Abrasive Blast Cleaning

Mechanical Blast Cleaning Equipment

© Copyright 2016 Fitz-Coatings Ltd

 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.

Centrifugal Blast Cleaning

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.
Health and Safety - 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

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 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.

The 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.

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 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 from 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 specifications 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, a 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.

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 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
Essential components of a centrifugal blast unit include;

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:

The Health and Safety aspects of the equipment.

Maintenance of the equipment.
Use of the 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 waste 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.

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 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 a 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.

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