Various types of weld and pre-fabrication primers can be used on

the steel plates.

This process is commonly used in fabrication facilities such as

shipyards etc.

Automation
Automatic blast and paint lines are now commonly used which will
abrasive blast clean and prime steel plates used for fabrication
etc.

This illustration details the relevant parts:

1. Loading table
2. Roller conveyor
3. Heater
4. Blast machine
5. Automatic paint booth
6. Heated tunnel
7. Slat conveyor to minimise paint damage
8. out-feed roller
9. Unload table

Computer Controlled

Some centrifugal blast units are so sophisticated that they are

controlled by computers.

The computer can set energy levels, speed of rollers etc.

Equipment is getting more sophisticated, especially as the

equipment is increasing in size and faster in speed.

Manufacturer's training is often given for this type of equipment.

© Copyright 2016 Fitz-Coatings Ltd Page 44

 Basic Principles of Use

The equipment uses motor driven wheels which hurl the abrasive
onto the surface.

The abrasive is generally fed through the center of the wheel onto
the blade as illustrated.

As the abrasives move down the blade they gather speed before
being hurled at the surface.

The wheels must be made from extremely tough material

otherwise it will wear aware very quickly.

A Centrifugal Blast Wheel

The abrasive is fed into the side opening of the wheel and thrown
off the wheel blades as it is spun at high speeds.

This diagram demonstrates the abrasive being gravity fed into the
wheel and projected onto the surface.

The process is simple and effective and has been around for
many years with great success.

Essential Components

Blast wheels.
Blast enclosures.
Conveyors - rollers.
Abrasive recovery unit.
Dust collection unit.

All these parts play an important part in the overall process and
must be maintained on a regular basis.

The supplier of the equipment should have maintenance manuals

available to the user.

Tumble blast
There are various forms of mechanical blast cleaning equipment
used for small factory assembled items. One type of equipment is
the tumble blast used for small parts.

The parts are placed in the tumble blast and the door is closed.
The parts are mechanically abrasive (shot) blast cleaned.

The parts being blast cleaned must be robust and solid as they
are flung together in the machine.

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 Portable Blast Cleaning Units

Portable blast cleaning units became popular in the 1960's. This

popularity has increased over the following years.

A reduced labour cost is achieved as the equipment is automated

to some extent.

There is a reduction in environmental impact, compared to air

blast cleaning, as the abrasive is contained within the body of the
unit.

Manufacturers Training

Manufacturer's training is usually required for both fixed equipment

and portable blast units, typically consisting of:

Health and Safety aspects of the equipment.

Maintenance of equipment.
Use of equipment.
Changing abrasives.
Fault finding.

Portable Blast Cleaning Units

Portable blast cleaning units are ideal for both steel and concrete
surfaces.

A test piece should always be conducted to assess the speed,

which in turn will determine the blast cleaning standard on the
substrate.

If the steel plate has high profile welds, or raised areas etc.
abrasive can escape out the side of the equipment creating a
potential Health and Safety issue, as well as wasting material.

Portable Abrasive Blast Unit in Operation

This video demonstrates the use of a mobile portable abrasive

blast unit.

The process is ideal for flat structures such as steel bridges and
decks on vessels and rigs.

The process is also ideal for concrete floors such as car parks
etc.

A high standard of blast cleaning can be achieved with this type

of equipment.

© Copyright 2016 Fitz-Coatings Ltd Page 46

 Vertical Blast Cleaning

Vertical portable blast cleaning units are also available.

These vertical blast cleaning units have found common place in

shipyards and tank refurbishment as illustrated.

Sometimes a crane has to be employed to hold the equipment in

place, alternatively the equipment can be hoisted from hangers
above the plates.

This form of preparation is extremely cost effective, especially on

large areas as no scaffold or sheeting is required and there is no
environmental impact.

Note:There are going to be areas that will have to be hand

cleaned.

Summary
This training unit reviewed the use of mechanical blasting
equipment used for surface preparation. Typical equipment
includes wheelabrators and mobile (track blast) units.

The equipment uses metallic (shot) abrasive which is recycled

within the centrifugal blast cleaning equipment.

Large equipment is used in shipyards, fabrication facilities and

steelworks etc. Smaller and more mobile equipment is available
for site works.

© Copyright 2016 Fitz-Coatings Ltd Page 47

 Types of Air Blast Equipment

Objective:
The objective to this training unit is to gain a thorough understanding of the air blast cleaning equipment
available

There are two main methods of air blast equipment used in the surface treatment industry:

Suction types.
Pressure types.

Both types will be reviewed in this unit.

Air Blast Equipment

Some types of equipment can fall into one or both categories.

Suction Type Equipment

Pressure Type Equipment

The abrasive blast cleaning operator will almost certainly use

some of the equipment in this unit.

This training unit will cover both types in detail.

There are two main types of abrasive blast cleaning equipment.

Some types of this equipment can fall into both categories.

The two types consist of:

Suction Type.
Pressure Type.

This illustration demonstrates both suction and pressure type

equipment.

Suction Blast Units

The suction type blasting equipment develops a vacuum which

draws abrasive from a non pressurised container.

The equipment may be small mobile units or factory cabinet

installations.

The illustration shows a portable suction blast unit which is

common for site works, specifically fabrication facilities.

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 Suction Gun

A suction gun may be used without the need for a hopper.

This process takes abrasives direct from the bag or load unit and
is therefore 'ready to go' with a set-up requirement.

This process is generally used in light application duties such as

site repairs, however there will be used abrasives to collect from
the surrounding area.

Surface preparation standard can be high and far better than

mechanical wire brush.

Blast Cleaning Gun

It is possible to abrasive blast clean with a suction type spray pot
and compressed air.

This method of abrasive blast cleaning is ideal for small locations,

repair areas etc.

The abrasive is placed in the suction pot gun which has a

specially designed tip which allows the abrasive to flow through.

Suction Cabinet

Suction cabinets can be found in many engineering workshops.

The process is ideal for cleaning and preparing small components

which can be easily handled.

The abrasive is drawn, under vacuum, into the handgun.

The gun then projects the abrasive onto the surface to be

prepared.

Suction Blast Cabinet

The equipment can be found in Engineering Workshops.

The process is ideal for small components.
The equipment is simple to use.
The abrasive is drawn under vacuum into the handgun which
is operated manually as illustrated.
The handgun projects the abrasive onto the surface before
falling back into the hopper.

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 Suction Vacuum Unit

Suction vacuum units are ideal if a 'dust free' environment is

required.

Suction vacuum units are effective, however the process is very

slow, making it expensive.

Recycled grit such as steel or iron grit is used and the equipment
is simple to operate.

During the preparation process the operator can not see the
surface so experience is required when using this type of
equipment.

This equipment is generally only used on small areas.

Suction Vacuum Blast Unit

This animation demonstrates the use of a suction vacuum blast

unit.

Compressed air is used with the unit which projects the abrasive
onto the surface being prepared.

The abrasive can be recycled.

It is important to check the abrasives on a regular basis to ensure

that it is still the correct grade etc.

Pressure Vacuum Unit

The pressure vacuum units are larger than the suction vacuum
units.

The pressure vacuum unit is more productive than the suction

vacuum unit.

The unit is generally air powered and is suited for use with
metallic abrasives such as iron and steel.

Surface preparation is expensive due to speed of the process.

Pressure Vacuum Unit

The pressure vacuum units are larger than the suction vacuum
units and offer increased productivity.

The blast head is held against the surface which projects the
abrasive onto the surface. The abrasive is then sucked back up
the hose back into the unit for re-use.

As previously discussed, the operator can not see the surface

when conducting the surface preparation and practice will be
required.

© Copyright 2016 Fitz-Coatings Ltd Page 50

 Pressure Vacuum Blast Cleaning
Pressure vacuum blast cleaning is an ideal process for removing
coatings to welds and other areas without the abrasive being
exposed to the environment.

An example is the weld inspection on a structure as illustrated.

All the coatings are successfully removed allowing visual

inspection and NDT of the weld locations.

Pressure Vacuum Cleaning

It is possible to to attach inside and outside corner brushes to the
equipment which will allow abrasive blast cleaning on corners and
edges without any loss of pressure or abrasive escaping.

Although the process will give you the desired quality finish it is
very slow and labour intensive.

Vacuum Blast Unit

It is possible to set up a complete vacuum blast unit using part of
the traditional blast unit.

A cyclone collector and dust collector are attached to the

pressure type blast unit.

Providing you have the different parts and hoses etc the system
is relatively simple to set up and use.

Video of a Pressure Vacuum Unit

Vacuum units are ideal for use if a dust free environment is

required.
Recycled abrasive can be used.
The process is very slow, although still faster than suction
vacuum.
The process has limited use due to the shape of the blast
head.

Vacuum units will achieve a good standard of surface preparation

but generally at a high price, due to size of blast head and speed
of process.

© Copyright 2016 Fitz-Coatings Ltd Page 51

 Pressure Blast Cabinet

Pressure blast cabinets can produce faster cleaning rates of 4-5

times that of suction blast cabinets

Pressure blast cabinets are ideal for high production work of hard
surfaces which are too tough for suction blast cabinets.

Suction blast cabinets can be upgraded to pressure blast

cabinets, making them more efficient.

This equipment is popular in engineering facilities and work shops

etc.

Pressure Blast Cabinet in Operation

As previously discussed, pressure blast cabinets are considerably

faster than suction blast cabinets.

They are ideal for high production work and used for preparing
surfaces which would be difficult to prepare in a suction blast
cabinet.

The paint on this steel panel was 300 microns (12 mils) thick and
easily removed in the pressure blast cabinet.

Pressure Blast Units

Pressure blast units are the most popular method of abrasive

blast cleaning equipment available.

Pressure blast units are widely used in abrasive blast cleaning

chambers and for site use.

These blast units are commonly called pots or kettles and have
been available for over 50 years.

The pressure blast units are very versatile and used in a number
of industries such as construction, offshore, marine, bridges and
general facilities.

Pressure Blast Units

Abrasive blast units are available in various sizes to suit the

contract requirements.
Abrasive capacity varies between 25 to 300 Kgs.
All abrasive blast units are pressurised units and have to be
independently tested and certificated before use. This testing
is usually conducted on an annual basis.
Always check the certificates and documentation to ensure
correct testing has been conducted.

Abrasive Blast Units

A test plate should be attached to the side of the abrasive

blast unit.
You should always check that the test plate is visible.
NEVER use a pressure unit that has not been tested. If in

© Copyright 2016 Fitz-Coatings Ltd Page 52

 doubt always ask.

Abrasive Blast Units - Test Plates

A test plate must be visible on the abrasive blast unit and the
certification must be traceable back to the ID on the blast unit.

Never use a abrasive blast unit that has not been tested and does
not have the relevant certification.

Check for damage to all plated signs on an abrasive blast unit.

Typical Mobile Pressure Abrasive Blast Unit

Compressed air is the energy required to pressurise the abrasive

blast unit.

The compressed air enters the abrasive blast unit via air lines and
the blast unit is switched on manually as demonstrated.

The air and abrasive mix together then leave the lower section of
abrasive blast unit via abrasive blast hoses to the nozzle and
projected onto the surface to be prepared.

Abrasive Blast Unit in Operation

This animation simply demonstrates how an abrasive blast unit

works.

The compressed air (blue) enters the blast unit. This is

usually operated manually.
The air closes the unit by pushing up the mushroom valve on
the inside of the blast unit.
The blast unit is now pressurised.
Compressed air and abrasive are mixed at the abrasive valve
and pushed down the hose to the surface to be prepared via
the blast hose and nozzle.

Typical Mobile Abrasive Blast Unit

A diagram of a complete air blast unit complete with the abrasive

blast cleaning operator.

The abrasive blast operator should get to know all the relevant
parts of the abrasive blast unit.

Training should be conducted on stripping down all the parts and

successfully putting the parts back in a safe and correct manner.

You may see slight variations on this process, however the

principal remains the same for most abrasive blast units.

© Copyright 2016 Fitz-Coatings Ltd Page 53

 Essential Components of an Air Blast Unit

This diagram demonstrates all the essential components on a

abrasive blast cleaning air unit.

There are various types of equipment across the globe, however

all blast units are generally similar with regards to the components
and parts.

Always use reputable suppliers who can guarantee the abrasive

blast unit was manufactured correctly and will supply the correct
documentation on testing etc.

Abrasive Metering Valves

There are a number of abrasive metering valves available

depending upon the type and size of the unit and the type of
abrasive to be used.

The most common form of abrasive metering valves are the type
developed for expendable abrasive and metallic abrasive.

Some special valves exist for very fine abrasives etc.

Check with suppliers of both the abrasive blast unit and

abrasives.

Expendable Abrasive Valve

Various types of valves exist between the different suppliers and

manufacturers.

It is extremely important that the abrasive blast cleaning operative

and assistant understand the use of the valve.

Also be aware of the wear and tear and when maintenance is

required.

The valve is an important element of the abrasive blast unit.

Working Expendable Abrasive Valve

The abrasive enters the top of the valve and meets the
compressed air at the bottom of the valve and the combined
abrasive and air are fed to the blast hose.

The abrasive can be adjusted on the side of the valve.

The correct mixture of abrasive and air will have a big impact on
the efficiency of the blast cleaning operation.

Ensuring the correct mixture of pressure and amount of abrasive

will significantly improve efficiency.

© Copyright 2016 Fitz-Coatings Ltd Page 54

 Steel Grit Valve

Steel grit valves are used when aggressive abrasives are used,
examples include:

Chilled Iron Grit.

Steel.
Aluminium Oxide.

The handle is simply turned to increase or decrease the flow of

abrasive.

Although this valve is made from a hard wearing material, wear

and tear is inevitable and will still need to be checked and
maintenance conducted on a ongoing basis.

Abrasive Blast Valve

This animation simply demonstrates how a abrasive blast valve is
adjusted.

The animation demonstrates a steel grit valve which is used with

metallic abrasives such as blast chambers etc.

Although operating a blast valve is a simple process, it is

important that the abrasive blast cleaning operator understands
why this operation is necessary.

More abrasive is not always the correct answer!

Remote Control Valve

All abrasive blast units have some mechanism for communication

and control.

If the abrasive blast cleaning operator is using a deadmans handle

system, the unit will have a remote control valve attached.

The remote control valve allows depressurisation and

pressurisation from the deadmans handle.

Once the deadmans handle is released, there will be pressure

remaining in the blast hose. The amount of pressure will depend
upon the length of the abrasive blast hose.

Electronic switches are available to stop the pressure at the blast

unit.

Deadman Handle

The deadman handle is usually placed on the blast hose, close to

the nozzle.

Never remove the deadman handle or 'tie' the handle in the open
position when in use.

Always remember the purpose of the deadman's handle.

Be aware also that there could still be pressure in the line even
after releasing the handle.

© Copyright 2016 Fitz-Coatings Ltd Page 55

 Deadman's Handle

This animation demonstrates the fitting of a deadman's handle.

The handle is attached to the blast hose directly behind the blast
nozzle.

Purpose made attachments are available and should be used

when possible.

The operator must be able to hold the deadman in position while

using the hose and nozzle. The deadman should not affect the
process.

Do not remove the handle during the operation.

Deadman's Handle

This is a simple animation of a deadman's handle.

The handle is pushed against the air line which allows the unit to
function.

Once released the abrasive and air will stop, however be aware
there will be some pressure in the line.

The amount of pressure in the line will depend upon the type of
operation and line length.

Special electrical units are available to alleviate this particular

problem by cutting the air at the blast unit.

Water Separator

An essential part of an abrasive blast unit is the water separator.

The water separator removes water droplets from the compressed

air to prevent the abrasive becoming damp.

Always check the water separator to ensure it is not damaged and

is working correctly.

The quality of water separators can vary so use reputable

suppliers.

Inspection Hatch

The inspection hatch can be found on the side of the abrasive

blast unit as illustrated.

The inspection hatch is used to inspect the inside shell and

generally clean out grit, debris etc.

Inspection hatches must be replaced correctly so ensure the seal

is tight before putting the unit back under pressure and in
operation.

Inspection Hatch
© Copyright 2016 Fitz-Coatings Ltd Page 56
 This animation simply demonstrates how an inspection hatch on
an abrasive blast unit is opened.

Once opened, a full inspection can be conducted on the internals,

including removal of damp abrasive etc.

Ensure the hatch itself is not damaged and fits back in place
before returning to service.

Pop-up Valve

The pop-up valve is a cone shaped casting with a wear resistant

urethane or neoprene rubber attached.

When air enters the blast unit, the pop-up valve is pushed up to
seal the unit.

Due to the force of the pop up valve hitting the blast unit, wear
and tear is possible so always ensure that a thorough inspection
regime is in place.

Worn pop-up valves can be hazardous and very worn or damaged

units can be forced out under high pressures through the hole on
the top of the blast unit.

Pop-up Valve

This animation shows a pop-up valve in operation.

Numerous types of material are available for the manufacture of

the valve including polyurethane, rubber and even metal.

Use reputable suppliers as cheap copies will be available and can

easily fail in service.

You must always check for wear and tear as a worn valve is
dangerous.

Pop-Up Valve Cover

You will see pop-up valve protection plates umbrella on new and
refurbished blast units.

These plates should be become mandatory and are designed to:

Stop operators fingers inserting into the unit.

Stop the pop-up valve projecting from inside the unit.

Always ensure that the protection plate is on all units and in

working order.

© Copyright 2016 Fitz-Coatings Ltd Page 57

 Abrasive Blast Unit Sieve and Cover

An abrasive blast unit sieve helps keep debris out of the blast
unit.

A cover should be used when the unit is stored outside as water

and dampness can enter the blast unit and corrode the inner wall
and valve parts.

The cover is usually a lightweight cover with a handle which can

be made from tin, metal or plastic.

This sieve is generally only used with metallic abrasive and

recycled in-house blast facilities.

Abrasive Blast Unit Sieve

This video simply demonstrates the use of a sieve used on the
top of the blast unit to allow recycled abrasive back into the unit.

The sieve should stop unwanted large debris and contaminants

being recycled.

Typically the sieves are used on abrasive blast units for blast
chambers using chilled iron abrasive, however they can be used
for site works if the environmental conditions are correct and the
abrasive does not get damp or wet.

Abrasive Blast Units - Maintenance

Little maintenance is required on the abrasive blast unit.

Abrasive Blast units should have robust and sturdy wheels for
moving the units around.

Inspection is still required on all units on a regular basis.

Insurance review is usually conduced annually and may include

wall thickness checks etc.

Summary
This training unit reviewed the various types of air blast equipment
available.

The two main categories of suction blast and pressure blasting

equipment were discussed.

There are various types and sizes of equipment, some of which

are permanent facilities, while others are mobile abrasive blast
units for both factory and site use.

© Copyright 2016 Fitz-Coatings Ltd Page 58

 Wet Abrasive Blast Cleaning

Objective:
The objective of this training unit is to understand how and when wet abrasive blast cleaning is conducted and
the equipment types utilised.

Wet abrasive blast cleaning is increasing in popularity due to environmental advantages.

Most major paint suppliers have developed coatings for wet abrasive blast cleaned substrates.

Wet Abrasive Blast Cleaning

There are three types of air blast equipment which are used for
surface preparation:

1. Pressure Blast Type.

2. Suction Blast Type.

3. Vacuum Blast Type.

The pressure blast units are, by far, the most popular of the three.

Vacuum blast units have limited use due to the slow speed of the
process.

Wet Abrasive Blast Cleaning

Wet abrasive blast cleaning is only conducted with the pressure

type equipment. The process can not be used with suction or
vacuum units.

The abrasive blast cleaning operator may utilise the wet abrasive
blast cleaning in their duties as more painting specifications are
specifying wet abrasive blast cleaning.

The process has been available for a number of years and the
equipment has been tried and tested.

Abrasive Blast Cleaning

The process of blast cleaning using the pressure type equipment

for wet abrasive blast cleaning remains the same as dry abrasive
blast cleaning, however, fresh water is combined with the grit prior
to impact

Wet abrasive blast cleaning has been available for a number of

years, with increasing popularity as this process is more
environmentally friendly compared to dry abrasive blast cleaning.

© Copyright 2016 Fitz-Coatings Ltd Page 59

 Why use water in the abrasive blast cleaning process?

Minimal Dust.
Less abrasive used is used if the correct mix ratio is
employed.
The use of water reduces soluble salts (depending upon the
extent and condition of the surface etc.)
A surface profile is still produced as abrasive is employed.
The process is ideal for safely removing toxic coatings such
as red lead etc.
Selective coats can be removed on a multi-coat system.
Reduce friction sparks.

Wet Abrasive Blast Cleaning

Due to the increase in wet abrasive blast cleaning, coating

manufacturers have developed coatings which can be applied
onto damp or wet surfaces.

Some coating manufacturers prefer the surface to dry and oxidise

prior to applying coatings. The level of oxidation (powder) remains
debatable, however standards now exist for assessing the level of
flash rusting.

Coating manufacturers are working on new coatings which can be

applied over wet and damp surfaces.

Wet Abrasive Unit

A wet abrasive blast unit is similar to a dry abrasive blast unit,

however, water is mixed with the abrasive in the unit.

The process is often referred to as slurry blasting due to the slurry

like debris caused during the blast cleaning. To much water can
create excessive slurry type debris.

There are also wet blast units which do not mix abrasive with
water until the abrasive leaves the nozzle or is mixed at the
nozzle.

There will always be variables as there are advantages and

disadvantages with all the different types.

Wet Abrasive Blast Cleaning

This video demonstrates the use of a wet abrasive blast unit.

The abrasive and compressed air are mixed together and

projected onto the surface.

Note the minimal amount of dust and debris that is exposed to the
atmosphere.

Water may be permitted in certain locations with the exception of

areas that will be near electrical appliances etc.

Wet Abrasive Blast Unit Set Up

The fresh water is fed up the hose and mixes with the abrasive at
the nozzle.

© Copyright 2016 Fitz-Coatings Ltd Page 60

 Some units spray the water into the abrasive airsteam as it leaves
the nozzle.

The water line is usually attached to the abrasive blast hose

(illustrated in blue) before entering the nozzle in the side wall.

Wet Abrasive Blast Cleaning

Wet abrasive blast cleaning can produce a high quality finish

although this can be hard to determine as the finish will be a wet
or gingered surface.

The process is effective in removing soluble salts from the steel,

especially within the surface profile.

The abrasive and water mix helps 'feather edge' existing coatings
if you are conducting maintenance preparation and spot repairs
are being conducted.

Wet Abrasive Blast Cleaning

The abrasive and water mix helps to reduce dust and is

increasingly popular with marine work such as ships, oil rigs etc.

The mixture of abrasive and water reduces dust and removes

soluble salts which are found on some steel structures due to the
local environment.

Some shipyards and fabrication facilities can not dry blast at all,
so some form of water preparation is a requirement.

Wet Abrasive Blast Cleaning

This video demonstrates the use of wet abrasive blast cleaning to
a steel structure.

While the abrasive blast standard is good, and the soluble salts
are considerably reduced the process does generate a water
waste.

This water waste is mixed with the spent abrasive and can be
very difficult to clean up.

it is advantageous to produce the minimal amount of water (whilst

still maintaining dust levels).

© Copyright 2016 Fitz-Coatings Ltd Page 61

 Environmental Concerns
The use of abrasive blast cleaning does create potential water
issues. The water could also be potentially contaminated from the
material on the substrate such as hazardous pigments etc.

The water must be contained and not allowed to enter the water
ways or rivers.

Allowing the water to soak into soil or general land is also not
acceptable.

An environmental plan should be in place prior to commencement

of the works.

Repair to Existing Coatings

Wet abrasive blast cleaning is well suited for maintenance

painting programs.

Spot abrasive blast cleaning can be conducted whilst feather

edging intact coating.

This picture demonstrates how wet abrasive blast cleaning can be

successfully used to conduct maintenance painting.

The level of preparation far exceeds mechanical preparation such

as wire brushing.

Water Injection Wet Abrasive Blast Unit

This animation simply demonstrates how the water is fed to a

mixing chamber with the abrasive before being projected onto the
surface to be prepared.

The water is fed alongside the abrasive blast hose to meet with
the nozzle at the end of the hose.

There are various types of water chambers available to suit the

type of operation.

Fresh water must always be used in the process.

Wet Abrasive Blast Head Attachment System

This animation simply demonstrates how the water is fed directly

to the nozzle where it is mixed with the abrasive as the abrasive
leaves the nozzle.

This process does not always give an ideal mix as the water,
depending upon pressure, will not always penetrate the amount of
abrasive coming through the nozzle.

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 Wet Abrasive Nozzles

Various nozzles for wet abrasive blast cleaning are available to

suit the requirements of the project.

The nozzles must be checked for damage, wear and tear etc.

Do not abuse the nozzles as they can be damaged if not handled

correctly.

Use the correct type of nozzle made from the correct type of
material.

Always check with the equipment supplier.

Wet Blast Cleaning

By using the correct pressures and abrasives, wet blast cleaning
can be used on a number of surfaces without causing damage to
the surface.

Surfaces such as fiber glass and plastics can be wet abrasive

blast cleaned.

Wet and Dry Abrasive Cleaning

Some specifications specify that the structure is wet abrasive

blast cleaned, allowed to dry and then re-blasted with dry abrasive
to achieve a recognized standard.

The above process will allow the use of traditional coatings,

however it is a longer process and obviously more expensive.

If you want a salt free surface with minimal dust and still use
traditional coatings this process is suitable, however at a higher
cost.

Wet Abrasive blast Cleaning

Surface Profile

Wet abrasive blast cleaning leaves a surface profile on the

substrate, which is ideal for coatings.

Most coating manufacturers prefer a surface profile rather than a

smooth surface which may be produced with high pressure
waterjetting if no previous surface profile already existed.

Always check the product data sheets and painting specification

for the surface profile requirement.

Steel Surface after Abrasive Blast Cleaning

This illustration demonstrates how the use of abrasive blast

cleaning can increase the surface area of a steel plate (lower steel

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 plate).

This process happens with both dry and wet abrasive blast
cleaning.

The increase in surface area will also increase the paint usage
however a suitable surface profile will help with paint adhesion.

Hydrojetting ( Waterjetting )

Although the use of water under extremely high pressures can

remove corrosion products, soluble salts etc. the process will not
produce a surface profile, unless a surface profile already exists.

Old corroded substrates can themselves give a surface profile.

As no abrasive are used with the high pressure water jetting, there
will be no spent abrasives to collect as with the wet abrasive blast
cleaning process.

Wet Abrasive Blast Cleaning

One of the major advantages with wet abrasive blast cleaning is

that soluble salts will be removed.

A gingered or oxidized surface is inevitable as the surface dries,

however this is better than having soluble salts present under the
coating system.

The level of gingering has been debatable between paint suppliers

however standards on oxidized surfaces are now available.

Note: SSPC/NACE will be issuing a set of 5 Wet Abrasive

Standards in 2016 titled " Industrial Wet Abrasive Blast
Cleaning"

Dry Abrasive Blast Cleaning

Dry abrasive blast cleaning will not remove soluble salts on the
substrate.

Fresh water washing may be necessary to remove the salts

following the dry abrasive blast cleaning.

The fresh water will not remove soluble salts as efficient as wet
abrasive blast cleaning due to the force of the mixture of abrasive
and water penetrating the surface, especially rough and pitted
surfaces.

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 Wet Abrasive Blast Cleaned Steel

When utilising wet abrasive cleaning, the surface dries and 'light'
oxidization occurs.

The surface is, however, clean from soluble contaminants and

some suppliers have developed coatings systems suited for such
surfaces.

Check with the paint suppliers and standards specified prior to

commencing the works.

A test piece or trial is always recommended so all parties agree

the standard.

Summary
This training unit reviewed the wet abrasive blast cleaning
process.

We reviewed the basic principles of water and abrasive as a

mixture and the advantages and disadvantages of the process.

We discussed the SSPC/NACE visual standards used for wet

abrasive blast cleaning.

We discussed the coating systems and how manufacturers have

developed coating systems for wet abrasive blast cleaned
surfaces.

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