Train the Inspector: Abrasive Blast Cleaning

Blast Media

© Copyright 2016 Fitz-Coatings Ltd

 Types of Abrasives

Objective:
The objective of this training unit is to gain a thorough understanding of the various types of abrasives used
for surface preparation.

The abrasive blast cleaning operator will use a number of abrasives during their tasks.
New "environmentally friendly" abrasives are becoming popular in the work place.

Types of Abrasives

There are numerous types of abrasives used in the abrasive blast

cleaning industry.

All the abrasives have disadvantages and advantages and are

generally specific to certain tasks.

The abrasive blast cleaning operator will use a number of different

abrasives.

Abrasives are an essential part of the abrasive blast cleaning

process.

Abrasives
Abrasives come in many sizes and shapes. They all have
different properties and come from many parts of the globe.

In the protective coatings industry, the main purpose of the

abrasive is to remove mill scale, rust or old coatings and leave a
suitably clean surface for the application of a coating.

There are however various types of surfaces other than steel and
numerous environments where abrasives can (or can not be)
recycled and this allows the use of more than one abrasive.

All the abrasives have different properties and some are more
effective and efficient than others. Some abrasives can be 10X
more expensive than others, however can they be reused a
number of times.

This unit will review the common and generic types of abrasive
used in the protective coatings industry.

Abrasive Selection
When selecting abrasives there are a number of things to
consider.

The substrate or surface to be blast cleaned

The shape and size of the structure
The abrasive blast cleaning facility ie blast chamber or site
works
Existing surface condition such as thick coatings or heavy
rust
Surface cleanliness requirements
Surface profile requirements

© Copyright 2016 Fitz-Coatings Ltd Page 1

 Protective coating type to be applied
Cost and availability of the abrasive

Metallic Abrasives

This video illustrates the use of metallic abrasives as they are

being loaded into an abrasive blast unit.

Metallic abrasives are far heavier than expendable abrasives,

however the metallic abrasives are more economical as they
can be recycled.
Metallic abrasives are very hard and do not break down as
quick as expendable abrasives allowing them to be recycled
a number of times.

Expendable Abrasives

This video demonstrates the use of expendable, use once only,

abrasive as it is being loaded into an abrasive blast unit.

After the abrasive has been used it must be discarded and not
used again.

This abrasive is ideal for site use where it is impractical to

use metallic abrasives.
The main disadvantage to this type of abrasive is the waste
disposal costs, which can also be classified as hazardous.

Abrasive Types

This diagram illustrates the various abrasives used in the abrasive

blast cleaning process.

The main groups are;

1. metallic
2. non-metallic
3. specialist products.

The diagram illustrates the vast range of abrasives that can be

used to clean a wide range of surfaces.

New abrasives will become available in the future.

Note. Although the table does include silica sand it can cause
silicosis and is banned by most countries globally and should not
be considered as a blasting media.

Abrasive Properties
There are a number of factors which have an effect on the
abrasive:

Hardness:

Measured on Rockwell or Mohs scale.(ISO 11127 Specific

Gravity)

The abrasives with the highest specific gravity are the most
efficient.

Information on the abrasive hardness and specific gravity will be

© Copyright 2016 Fitz-Coatings Ltd Page 2
 found on the product data sheets for the abrasive.

Abrasive Properties
Particle Size

The particle size is very important. With metallic abrasives, a

mixture of different sizes is usually best.

With expendable abrasives, they are usually supplied as one size.

In general, the larger the abrasive the larger the surface profile.

The type of surface and coating type and thickness will dictate
the size of abrasive.

Metallic or Non-Metallic
The decision to use metallic or non-metallic abrasive is
determined by the substrate and whether or not you can recycle
the abrasive.

There could be a considerable cost difference between abrasives,

so an evaluation is essential.

Most fixed coating facilities with blast chambers typically use

metallic abrasive.

Metallic abrasive can be used for temporary site works, however

the abrasive must not get damp or wet.

Cast Iron Abrasives

Iron

Cast iron abrasives are supplied in angular grit particles.

They contain hard iron carbides, and since they fracture in a brittle
way upon impact, they clean rapidly by a cutting action similar to
slag abrasives

Cast Iron Abrasives

Steel

Steel abrasives are available in high and low carbon content.

Because of their sharp, angular structure, grit particles are

particularly effective for surface cleaning.

Grit is available in various levels of hardness.

This is an illustration of a typical abrasive blast cleaning chamber

which will use recyclable abrasives such as chilled iron grit.

Abrasive Blast Cleaning in a Blast Chamber

© Copyright 2016 Fitz-Coatings Ltd Page 3

 This video demonstrates the use of metallic abrasive in a small
purpose built blast chamber.

Metallic abrasives such as chilled iron grit can be recycled

making the process effective and efficient.

The abrasives are cleaned and fed back into the abrasive blast
units. New abrasives are required as the abrasive breaks down
over time leading to lower efficiency and a smaller surface profile.

Mechanically Produced (cut wire)

The most common type of metallic abrasive produced by

mechanical processing is cut wire.

Mixtures of grit and shot abrasive can be used to get the correct
surface profile.

Using grit abrasive on it's own will create early wear and tear to
the equipment.

If you have too much shot abrasive you could create a low
surface profile.

The correct mix of grit and shot is important.

Chilled Iron Grit

Chilled Iron Grit is;

sharp
angular
hard and brittle.

On impact the particles break down to form fresh sharp edges

contributing to their rapid cleaning and etching properties.

Chilled iron grits are especially suited for air blast applications
requiring an aggressive cutting rate.

Chilled iron grits produce a very angular profile which is ideally

suited to surface preparation prior the application of metal spray
coatings.

Chilled Iron Grit

This video demonstrates the chilled iron grit abrasive going
through the recycling stage.

The abrasive has been used in an abrasive blast enclosure,

collected after use, cleaned and then returned to the abrasive
blast pot.

Chilled iron abrasive (shot and grit) is very economical as it can

be used a number of times.

Site use may be limited due to the risk of water or moisture

contact with the abrasive.

Damp chilled iron simply corrodes, sticks together and damages

equipment.

© Copyright 2016 Fitz-Coatings Ltd Page 4

 Stainless Steel Abrasive
Stainless steels are one of the most durable abrasives used.

Due to the high cost, this material is used in special industries.

The molten steel is poured in streams through high pressure water

jets, which breaks the material into individual pieces of metal.

Stainless has excellent consistency with regards to density and

hardness.

Automatic Abrasive Blast Cleaning Equipment.

This video demonstrates a pipe that has been pre-cleaned prior to

abrasive blast cleaning in a wheelabrator type equipment.

Mixture of abrasives are often used to achieve the correct

cleaning rate and surface profile.

Periodical inspection should be conducted on the mix of abrasives

used in the blast machine.

Typical Wheelabrator in Operation

This animation demonstrates the use of a typical wheelabrator.

The steel is placed on rollers and pushed through the blast

machine.

This process can be very efficient, especially for flat plate etc.

A mixture of abrasives are used to suit the project requirements.

Centrifugal Blast Machine

The centrifugal (wheelabrator) blast cleaning machine generally
uses shot (round) chilled iron abrasive within the machine.

The surface profile produced is generally low.

The abrasive is recycled and is an ideal process for steel plates

etc

Angular abrasive would wear certain parts of the equipment so

most operators used the shot abrasive.

© Copyright 2016 Fitz-Coatings Ltd Page 5

 Mechanically Produced

Cut wire abrasives have excellent cleaning rates where an

aggressive abrasive is required.

This is an illustration of a portable abrasive blast unit which is

used to abrasive blast clean flat surfaces such as road surfaces
and ships decks etc.

The abrasives are recycled within the body of the blast unit
making the process very economical.

The blast unit is a dust free process so other trades are not at risk
from flying debris etc.

Portable Blast Unit

This video demonstrates the use of a portable blast unit on a flat

steel structure.

Metallic abrasives such as shot abrasive are typically used within

the machine which are recycled.

It is important that the abrasive does not get damp or wet.

The process can be used around other trades as the abrasive is

contained within the blast unit.

Close up of: (in order)

Metallic Abrasive (Grit) - Angular

Copper Slag (Expendable) - Angular
Metallic Abrasive (Shot) - Round

The amount of abrasive used will vary depending upon the

thickness or amount of rust or paint on the surface, hardness of
abrasive, if the surface is pitted, pressures used and skill of the
operator.

25 to 75 kilos per square metre (5.5 to 16.5 pounds per square

feet) can be used, depending upon the configuration and condition
of the surface.

Note: The most common pressure at the nozzle when using a

non-metallic abrasive such as coal slag is 80-110 psi.

Abrasive Blast Cleaning - Shot

This animation demonstrates the abrasive blast cleaning with the

use of shot as the blast material.

Shot abrasive will give a low surface profile and generally a

smoother surface.

Shot abrasive is generally used in automated equipment.

Sometimes grit abrasives are mixed with the shot abrasive to give
a better mix.

Abrasive manufacturers typically relate their products to type and

size ie S 330 which is Shot (s) and 33 thousands of an inch =
.85mm. or S 220 which is shot at 22 thousands of an inch
=.56mm.

© Copyright 2016 Fitz-Coatings Ltd Page 6

 Abrasive Blast Cleaning - Grit

This animation demonstrates abrasive blast cleaning with the use

of grit abrasive.

Grit abrasive will give a bigger surface profile than shot abrasive.

Grit abrasive is available in a number of grades and different

levels of hardness.

Various levels of surface profile can be achieved with grit

abrasive.

Always check the painting specification for the exact surface

profile requirements.

Natural Abrasives

There are a number of natural abrasives available:

Silica - Not used due to the associated health risks such as

silicosis.
Olivine - A silicate of iron and magnesium.
Garnet - Hard silicate mineral available from different regions
of the globe.
Calcium Carbonate -A natural material in the form of a
powder.

Garnet
Garnet is an ideal abrasive for conducting surface preparation on
repairs or field welds.

The abrasive is sharp and can give a good surface profile even at
low pressures.

Although the abrasive has to be contained and collected it is

cleaner than iron silicates (copper slags) and similar dark and
dusty abrasives.

Spot Repair
The type of abrasive can influence how a spot repair is conducted
on an existing coating.

This photo demonstrates a blast repair to a relatively thick

existing coating (1000 microns - 40 Mil).

The blast cleaned steel can be seen along with the hi-build
coating (grey) and top coat (yellow).

By selecting the correct abrasive and utilizing the right pressure

the blast cleaning operative can feather edge the edges on the
existing coatings.

Minimal grinding or hand abrade will be required.

© Copyright 2016 Fitz-Coatings Ltd Page 7

 Walnut shells
Walnut shell is a biodegradable, natural product made entirely
from ground or crushed walnut shells.

As the product is relatively soft, there is little chance of damage

to component substrates.

Applications Include;

Removal of corrosion and carbon from automotive components

and electrical equipment

Surface cleaning without the risk of dimensional change.

Cleaning marine turbines.
Removing paint and graffiti

The walnut generally removes the risk of damage to a surface or

surface parts and can be controlled by the operator.

Synthetic Abrasive

A number of synthetic abrasives are available:

Iron silicate - More often referred to as 'copper slag'.

Aluminium silicate - Bi-product of power stations.
Calcium silicate - Bi-product of iron smelting.
Aluminium oxide - Hard abrasive which is generally
recycled.

Synthetic Abrasive

Other synthetic abrasives include:

Bauxite - Hydrated aluminium oxide.

Glass bead or grit - Bead used in peening applications.
Plastic - Used extensively in the aerospace industry. This
abrasive is made from recycled white products as well as
manufactured pellets.

Glass Abrasive
Crushed glass abrasive blast is generally made from 100%
recycled glass.

This is an inert abrasive that is recommended as a substitute for

slag and mineral abrasives.

Glass contains no heavy metals, no free silica, and is therefore

good for blasting projects where it is impractical to recover lost or
spilled spent abrasive.

Glass abrasive is available in a number of sizes to suit the

project.

© Copyright 2016 Fitz-Coatings Ltd Page 8

 Glass abrasives are generally available in brown or green colours.

Iron Silicate
Iron silicate (commonly referred to as copper slag) is an abrasive
made from granulated slag which is a byproduct of metal melting
processes.

This abrasive is very popular for general abrasive blast cleaning

where the abrasive is used once only (expendable).

The abrasive is generally available in a number of sizes to suit the

requirements.

The abrasive is dark and breaks down rapidly so early clean up is

essential.

Specialist Product

Specialised abrasives are also available to suit some

applications:

Natural abrasives - Walnut shells, olive stones, peach

stones, corncobs etc.

Sodium bicarbonate - Also known as baking soda, a soft

white crystalline product that is an alkaline water-soluble
chemical.

Bicarbonate Soda Abrasive

Bicarbonate soda is a relatively soft and friable media.

Upon striking the work surface, the media crystals quickly

disintegrate without damaging the surface or distorting the
substrate.

The process can remove grease, oil, graffiti and paint from
delicate parts and surfaces.

The equipment is portable and the pressures can be adjusted to

suit the task.

Abrasive Blast Cleaning - Dry Ice

This animation illustrates the use of abrasive blast cleaning with

the use of dry ice.

The abrasive will remove dirt and grime but will not remove the
coatings.

The process is popular in some industries where abrasive blast

cleaning will not be permitted.

© Copyright 2016 Fitz-Coatings Ltd Page 9

 Dry Ice Abrasive
Dry ice blasting is also known as dry ice cleaning or CO2 (carbon
dioxide) blasting.

Solid carbon dioxide (as illustrated) is propelled at high velocities

to impact and clean a surface.

As the ice hits the surface, it immediately turns from a solid state
into carbon dioxide vapour to many times its volume.

Kinetic energy is transferred from the dry ice media to the surface
being cleaned.

Sponge Blast

Special sponge-like media impregnated with an abrasive.

The sponge blast media reduces abrasive break-up and traps

surface material on impact to minimize dust and airborne
contaminants.

Various abrasives used with the different types of sponge.

Sponge blasting has become popular as there is minimal dust

created while still preparing the surface.

Sponge Blasting Media

Sponge Blasting Media is manufactured by surrounding the
abrasive with a tough, porous urethane sponge material, which
controls or suppresses dust.

The sponge blast media is available in various types of abrasive

to suit the requirements of the contract and has been shown to
suppresses up to 99% of what would normally become airborne
dust.

Sponge media particles flatten as they strike the surface, then

expose the abrasive to cut into the coating and substrate.

Various types of surface profile can be achieved.

Abrasive Blast Cleaning - Sponge

This animation demonstrates the use of abrasive blast cleaning

with the use abrasive encapsulated in a sponge matrix.

Little bounce back is found with the abrasive, as the energy is lost
within the sponge matrix.

The sponge has to be collected and reused to make the process

economical.

The sponge can also be dampened.

© Copyright 2016 Fitz-Coatings Ltd Page 10

 Abrasive Contamination
It is important to order abrasives from reputable abrasive suppliers
who will supply a certificate of conformity and detail the analysis
which should include salt content etc.

Two basic site tests can be conducted as a guide on other

contaminants:

Dust – Place abrasives in a jug and pour fresh water over the top
to cover the abrasive and slightly stir or shake. Assess the dust
content on the water.

Oil or grease – Place abrasives in a jug and pour solvents over

the top to cover the abrasive and slightly stir or shake, pour the
solvent onto a clean glass plate and allow to evaporate. Any
contamination will be left on the glass.

Note – Take Health and Safety Precautions on the tests and note
these are guidelines only and a full laboratory analysis would be
necessary to obtain exact results.

Vial Test
You can conduct a simple test on abrasives by dropping some
water into the abrasives and shake. Typically it is one volume
water and two volume abrasive.

Inspect the top of the water for visible grease or oil. You can also
check turbidity (cloudiness due to sediment) which is usually a
sign of excess dirt, dust etc. If you use deionized water you can
also do a pH test with litmus paper (should be about 5 to 8).

Reference document; ASTM D7393 Standard Practice for

Indicating Oil in Abrasives

Abrasives
When the abrasives are delivered to site they should be checked
against the purchase order to ensure it is the correct grade and
size etc.

There should be no damage to the bags.

The abrasive should be suitably stored and kept away from

moisture and general dampness.

Check the coating specification for any batch testing etc.

If there are any particular issues keep a sample of new and used
abrasive for any investigation.

© Copyright 2016 Fitz-Coatings Ltd Page 11

 Abrasive Size
Abrasive is generally available in one or more sizes. Abrasives
are graded according to how fine a mesh or sieve screen they can
pass through without one particle of the abrasive remaining on the
mesh.

Approx 2.2 Ibs (1,000 g) is generally used and poured into the
nested screens.

The screens are nested so that the screens with the largest
openings is on top. The screens get gradually smaller.

The specification will specify the grade of abrasive to be used.

Abrasive Standards
There are various standards globally for abrasives.

The SSPC Society for Protective Coatings has four standards

available for abrasives which relate to the coatings industry.

SSPC-AB 1 (Mineral & Slag Abrasives)

SSPC-AB 2 (Cleanliness of Recycled Abrasive)
SSPC-AB 3 (Ferrous Metal Abrasives)
SSPC-AB 4 (Recyclable Encapsulated Media)

These standards have various methods of tests such as size,

specific gravity, composition, hardness, durability, cleanliness
etc.

Summary
This unit has demonstrated that there are various types of
abrasive used globally.

The abrasive blast cleaning operative will probably utilize many

types of abrasives as they are specifically chosen for the task.

The main groups are metallic (iron and steel) and non-metallic
(natural and synthetic) also specialist products such as ice etc.

The abrasives are very important for surface treatment and will
influence a number of things including, surface profile, cleaning
rates, environmental constraints, cost of the process.

© Copyright 2016 Fitz-Coatings Ltd Page 12

 Surface Profile

Objective:
The objective of this training unit is to gain an understanding of surface profile and how it effects coatings
systems.

Surface profile can have an influence on coating performance.

A number of factors effect surface profile such as type of abrasive, pressures used, angle of abrasive
impact etc.

Surface Profile

Surface profile is generally defined as the maximum average peak

to valley depth caused by the impact of the abrasive, which has
been projected onto the substrate.

Surface profile is also called:

Surface roughness.
Anchor pattern.
Amplitude and etch.

The term can vary from country to country.

Surface Profile

Abrasive blast cleaning increases the surface area of the steel.

It is an important issue in corrosion protection of steel surfaces as

the surface profile provides the mechanical key for the coating to
adhere to.

The surface profile can determine the adhesion value of a coating

and is a very important aspect to coatings and corrosion
protection.

If a blast cleaned standard is specified you will usually find the

surface profile is specified also.

Surface Area

This illustration demonstrates the surface area between a smooth

plate and a plate that has been abrasive blast cleaned.

The surface area is increased on the abrasive blast cleaned plate.

This increase in surface area will use more paint material if the
surface is to be coated.

Generally the rougher the surface the thicker requirement for the
paint film thickness to ensure all the peaks are fully coated.

© Copyright 2016 Fitz-Coatings Ltd Page 13

 Surface Profile

The main contributing factor in obtaining a surface profile is the

abrasive particle size.

Other factors include:

The condition of the steel surface.

Pressures used during abrasive blast cleaning.
The angle to which the abrasive blast cleaning is conducted.
The distance between the nozzle and the surface.

Abrasive (grit)

The use of grit will produce a roughened surface.

The larger the particle size the larger the surface profile.

Large surface profiles may suit thick coatings i.e. solvent free
high build coatings used for steel protection.

Rust rashing is a possibility with a high surface profile and a low

dry film thickness coating as some of the steel peaks may not be
covered by the paint.

Surface Profile -Grit Abrasive

This schematic represents a surface profile with the use of grit

abrasive.

The angular surface is ideal for the mechanical key required by

some coatings.

The surface should have an irregular surface as illustrated which

can be good for gripping the coatings and offering good adhesion,
especially for coatings such as thermal metal spray.

Abrasive Blast Cleaning -Grit Abrasive

This animation illustrates the use of abrasive blast cleaning with

the use of grit as the blast medium.

The grit will produce a roughened surface profile.

The larger the particle size the larger the surface profile.

Always check the painting specification for surface profile

requirements during abrasive blast cleaning.

© Copyright 2016 Fitz-Coatings Ltd Page 14

 Abrasive (Shot)

The use of shot abrasive will produce a smoother surface than grit
abrasive.

Shot abrasive is generally used in mechanical equipment such as

wheelabrators, tumble blast and portable blast machines.

The use of grit abrasive alone in mechanical equipment will

increase wear on the equipment parts.

Surface Profile - Shot Abrasive

This schematic demonstrates the surface profile on a steel plate

that was abrasive blast cleaned using shot abrasive.

The smooth profile is typically found with mechanical blast

cleaning equipment when the abrasive is worn.

The illustration demonstrates the difference between shot

abrasive compared to grit abrasive.

Check the paint specification for specific requirements on surface

profile before you commence the work.

Abrasive Blast Cleaning - Shot Abrasive

This animation illustrates the use of abrasive blast cleaning with

the use of shot as the blast medium.

The use of shot as an abrasive will produce a smooth surface.

Some coatings require a minimum surface profile so it advisable

to check the product data sheet and specific suppliers.

Surface profile and coatings

As a general rule, a bigger surface profile is required when using

thick coatings such as solvent free or hi-build glass flake
coatings.

If the surface profile is not covered by the coating, rust spotting is

inevitable.

This picture demonstrates rust spotting on a blast primer with a

high surface profile.

Ensure the surface profile is the correct size and the coating is
the correct thickness.

Surface Profile

Animation of a slow drying coating which may move away from

the peak of the profile leaving some metal exposed.

As a general rule, a large surface profile should be covered by a

thicker coating.

If the surface profile is not covered by the coating, rust spotting is

© Copyright 2016 Fitz-Coatings Ltd Page 15

 inevitable.

Ensure you achieve the correct size surface profile.

Surface Profile

This animation demonstrates the use of a fast drying coating on

the surface profile.

Certain coatings dry very fast which allows the coating to cover
the surface profile and not run away from the peak.

Typically these coatings are blast primers and have fast solvents
allowing quick evaporation and drying.

Blast Primer Application

This video demonstrates the application of a blast primer applied

to an abrasive blast cleaned surface.

As the blast primer is fast drying it will cover all the surface
profile.

This process is widely used in paint shops and general fabrication

and will minimize the risk of rust spotting as the peaks of the
primer should be covered.

High Build Coatings

Some coatings are applied at 500, 750 or 1,000 microns ( 20, 30

or 40 mil ) and above.

A high surface profile is generally recommended by the coating

manufacturers and it is advisable to check the application data
sheets.

Always check the painting specification for details of the surface

profile. Also test methods such as ASTM D4417 which defines
three methods for field measurement of surface profile of blast
cleaned steel.

Sometime a range is specified such as 75 to 100 microns (3 to 4

mils).

High Performance Coatings

High performance coatings such as thermal metal spray coatings

require both:

High level of cleanliness.

The correct surface profile and degree of roughness.

If one or both of the above are not achieved, adhesion failure is a

possibility.

This picture demonstrates the use of Arc spray thermal coatings

onto an abrasive blast cleaned surface which has a high level of
cleanliness and roughness.

Thermal Spray Coating Application

© Copyright 2016 Fitz-Coatings Ltd Page 16

 This video demonstrates the application of a thermal spray
coating onto a abrasive blast cleaned surface.

The correct surface profile is essential to achieve the mechanical

key for this type of coating.

The surface profile must be consistent throughout the process.

New abrasives may increase the surface profile and old abrasive
may reduce the surface profile.

Thermal Metal Spray

This animation illustrates the use of thermal spray equipment to

apply melted wire, usually zinc and aluminium, to a prepared
surface.

As the melted wire sticks mechanically, it is essential to have the

correct surface profile.

Adhesion values of the applied coatings is often checked as this

test can be conducted immediately after application.

Check the coating specification for the minimum adhesion values

and exact method of testing.

Surface Profile

There are a number of methods for testing or checking of the

surface profile.

One of the earliest and most widely used is the needle gauge.

Needle Gauge

The gauge is placed onto the surface and the needle is pushed
into the trough. The instrument provides a direct reading of the
surface profile onto the gauge which can be read immediately.

Surface Profile Gauge

This gauge is used to check the surface profile on an abrasive

blast cleaned surface.

The gauge is pressed directly down onto the blast cleaned surface
as demonstrated.

The needle measures the peak to trough or valley, which is then

shown on the dial.

The process is simple to use and operate, however single

readings are given only so a number of readings are required to
get an average.

© Copyright 2016 Fitz-Coatings Ltd Page 17

 Surface Profile Replica Tape

The tape is pressed onto the surface profile and rubbed with a
round headed spatula.

The profile is 'copied' onto the tape which is then measured with a
micrometer.

The tape replicates maximum profile readings.

The tape can then be kept for record purposes and generally
attached to the inspection report.

Surface Profile Testing - Replica Tape

The tape is pressed onto the surface profile and rubbed with a
round head spatula as illustrated.

The surface profile is copied onto the tape, which is then

measured with a micrometer.

Three main grades of the tape are available so you have to ensure
you purchase the correct grade to suit the process.

Coarse 20 to 64 microns (0.8 to 2.5 mils)

X-Coarse 38 to 115 microns ( 1.5 to 4.5 mils)

X-Coarse Plus 116 to 127 microns ( 4.6 to 5.0 mils )

Note: A fourth grade "coarse minus" 12-25 microns (.5 to 1.0 mils)
exists but is rarely used in the coatings industry.

Replica Tape Measurement

It is also possible to measure the replica tape with an electronic
instrument. The instrument automatically deducts the thickness of
the replica tape giving an instant reading on the front of the
instrument as illustrated.

The replica tape can be attached to the daily inspection report for
future reference.

Surface Profile Comparator Gauge

The comparator gauge is an ISO standard and therefore frequently

specified and used.

It is also addressed in ASTM D4417, Method A.

The comparator is visually made from nickel plate and is available

in grit (G) and shot (S) grades.

The comparator has four segments which are compared against

the surface profile as demonstrated in this picture.

Ensure you read the instructions and specific standard before

using the comparator.

© Copyright 2016 Fitz-Coatings Ltd Page 18

 Surface Profile Testing - Comparator

This video demonstrates the use of a comparator gauge to

assess the surface profile on a abrasive blast cleaned surface.

It is not always easy to view due to the colour of the comparator

and colour of the abrasive blast cleaned surface etc.
Environmental lighting may also affect the visual appearance.

Tactile testing can also be conducted with the back of your nail.

Keane-Tator Surface Comparator

A Kean-Tator surface comparator is also available.

This comparator conforms to an ASTM Standard (D4417) and

uses a Nickel Comparator which is available in sand, shot and
grit/slag.

The disk is held on the surface with a illuminated magnifier.

There are five segments to each type of comparator each

illustrating different surface profiles.

This gauge is used widely in North America.

Summary
This training unit reviewed the reasons why abrasive blast
cleaning gives a surface profile, also the importance to achieving
the correct surface profile prior to coating application.

We reviewed the steps that can be taken to increase or decrease

the surface profile and the instruments used to measure the
surface profile.

© Copyright 2016 Fitz-Coatings Ltd Page 19