Train the Inspector: Abrasive Blast Cleaning

Standards and Quality Control

© Copyright 2016 Fitz-Coatings Ltd

 Visual (Photographic) Standards

Objective:
The objective of this training unit is to gain a thorough understanding of recognised standards used in the
coatings industry.

The Abrasive Blast Cleaning Operator will have their work assessed against visual (photographic)
standards and guides.
A number of visual (photographic) standards exist in the coatings industry.

Abrasive Blast Cleaner

The role of the abrasive blast cleaning operative is to abrasive
blast clean a substrate (steel) free from corrosion, rust, old
coatings or a mixture of all theses items.

The surface that remains can be checked against specific

standards. These standards will be specified in the coating
specification.

Visual (pictorial) standards and guides have been developed to

ensure that abrasive blast cleaning standards can be defined prior
to commencement of the works.

It is important that the abrasive blast cleaning operative

understands the principals of visual standards.

Steel Condition
Everywhere you look you will see steelwork which is used in
abundance for bridges, fabrications, ships/vessels, oil rigs, jetties,
tanks, pipe work etc.

Steelwork will be exposed to various types of environmental

exposure, with some structures being well maintained, while
others have little maintenance.

The abrasive blast cleaning operative will also need to understand

that abrasive blast cleaning visual standards will differ depending
upon the initial condition of the structure.

Steelwork Initial Condition

When steel is manufactured, mill scale is formed as the metal is
cooled. This mill scale (steel mill) is a very tough and tenacious
layer which would protect the steel if it stayed on the surface.

However over time the mill scale is detached (hot/cold

temperature changes etc) and the steel is then exposed to the
environment. The steel will corrode (rust) over a period of time.
This period of time will depend on the environment and the extent
of corrosive species such as soluble salts etc.

Visual Standards have been developed which used four levels of

initial steel condition from intact mill scale to pitted steelwork.

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 Mill Scale and Temperature Changes
This animation demonstrates how mill scale cracks as it has a
lower thermal expansion than steel.

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.

Visual Standards
Visual Standards are only produced by a few organizations.

SSPC The Society for Protective Coatings and NACE are the two
USA based organizations who produce Joint surface preparation
standards.

These standards are specified widely in the USA, Middle east,

Africa and Far East.

Some of the standards are multi-language.

Visual Standards
ISO (International Standards Organization) also produces visual
standards for surface preparation.

These documents are widely specified throughout Europe and are

also used in the Middle East, Africa and the Far East, Australasia
etc.

The standards have various languages translations

SSPC/NACE Visual Standards (guides and

reference photographs)
There are two visual abrasive blast cleaning standards from
SSPC/NACE.

SSPC-VIS 1*

Guide and reference photographs for steel surfaces prepared by

dry abrasive blast cleaning

SSPC-VIS 5/NACE VIS 9

Guide and reference photographs for steel surfaces prepared by

wet abrasive blast cleaning

We will briefly review both these visual standards

Note: The visual guides are intended to supplement the SSPC

- NACE written Standards

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 * Not a joint SSPC/NACE standard

ISO Visual Standards

There are three ISO visual standards relating to abrasive blast
cleaning.

ISO 8501-1

Preparation of steel substrates before application of paints and

related products- Visual assessment of cleanliness-

Part 1: Rust grades and preparation grades of uncoated steel

substrates and of steel substrates after overall removal of
previous coatings.

ISO 8501-2

Preparation of steel substrates before application of paints and

related products- Visual assessment of surface cleanliness-

Part 2: Preparation grades of previously coated steel substrates

after localized removal of previous coatings.

We will briefly review these two documents.

SSPC-VIS 1 Guide and Reference Photographs

This is the SSPC Visual guide for dry abrasive blast cleaning.

The guide is a laminated fold-back booklet which is available in

English and Spanish.

Scope:

The guide describes the use of reference photographs depicting

the appearance of both previously unpainted and previously
painted and partially hot-rolled carbon steel prior to and after
abrasive blast cleaning. The photographs are intended to be used
to supplement written SSPC/NACE International blast cleaning
standards.

SSPC-VIS 1
The guide depicts four initial conditions of unpainted steel.

Degree of cleaning over condition A

Degree of cleaning over condition B
Degree of cleaning over condition C
Degree of cleaning over condition D

'A' has little or no rust and 'B' is covered in rust and is pitted.

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 SSPC-VIS 1
There are three initial conditions over painted steel.

Degree of cleaning over condition G1

Degree of cleaning over condition G2
Degree of cleaning over condition G3

Condition G1 has extensive pinpoint rusting and Condition G3 has

severe pitting.

All G conditions refer to coatings applied over mill scale bearing

steel: system thoroughly weathered, blistered and stained.

SSPC-VIS 1
The pictorial blast standards are then shown for the:

1. Initial Condition (A,B,C,D, or G1 , G2 , G3 )

2. Specific Standard:

SP 5/NACE No.1 White metal blast cleaning

SP 6/NACE No.3 Commercial blast cleaning
SP 7/NACE No.4 Brush off blast cleaning
SP 10/NACE No.2 Near-white blast cleaning
SP 14/NACE No. 8 Industrial blast cleaning

There are photographs labeled H, L and D which reference the

angle of view.

Note; The blast standards will have written descriptions and detail
the extent of material ie. SP-10 permits no more than 5% rust
staining.

SSPC-VIS 5/NACE VIS 9

The SSPC-VIS 5/NACE VIS 9 is the visual guide used for wet
abrasive blast cleaning.

The guide is a laminated fold-back booklet which is available in

English only.

Scope

The scope of the guide describes the use of reference

photographs depicting the appearance of unpainted, rusted carbon
steel prior to and after cleaning by wet abrasive blast cleaning
(WAB) (slurry blasting).

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 Initial Condition
The reference photographs illustrate two initial conditions of
previously unpainted, rusted carbon steel before surface
preparation.

Condition C: Steel completely covered with rust, little or no

pitting visible. (SSPC-VIS 1)

Condition D: Steel surfaces completely covered with rust, pitting

visible (SSPC-VIS 1)

End Condition
The reference photographs illustrate surfaces prepared by wet
abrasive blast cleaning using one abrasive. The various degrees
of cleaning represented are:

SSPC-SP 6/NACE No.3 Commercial blast cleaning

SSPC-SP 10/NACE No.2 Near white blast cleaning

The guide also illustrates photographs of flash rusting:

L = Light flash rust

M = Moderate flash rust
H = Heavy flash rust

So this photograph depicts:

Initial steel condition 'D', wet abrasive blast cleaned SSPC-SP

6/NACE No.3 Commercial blast cleaning and a 'H' heavy flash
rusting

ISO 8501-1
The ISO 8501-1 is a hard back A5 book which includes the
pictorial standards and text in a number of languages.

The title of the standard is:

Preparation of steel substrates before application of paints and

related products-Visual assessment of surface cleanliness-

Part 1: Rust grades and preparation grades of uncoated steel

substrates and of steel substrates after removal of previous
coatings.

Initial Steel Conditions

There are an four initial grades rust grades (A,B,C and D):

A - Steel surface largely covered with adhering mill scale, but little
if any rust.

B - Steel surfaces which have begun to rust and from which the
mill scale has begun to flake.

C- Steel surface on which the mill scale has rusted away or from
which it can be scraped, but with slight pitting under normal
vision.

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 D- Steel surface on which the mill scale has rusted away and on
which general pitting is visible under normal vision.

Blast Cleaning Standards

The standard has four blast cleaning grades: (all viewed with
magnification)

Sa 1 - Light blast cleaning. Surface shall be free from visible oil,

grease, and dirt and from poorly adhering mill scale, rust, paint
coatings and foreign matter.

Sa 2 - Thorough blast cleaning. Surface shall be free from

visible oil, grease or dirt, and from most of the mill scale, rust,
paint coatings and foreign matter. Any residual contamination
shall be firmly adhering.

Blast Cleaning Grades

The standard has four blast cleaning grades: (all viewed with
magnification)

Sa 2 1/2 - Very thorough blast cleaning. Surface shall be free

from visible oil, grease and dirt - and from mill scale, rust, paint
coatings and foreign matter. Any remaining traces shall show only
as slight stains in the form of spots or stripes.

Sa 3 - Blast Cleaning to visually clean steel. Surface shall be

free from visible oil, grease and dirt - and shall be free from mill
scale, rust, paint coatings and foreign matter. It shall have a
uniform metallic colour.

Different Abrasives
The ISO 8501-1 also includes representative photographic
examples of the change of appearance imparted to steel when
blast-cleaned with different abrasives.

Abrasives include:

High-carbon cast steel shot

Steel grit
Chilled iron grit
Copper refinery slag
Coal furnace slag

ISO 8501-2
The layout of this standard is similar to the ISO 8501-1.

This standard is entitled: the preparation of steel substrates

before the application of paints and related products - Visual
assessment of surface cleanliness-

Part 2: Preparation grades of previously coated steel substrates

after localized removal of previous coatings.

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 ISO 8501-2
The abrasive blast cleaning section of the standard refers to
localized blast-cleaning of previously coated surfaces, P Sa

The standard uses a number of plates to demonstrate:

1. Typical cases of very thorough localized blast cleaning (P Sa

2½)
2. Extreme cases of very thorough localized blast cleaning (P
Sa 2½)

ISO 8501-2
Typical cases of very thorough localized blast cleaning (P Sa
2½)

This is an example of a typical case of very thorough localized

blast-cleaning (P Sa 2½) to a red oxide shop primer.

The rusted welds were localized blast cleaned, leaving the iron
oxide primer intact other than the weld areas.

ISO 8501-2
Typical cases of very thorough localized blast cleaning (P Sa
2½)

This photograph is another typical case of a very thorough

localized blast-cleaned corrosion protection system (P Sa 2½)

The coating is a red lead/ micaceous iron oxide which has been
exposed for a long period of time.

ISO 8501-2
Extreme cases of very thorough localized blast cleaning (P
Sa 2½)

This photograph shows a localized blast cleaning of spots on

areas showing a generally sound coating that required only partial
repair.

© Copyright 2016 Fitz-Coatings Ltd Page 7

 Summary
This training unit has reviewed the following standards and guides
which are used as visual standards for wet and dry abrasive blast
cleaning.

SSPC-VIS 1

SSPC-VIS 4/NACE VIS 7

ISO 8501-1

ISO 8501-2

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 Surface Cleanliness

Objective:
The objective of this training unit is to understand the importance of surface cleanliness after abrasive blast
cleaning and prior to coating operations.

It is essential that the abrasive blast cleaned surface is clean prior to coating operations.
It is generally the duty of the Abrasive Blast Cleaning Operator to ensure that light dust and debris is
removed after abrasive blast cleaning.

Surface Cleanliness

The general objective for an abrasive blast cleaning operator is to

abrasive blast clean a surface, usually steel, to a specified
standard such as ISO, NACE, SSPC etc.

Once the specified standard has been achieved the next process
prior to coating is to ensure the surface is free from dust, grit etc.

It is no good achieving a high standard of surface preparation and

not cleaning correctly before coating.

Surface Cleanliness

If dust, grit etc. is left on the surface prior to coating application,

the coating will not 'wet' the substrate.

Once the coating has dried it will fall away from the substrate.

It is essential that applicators and inspectors fully understand the

implications of inadequate cleaning.

The inspection process must follow through from visual inspection

of the substrate to the cleanliness inspection.

Abrasive Blast Cleaned Steel

This schematic illustrates an abrasive blast cleaned surface

which has dust in the bottom of the surface profile.

If paint is applied to a dusty surface the paint will not be able to

wet this surface and achieve the desired adhesion.

Note. It may be some time after abrasive blast cleaning, before all
the dust settles on the horizontal surfaces.

Coating Application

This animation demonstrates that if a abrasive blast cleaned

surface is not clean from dust and debris coating will not adhere
and failure is inevitable.
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 Some dusts can be tiny and a very thorough cleaning is
recommended.

Be aware that the dust is not always clearly visible, especially in

areas of poor lighting.

A clear sellotape dust test method such as ISO 8502-3 may be a

requirement, however always check the painting specification for
the exact test method.

Abrasive and Dust collection

Specialised equipment such as grit recovery systems and dust

removal systems are used during and after abrasive blast
cleaning.

Light dust, however, usually settles on horizontal surfaces and

final cleaning is required.

These dust extraction units are available in a number of sizes to

suit the application from factory units to smaller site units.

Dust Collection
It is essential that adequate dust collection is used on a
continuous basis throughout the abrasive blast cleaning process.
Ideally there should be about eight air changes per hour. This will
ensure the abrasive blast cleaning operative can see clearly and
the area remains a safe area.

Mobile units are avaialble as illustrated.

Good dust collection will also minimize the final clean after the
abrasive blast cleaning.

The equipment should remain in operation during both the

abrasive blast cleaning up to the final cleaning.

Compressed Air

A light blow down with clean dry air is sometimes conducted.

However, beware of blowing the dust from one area to another.

Full personal protection equipment is required for this task:

Eye protection.
Mouth inhalation protection.

Vacuum cleaning may also be required on some surfaces.

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 Abrasive Cleaners
It is essential that the cleaning operation is conducted by
personnel with the use of correct air fed full face protection.
Cleaning abrasive and final cleaning will create a lot of air borne
dusts that will be hazardous to the operatives and can easily be
inhaled.

Some spent abrasives can be extremely hazardous as they could

be mixed with contaminated coatings which may contain lead etc.

Body and hand protection is also a requirement.

Vacuum Cleaning

Vacuum cleaning for final clean is often specified and conducted,

especially in tank and vessel painting.

This process ensures all dust and debris is removed prior to

coating operations.

Try and remove dust in a logical fashion starting at one end and
finishing at another.

Vacuum Cleaning

This animation illustrates how effective vacuum cleaning can be,

especially to horizontal flat surfaces.

All the dust is collected from within the surface profile.

The vacuum units can be quite powerful and are available with
different heads to suit the task.

Regular cleaning of the equipment is often necessary.

Vacuum Cleaning
This video demonstrates the vacuum cleaning process that is
being conducted on an abrasive blast cleaned substrate.

Vacuum cleaning is an essential process for certain coatings in

specific environments such as tank and vessel lining.

The cleaning operative must have personal protection along with

coveralls and cover shoes as illustrated.

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 Dusts

Inspection for light dust can be easily conducted with the use of
clear tape pressed onto the surface and inspected for dust
attachment.

This method is recognized in the ISO standard 8502-3.

Check the painting specification for the requirements on

inspection and test method.

Some locations and coatings are more sensitive to dusts than

others. You may see this test method specified for special linings
used for immersion services.

Dust Test
The dust test is a simple test to conduct and comes in a dust test
kit consisting of the tape and assessment sheets. The tape can
be applied directly to the sheet as illustrated.

The coating specification will define the minimum size and

quantity of the abrasive which can be compared with the dust
charts.

The test is a pass/fail test.

Soluble Iron Corrosion Products (Soluble Salts)

Even when the steel has been blast cleaned to a high standard
(Sa3, SP5 etc) there is no guarantee that the surface is free from
surface contaminants, such as soluble salts.

Dry abrasive blast cleaning will not remove these salts, which left
on the surface will be detrimental to coating systems.

These salts are formed by the action of sulphate or chloride

contaminants.

While the abrasive blast cleaning operative is responsible for

removing dusts and debris after abrasive blast cleaning they can
not remove soluble contamination on an abrasive blast cleaned
surface without additional methods of surface cleaning.

Soluble Salt Assessment

You will not see the soluble salts on the surface immediately after
blast cleaning as they are virtually invisible. (they will eventually
discolour as previous picture)

The coating specification will specify the maximum amount of

salts allowed and may also specify the standard to determine the
figure.

If the maximum amount of soluble salts are exceeded then an

additional form of surface cleaning will also be required.

As the salts are soluble then removal with water is generally

conducted.

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 Wet Abrasive Blast Cleaning
If soluble salts are present above the specified or recommenced
amount the options generally available consist of:

1. Washing the blast cleaned (dry) surface and reverting back to

another dry blast.
2. Wet abrasive blast clean (as illustrated). A change in the
coating specification may then be required.
3. Water jetting with high pressures without the use of abrasive.
No surface profile is achieved with water alone.

Soluble Salts

This illustration demonstrates a clean abrasive blast cleaned

surface free from soluble salts.

These salts, if present, must be removed or there is a risk of

premature coatings failure.

The salts can be more of a problem if coatings are subject to

immersion. Osmotic blistering can be a major problem with certain
immersed coatings.

Soluble Salts

The soluble salts can be found in the marine environment and

coastal locations.

A fresh water wash may be necessary to remove these salts after

abrasive blast cleaning.

Some salts are however found at the bottom of pitted steel and
very difficult to remove.

Wet abrasive blast cleaning is an option or water jetting if a

surface profile already exists.

Summary
This training unit reviewed the cleaning after the abrasive blast
cleaning process in order to ensure that surfaes are free from dust
and debris prior to any coating operations.

The test method for dust determination was also reviewed and we
discussed surface contamination with soluble salts and the
options on how to remove them.

© Copyright 2016 Fitz-Coatings Ltd Page 13

 Environmental Conditions

Objective:
The objective of this training unit is to understand the requirement to use, control and monitor environmental
plant and equipment during and after abrasive blast cleaning.

Environmental conditions must be maintained to ensure premature deterioration of abrasive blast cleaned
surfaces does not occur.
The Abrasive Blast Cleaning Operator must be familiar with Environmental Requirements.

Environmental Conditions

It is clear there is abundant moisture in the atmosphere.

The amount of moisture will give a level of relative humidity in the

workplace or working location.

Both internal and enclosed locations will have variable levels of

moisture and humidity.

With this knowledge, we can try to assess the levels which are
needed or detrimental to surface treatment.

Moisture

If we reduce moisture in the environment below a certain level to

less than 40% relative humidity and, providing the surface is free
from pollutants, corrosion will not occur.

Moisture content can be controlled in most environments where

the abrasive blast cleaning is conducted.

Controlling the relative humidity will allow extending the blast

cleaning periods before the need to apply the coating.

Relative Humidity

A whirling hygrometer is used to assess the amount of relative

humidity in the air.

Relative humidity is expressed as 'the amount of moisture in the

air compared to the maximum amount possible'.

Relative humidity is expressed as a percentage 1-100%.

Quality Control Conducting Relative Humidity Tests

This video demonstrates the use of a whirling hygrometer to

record the relative humidity in a paint shop.

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 The equipment is simple to use, providing training has been
conducted.

Electronic versions are also available which give instant readings

of the relative humidity and only need to be switched on.

Sampling over the entire area should be conducted and not

restricted to one location as micro-climates may exist. It is not
uncommon to find different levels of relative humidity in close
proximity.

Environmental Conditions

Equipment is now available that can measure the relative

humidity, dew point and steel temperature.

The gauge is simple to operate, fast and reliable.

Ensure the equipment is in working order and calibrated correctly

before use.

Do not drag the probe over the surface as this can damage the
sensor and give potentially incorrect readings.

Note: As a general rule the steel temperature should be 3o C (5o F)

above the dew point during abrasive blast cleaning.

Steel Temperature Gauge

This video simply demonstrates the use of a digital thermometer

used to check the steel temperature.

The process is simple providing the equipment is working and

calibrated correctly.

Do not drag the probe over the surface as you will damage the
equipment.

Magnetic versions for steel temperature are also available,

however a 10-15 minute stabilization period is generally required.

Thermometers

This animation simply demonstrates the use of a digital and

magnetic steel temperature gauge.

The digital thermometer will give instant readings while the

magnetic thermometer may take 10-15 minutes.

It is much quicker and easier to use the digital thermometer

providing it is not damaged and calibrated correctly.

Magnetic thermometers are also easy to lose.

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 Grit/Abrasive Storage

It is essential that dry grit or abrasive is employed unless you are

wet abrasive blast cleaning.

Abrasives must be stored correctly until they are ready for use.

Wet abrasive will clog the equipment, wet the surface and
increase the moisture in the local environment.

Secondary sheeting can also be used to protect the abrasive for

site use.

Compressors

Air compressors must have water separators fitted to the unit.

Most modern compressors have water separators built into the

body of the compressor.

Moisture can be visually checked by blowing the air on a dry

surface.

Use reputable suppliers of compressed air equipment and

organisations who understand your business.

If you own your own compressors, ensure a proper maintenance

program is in place and don't wait until the compressor breaks
down before doing any maintenance.

Abrasive Blast Equipment

Water separators are required on the abrasive blast units,

commonly referred too as blast pots or kettles.

These water separators will reduce moisture into and out of the
abrasive blast cleaning unit.

Check the separators for damage, wear and tear before every use.

Check the water separators on a daily basis as adjustments and

moisture removal may be necessary.

Blotter Test (ASTM 4285)

The blotter test is used to check visually for any trace of oil or
water in compressed air to be used in abrasive blast cleaning or in
air used for conventional air spray application.

Allow the compressed air to reach operational conditions

Use an absorbent collector such as a blotter paper or non
absorbent collector such as rigid transparent plastic
Conduct test without any abrasives
Position the collector 61cm (24 inches) away from air
discharge point

According to ASTM D 4285 any indication of oil discoloration on

the collector shall be cause for rejection.

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 Surface Oxidation

If the moisture content is high during or on completion of abrasive

blast cleaning the surface will deteriorate or oxidize (flash rusting)
and you will not be able to maintain the blast standard.

The most economical way of controlling the relative humidity in a

confined area or location is with de-humidification.

Dehumidification units are available which lower the relative

humidity, which will maintain the standard and allow painting to
continue.

De-Humidification/Heating

The main advantage of de-humidification with or without heating,

is that abrasive blast cleaning can be conducted over a number of
days or weeks without the need to re-blast prior to coating.

Mobile units are available to work in shipyards, fabrication

facilities, bridges etc.

The use of de-humidification will allow working all year round

without the risk of losing the blast standard.

De-Humidification

De-humidification equipment has to be set up by experienced

personnel trained in the use of equipment.

Training is usually conducted by the supplier of the equipment.

A calculation based on the area or capacity (cm3 ) has to be

established to operate the equipment efficiently.

This calculation should be conducted prior to hiring or purchasing

the equipment.

De-Humidification

Operators of de-humidification must have an understanding of:

Electricity requirements.
Trunking and ventilation.
Setting up equipment.
Health and Safety implications.
Inspection of equipment.

Always use qualified staff or the suppliers own qualified staff.

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 Environmental Conditions

Many internal areas such as ballast tanks etc are abrasive blast
cleaned and coated.

As the exact area can be calculated, the use of de-humidification

can be set up allowing surface preparation and coating operations
all year round.

This process is used in ship building and ship repair yards around
the globe.

Tank and vessel drawings will assist with calculations.

Temporary Locations

De-humidification to a temporary location such as scaffold with

sheeting can be an easy area to get inlet and outlet locations for
trunking.

The sheeting should be regularly inspected for damage otherwise

dry air and heating can escape.

The above illustration shows the de-humidification of a temporary

sheeting location on a bridge structure.

The process allows all year painting.

De-Humidification in Operation

This animation demonstrates the use of de-humidification used

during abrasive blast cleaning.

A calculation must be conducted on the area, size and type of

equipment.

The use of the de-humidification will allow a longer abrasive blast

cleaning time along with longer painting and curing time.

Always remember, if heating is used this will rise to the upper

locations.

Summary
This training unit reviewed the requirement controlling
environmental conditions during abrasive blast cleaning.

The importance of monitoring the relative humidity and dew point

were discussed along with using the inspection equipment,
moisture checks in the equipment and controlling humidity with
the uses of de-humidification.

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