Chapter 2.
5
Abrasive Air Blast Cleaning
Scott Blackburn
The Process
Abrasive air blast cleaning is the process of
propelling abrasive particles from a blast machine,
using the power of compressed air. Converting
abrasive particles and compressed air into an effective
cleaning treatment takes skill, properly engineered
equipment and good judgment. Each component
contributes to the overall performance of the system
(Figure 1).
Primary Elements of a Blasting System
• Air compressor–properly sized to produce sufficient
volume and pressure
• Moisture separator and air drying equipment – to
reduce or eliminate troublesome stoppages caused by
water
• Air supply line–large, with unrestrictive fittings to
maintain pressure
Figure 1. Blast cleaning system components.
Courtesy Clemco Industries Corp.
• Blast machine–with the capacity, valves, and piping
for high production
• Abrasive metering valve – engineered for steady,
uniform flow
• Remote controls–for safe, efficient operation
• Blast hose and couplings–sized to minimize friction
loss
• Blast nozzle–matched to compressor output
• Operator safety equipment–NIOSH approved and
available for all personnel
• Abrasives–high quality (clean, angular) and intended
for blast cleaning
• Blast Operator–experienced and trained for the job
Air Compressor
A standard pressure blast system uses
compressed air to pressurize the blast machine,
convey abrasive to nozzles, provide breathing air, and
operate valves and accessories. A compressor’s
output is measured in pressure and volume. Pressure
is expressed in pounds per square inch (psi) or
pounds per square inch gauge (psig), volume in cubic
feet per minute (cfm). Metric systems use cubic meters
per hour or minute to express volume and bar to
express pressure (Figure 2).
Figure 2. Air compressor. SSPC file photo.
Most air tools operate by using air-driven
pistons or diaphragms, which consume the
compressed air intermittently. Air supported abrasive
blast cleaning equipment demands more from a
compressor than any other air-powered tool. High air
pressure is not enough – blasting requires a steady
supply of high-pressure, high-volume air.
Choose an air compressor that will generate a
steady flow of air at high pressure and high volume,
built to withstand the environmental conditions found
at blast sites, and position the compressor upwind of
dust generated by blasting. Also, locate the
compressor where vehicle exhaust will not enter the
air inlets and ensure that the compressor’s own
exhaust is directed away from its air inlet.
Moisture Separators and Air Drying Equipment
Water and oil are the worst enemies of
abrasive blast equipment. They cause clumps to form
in the abrasive, which can clog metering valves, blast
hoses, and nozzles. If moisture reaches a steel
surface being cleaned, it will cause the steel to rust. If
oil reaches a surface, it can cause coating failure
(Figure 3).
The air around us contains moisture. In the
process of getting air to the nozzle for abrasive
blasting, the air is heated during compression and then
allowed to cool in the line between the compressor
and the nozzle. When this air is subjected to rapid
expansion at the blast nozzle, the air can be cooled
below the dew point, and condensation will form as a
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Figure 3. Moisture separator. Courtesy Clemco
Industries Corp.
water mist. Depending on conditions, condensation
can also form in the blast machine and in the blast
hose.
Depending on the relative humidity in the
ambient air, the tools used for removing oil and
moisture from compressed air vary. Representatives
from compressor manufacturers can recommend air
drying equipment based on the application and the
humidity normally encountered on a given job site.
Air Supply Lines
Air flows best through straight, hard air lines.
On large-scale, long-term field applications, such as
bridges, some contractors install rigid lines in fixed
locations. Where hard piping is impractical, the
contractor should invest in high-quality, fabric-
reinforced rubber air hose. The inner tube of the hose
should be of a material that resists swelling caused by
moisture and oil. The outer casing should be of
durable material, which will provide pressure strength
and support the round shape of the inner tube to
minimize pressure loss through the system.
Keep the hose length as short as possible and
avoid erratic bends. Even correctly sized air hose
loses two to three pounds of air pressure for every 50
feet (15 meters) of length. Just one 90 degree bend
increases this loss to five or six pounds. Use only as
much hose as required for the specific job.
 Using the proper size air lines is critical for Pressure blasting is used to clean tough surfaces and
obtaining the best results from the compressor and the large areas, indoors and out.
blast system. The inside diameters of the air line sizes
must be consistent with the inner diameters of all
fittings to allow smooth air flow. For air lines up to 100
feet in length (30 meters), the inner diameters should
be at least four times the blast nozzle orifice size.
Refer to the Minimum Compressor Air Line
Sizes chart to determine the absolute minimum inside
diameters to use. Use air lines larger than the
minimum recommended whenever possible. No air
line is too large (Figure 4).

Figure 5. Suction blasting container. Courtesy Clemco

Industries Corp.

Suction Blast. Suction blasting, sometimes referred to

as venturi blasting, draws the abrasive from a non-
pressurized container into a blast gun chamber, then
propels the particles out a nozzle (Figure 5).
Figure 4. Minimum Compressor Air Line Sizes. Courtesy
A typical suction system consists of an
Clemco Industries Corp.
abrasive container, an air hose, an abrasive hose, and
a blast gun and nozzle. Compressed air flows through
Choose air hose connectors that offer the
an air jet located in the blast gun to create suction.
least resistance and the greatest internal area. Do not
This suction pulls abrasive from the container, through
confuse inside diameter (I.D.) with outside diameter
the abrasive hose and into the gun body where it is
(O.D.). An air hose connector’s size refers to pipe
accelerated out the nozzle with the air.
thread size or to the I.D. of hose it fits. A 1-1/2 inch (38
This less-forceful blasting is appropriate for
mm) threaded air hose connector has an O.D. of 1-1/2
light to moderate cleaning and for spot applications
inches (38 mm) but only an I.D. of 1-1/4 inches (32
and is useful where the air supply is very limited
mm) or less, which limits the volume of air that is
(Figure 6).
allowed to pass.
Be especially wary of quick disconnect
Pressure Blast. In pressure blasting, abrasive feeds
connectors and threaded swivel air hose fittings.
into a moving stream of compressed air through a
While these may seem to offer convenience and
metering valve that is mounted beneath the blast
reduce kinking, the internal passageways can be too
machine to regulate the quantity of abrasive fed into
small and limit air volume.
the system. Blast machines are known by a variety of
names–blast pots, pressure generators, pressure
Blast Machines
vessels, tanks, and so on (Figure 7).
There are two basic types of blast machines–
Pressure blast systems are easily
suction blast and pressure blast. Suction blasting is
distinguishable from suction systems by the single
less aggressive than pressure blasting and is generally
hose that feeds the blast nozzle. Air and abrasive
used for light-duty work, such as touch-up blasting.
travel through this blast hose at high pressure and

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Figure 6. Pressure blasting equipment. Courtesy Clemco
Industries Corp.
Figure 7. Abrasive air blast machine. Courtesy Clemco
Industries Corp.
high speed, exiting the nozzle at about four times the
velocity produced by suction blasting. Pressure blast
machines are used in structural steel blasting, for their
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high production rates, and in lightweight media
blasting, for their precise regulation of media flow.
While it may appear to be little more than a
steel tank, a blast machine has integral parts that
make sizable differences in safety, efficiency, and
convenience. Poorly designed blast machines can
have restrictions that reduce air flow and air pressure,
thereby reducing productivity.
In the United States, all pressure blast
machines must be built to meet American Society of
Mechanical Engineers (ASME) standards. ASME
specifies the type of steel and welding methods used
in the manufacture of blast machines, and an ASME-
Authorized Inspector supervises the hydrostatic testing
of each pressure vessel. A National Board certificate of
approval is issued and a metal plate, which bears the
board approval number is permanently affixed to the
approved machine. Most countries have similar
requirements, though the specifications may differ.
In the U.S., most pressure blast machines are
manufactured with a rated working pressure of 125 psi
(8.8 bar/880 kPa) or 150 psi (10.3 bar/1033 kPa).
ASME requires all machines be built with a safety
margin 30% greater than the working pressure. If a
machine’s working pressure is unknown, check the
National Board approval plate. Never operate a
pressure blast machine that does not have a National
Board approval number stamped on a permanently
affixed plate and never exceed the rated working
pressure of the machine. Serious injury or death may
occur if a blast machine explodes under air pressure.
Pay particular attention to a blast machine’s
external plumbing and valves. Air and abrasive flow
through hoses, piping, couplings, valves, and blast
nozzles that are all cylindrical. Any reduction in the
diameters of these cylinders dramatically reduces the
rate of flow. As an example, a 1 inch I.D. (25 mm)
cylinder has an area of .80 square inches (49 cm2). A
1/2 inch I.D. (12.5 mm) cylinder has an area of only
.20 square inches (12.3 cm2). Reducing the diameter
of the cylinder by half, reduces its area by three-
fourths.
Choose a blast machine that has the capacity,
portability and convenience features that best fit the
type of work to be performed. The blast nozzle orifice
size determines the amount of work that can be done
and the amount of air required to perform the work.
The compressor must be able to supply sufficient air
for the nozzle, plus any accessories, plus a reserve
amount to compensate for nozzle wear.
Based on the compressor and nozzle that will
be used, choose a blast machine with an abrasive
capacity to supply a minimum of 20 to 30 minutes of
steady, non-stop blasting.
Abrasive Metering Valves
In the vast majority of pressure blast machines
used for high-production work, a metering valve uses
gravity to feed abrasive into a fast-flowing stream of
compressed air. Too little abrasive can result in a wide-
spread pattern, which slows production and leaves
non-blasted surfaces.
Too much abrasive causes particles to collide
with each other, which wastes energy and disperses
particles unequally within the blast pattern. Exorbitant
abrasive usage wastes material and labor (Figure 8).
Properly adjusted metering valves ensure the
maximum in cleaning power from each abrasive
particle. Begin by closing the valve completely.
Engage the remote control handle to start air flowing
from the nozzle, then slowly open the valve a little at a
time. Observe the air and abrasive mixture exiting the
nozzle.
A proper valve setting will show a slight
coloration of abrasive in the air stream, and
experienced operators can hear a steady abrasive
flow. Too little abrasive causes a high-pitched sound;
too much abrasive, an erratic, pulsating sound.
Figure 8. Abrasive metering valve. Courtesy Clemco
Industries Corp.
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Remote Controls
The Occupational Safety and Health
Administration (OSHA) requires remote controls on all
abrasive blast machines (Ref: OSHA 29 CFR
1910.244). Using a blast machine without remote
controls, especially a “deadman” switch, is a
dangerous practice that may result in serious injury or
death to an operator or others who may be on the job
site. In addition to their safety features, remote
controls save substantial amounts of labor,
compressed air, and abrasive. If a blast operator must
wait for someone to turn off the machine, air and
abrasive are squandered. Also, removing the need for
a dedicated pot tender saves labor by allowing one
person to load abrasive for several machines or do
other work between refills (Figures 9 and 10).
Figures 9 and 10. Pneumatic and electric remote control
handles. Courtesy Clemco Industries Corp.
Two basic remote control operating principles
are used in abrasive air blasting. The most popular,
pressure-release, allows the machine to depressurize
each time the remote control handle is disengaged by
the blast operator. This handle must always be located
near the blast nozzle and must be used correctly by
the operator. Pressing down on the remote control
handle causes the machine to pressurize and blasting
to begin. Releasing the handle stops the air supply to
the machine, which depressurizes. Abrasive that is
held in the blast machine’s concave head, or in an
overhead storage hopper, automatically refills the
machine.
Pressure-hold systems maintain air pressure
in the machine even when blasting stops. On a
multiple-operator machine, a pressure-hold system
allows one operator to stop blasting without affecting
the other operator(s). Also, pressure-hold systems can
be installed if the blasting demands frequent on and off
cycles that might waste too much time, and air, in
pressurizing and depressurizing.
Most remote control systems work
pneumatically and are well suited for distances up to
150 feet (45 meters). Electric remote control systems
may be better suited for distances greater than that.
Different types of air hoses are used with
different brands of remote controls. When replacing
any control lines or valves, use only those replacement
items specified by the manufacturer of the remote Figure 11. Types of hoses. Courtesy Clemco Industries
control system and install the replacements according Corp.
to the instructions in the owners operator manual.
the blast machine to the nozzle, blast hose should
Blast Hose and Couplings have a sufficient inside diameter and the hose length
should be kept as short as possible.
Blast Hose. Blast hose is subject to rapid wear and Using a blast hose with an inner diameter that
tear due to the eroding action of high-velocity abrasive is smaller than the blast machine outlet diameter
on the inside and harsh treatment and weathering on greatly reduces the amount of air and abrasive flowing
the outside. While couplings rarely wear out they do to the nozzle.
break from rough handling or are crushed by vehicles. As an example, a high production blast
The best way to help keep costs in line and machine with 1-1/4 inch (32 mm) I.D. piping feeding a
production high is to use appropriately sized, top- 3/4 inch (19 mm) I.D. blast hose must overcome a
quality blast hose, specifically manufactured for 64% reduction in capacity. Air and abrasive are now
abrasive blasting and rated at the appropriate working being forced into an area that has one-third the
pressure. Install only top-quality couplings, designed capacity of the blast machine’s external piping. This
specifically for use with blast hose (Figure 11). would not be a problem if the blast nozzle is sized for
When installing couplings, take extra care to the smaller diameter blast hose. However, if the blast
ensure that the blast hose end is cut squarely for a nozzle chosen is sized for a large diameter (1-1/4 inch
firm, uniform seal against the coupling shoulder. I.D.) blast hose, the nozzle pressure will drop
Abrasive that escapes around the end of a sloppily cut dramatically. The blast hose I.D. should be three to
hose end will wear away the coupling wall in a matter four times the size of the blast nozzle orifice.
of minutes.
Like all hose, blast hose is rated for a given Couplings. Blast hose couplings and nozzle holders
working pressure and it should never be used beyond are available in a wide variety of materials, sizes, and
this rating. Its working pressure should be stamped configurations. Some of the more common materials
along the length of the hose. are aluminum, steel, brass alloy, and glass-filled nylon.
To efficiently convey air-driven abrasive from Like blast hose, couplings and nozzle holders are

96
subject to wear from the inside as well as the outside
(Figure 12).
Figure 12. Couplings. Courtesy Clemco Industries Corp.
Operators should choose couplings and
holders based on their safety and suitability for specific
job site conditions—not on their cost. Couplings and
holders can become a major replacement expense if
the wrong types are chosen.
Couplings should have two locking lugs,
identically formed to allow any two sizes of couplings
to be firmly connected. These compatible locking lugs
are typically found on couplings for blast hoses
ranging from 1/2 inch to 1-1/2 inch I.D. (12.5 to 38
mm). When two couplings are placed together for
connection, it is important to ensure that each coupling
is fitted with a serviceable gasket and that when the
couplings are twisted together, firm compression is
maintained between the gaskets. Worn gaskets can
cause serious air pressure loss and can be a threat to
safety. Couplings can become worn to the point where
the locking lugs no longer have the material and
strength to hold together, destroying the coupling and
accidentally disconnecting the blast hose while the
hose is under pressure.
Blast Nozzles
Nozzles accelerate the air-driven abrasive into
a highly effective abrading or cutting force to handle
the toughest applications. The size, type, and shape of
the nozzle help determine the production speed and
the appearance of the end product. Using the most
appropriate nozzle for the application yields a
substantial payback in productivity. Additionally,
performance of the nozzle reveals whether or not all of
the previous requirements for air and abrasive flow
have been correctly followed (Figures 13 and 14).
There are two basic styles of blast nozzles–
straight bore and venturi. Most contractors prefer blast
nozzles designed with wide, cone-shaped entrances
and gradually tapered exits, which together, form a
venturi. Abrasive enters the converging end of the
nozzle, funnels through the orifice, and then rapidly
expands into a high-powered stream through the
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diverging exit end. The venturi style nozzle offers
greater cleaning capabilities than the straight bore
style.
Figures 13 and 14. Blast nozzles. Courtesy Clemco
Industries Corp.
However, as the nozzle wears beyond 1/16
inch (1.5 mm) over its original size, it loses its venturi
shape and much of the accelerating force that shape
provided.
The nozzle liner material primarily affects wear
life, which is more than just how long a nozzle will last;
it is critical to air consumption. As the nozzle orifice
wears, it requires more air volume to maintain a given
air pressure. A nozzle with a 3/8 inch (9.5 mm) orifice
requires approximately 200 cfm (5.5 m3/min) to
maintain 100 psi (7 bar/689 kPa) working pressure.
Through normal use, when this orifice enlarges by
1/16 inch (1.5 mm), the air requirement increases to
more than 250 cfm (7.2 m3/min) – a 25% increase. If
the air compressor is unable to maintain nozzle
pressure, due to increased demand as the nozzle
wears, that pressure loss will decrease productivity.
Each one-pound drop in nozzle pressure caused a
1-1/2% reduction in productivity.
It can not be overstressed that maintaining
adequate nozzle pressure is essential to high-
production blasting. The gauge on the air compressor
indicates the air pressure at the compressor only. It
does not indicate blasting pressure. Air and abrasive
hoses, air filters and moisture separators, blast
machines, and other components between the Air-Fed Helmets. OSHA defines an air-fed helmet for
compressor and the nozzle all contribute to friction and abrasive blasting as a continuous-flow, supplied-air
pressure loss. respirator. These units are also commonly referred to
To accurately determine nozzle pressure, the as, simply, helmets (Figure 15).
use of a hypodermic needle gauge is highly
recommended for all air abrasive blast operations.
This simple, inexpensive tool consists of a needle that
is affixed to an air pressure gauge. In use, the needle
is inserted into the self-sealing blast hose, just behind
the entrance end of the nozzle. The gauge will indicate
the actual pressure at the nozzle. The volume and
pressure of air that is maintained at the nozzle directly
affects the amount of work that can be completed
properly.
The blast nozzle should be regularly inspected
to ensure that it is not worn or cracked since either
condition could lead, not only to a reduction in
productivity, but to increased abrasive usage, a less
effective blast pattern, and injury, should the liner fail.
Figure 15. Air-fed helmut. Courtesy Clemco Industries
Corp.
Operator Safety Equipment
The helmet should furnish the operator with
Air abrasive blasting can be dangerous for a
breathing air, protect the face and head from rebound-
poorly trained, poorly equipped operator. A blast
ing abrasive and from impacts, muffle noise, and allow
machine produces a powerful stream of sharp particles
for an unobstructed field of view.
that, in addition to cleaning a surface, creates clouds
While OSHA regulations dictate that noise
of potentially toxic dust. To prevent a variety of injuries
levels generated by the respirator at maximum airflow,
and illnesses, personal safety equipment is mandatory
and measured inside the helmet not exceed 80 dBA
for blast operators and other personnel in the work
(decibels on the “A” scale), job site noise can many
area.
times exceed the permissible level. In those instances,
operators must wear hearing protection appropriate to
Regulations. Throughout the world, laws govern air
the surrounding noise environment.
abrasive blasting safety. Most countries use safety
Helmets are available in two basic types: high
standards similar to United States standards. In the
and low pressure. The high-pressure versions operate
U.S., the Occupational Safety and Health
from a compressed air supply and the low-pressure
Administration (OSHA) enforces the regulations
units require an air pump. These pumps are commonly
pertaining to the safe operation of abrasive blast
known as ambient air pumps or free-air pumps. Air
equipment.
pumps do not compress air; they merely draw in
Respirators, such as air-fed helmets and
ambient air and push it through the breathing air hose
hoods and pressure-demand full-face models, along
to the helmet.
with most of the other components of the breathing air
The helmet window lens system protects the
system, must be tested and approved by the OSHA
operator’s face from rebounding abrasive. NIOSH
departments of the National Institute of Occupational
requires a single lens of at least .040 inch (.01 mm)
Safety and Health (NIOSH) and the Mine Safety and
thick. Most helmets have frames designed to hold
Health Administration (MSHA).
several thin, sacrificial lens covers, which protect the
Contractors should always consult with local
thicker inner lens. When these outer lenses become
safety agencies for current regulations. Blast operators
frosted, by use, the operator is able to tear away the
who are properly trained and fitted with the best safety
outermost cover to expose another lens.
and comfort equipment will be much more confident
and efficient.
Breathing Air Filters. OSHA requires that breathing air

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filters comply with the requirements for Grade D air hose carries a NIOSH-approval stamp (Figure 17).
(Ref: OSHA 29 CFR 1910.134). These filters are
designed to remove oil mists, water vapor, and
particles larger than 0.5 micron, which are commonly
associated with most air compressors used for
abrasive blasting. They should be high-capacity and
super-efficient, especially designed for breathing air
systems (Figure 16).

Figure 17. Breathing hose in place. Courtesy Clemco

Industries Corp.

Never substitute other types of hose for

breathing air hose. This special hose is manufactured
with strict tolerance for I.D. to ensure unrestricted,
steady airflow. Also, breathing air hose is produced
without using toxic chemicals in the hose or in the
release agents applied to molds and mandrels that are
Figure 16. Breathing air filter. Courtesy Clemco
used in the manufacturing process.
Industries Corp.

The filter has to be able to handle sufficient air

volume to supply all the respirators connected to it and
it should have an easily replaceable cartridge. It must
have a pressure regulator and gauge, not only to
regulate the air pressure to the helmet, but also to
indicate when the cartridge need replacement. The
gauge will show declining pressure as the cartridge
becomes saturated with liquid and solid matter that
has been removed from the incoming air supply.
Figure 18. Air temperature valve. Courtesy Clemco
Breathing Air Hose. The breathing air hose, which Industries Corp.
carries air from the air filter to the helmet air control
valve, must meet NIOSH specification size, strength, Air Temperature Valves. Two types of air control
composition, and manufacturing techniques. As with valves are available for use in place of the standard air
all other regulated parts of this air supply system, the control valve that is provided with helmets. One valve

99
cools the air directed to the helmet and the other valve
can cool or heat that air (Figure 18).
When the outside air is warm and the
compressed air is hot, a valve that provides cooling
can reduce the temperature of the air entering the
helmet by approximately 30˚F. On the other hand,
when working in cold temperatures, a valve that can
direct the warm air into the helmet could be very
beneficial to the comfort of the operator.
Carbon Monoxide Alarms and Converters. Oil-
lubricated air compressors sometimes produce carbon
monoxide (CO), a colorless, odorless, deadly gas. Air
compressors that are used to supply breathing air
should be serviced at the manufacturer’s
recommended intervals and overheating, shut-off
devices, and/or carbon monoxide alarms should be
installed. If only an overheating device is used, OSHA
regulations require that the air be frequently tested for
CO (Ref: OSHA 29 CFR 1910.134) because even brief
exposure to CO can kill (Figure 19).
Figure 19. Carbon monoxide system. Courtesy Clemco
Industries Corp.
An alarm continuously tests air samples for
CO. These systems measure the amount of carbon
monoxide in the air line and trigger an alarm if the gas
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exceeds permissible levels. Carbon monoxide
converters use chemicals to change CO to carbon
dioxide (CO2). The human respiratory system can
tolerate much higher levels of CO2 than CO.
Protective Clothing. High-velocity abrasive can inflict
serious injury upon an unprotected operator. OSHA
regulations 29 CFR 1910.94 and 1910.134 require that
operators wear canvas or leather gloves and aprons or
the equivalent. If the operator is on or around heavy
materials, safety shoes are required as well (Figure
20).
Figure 20. Protective clothing. Courtesy Clemco
Industries Corp.
High quality blast suits have leather, canvas,
or equivalent fortification over the areas exposed to
rebounding abrasive, usually including the sleeves and
the front area of the garment, from the waist to the
ankles. The helmet cape usually shields the operator’s
chest.
Communication Equipment. The age-old method of
getting the blast operator’s attention is to shut down
the blast machine. The operator then has to remove
the helmet in order to hear and to respond to what is
being said—possibly becoming exposed to toxic dust
(Figure 21).
A better method is to use battery-powered
radio sets, specifically designed for blasting. These
sets allow a supervisor to communicate with several
operators at distances as great as one mile (1.6 km).
Figure 21. Helmet communication system. Courtesy
Clemco Industries Corp.
Helmet communication systems can speed
training of new operators and increase productivity of
experienced operators. Communication is more than a
convenience, however. A communication system can
provide an extra measure of a safety when blasters
work outside visual range and blasters can alert their
supervisor to any trouble they may encounter.
Abrasives
The air compressor powers it, the blast
machine stores and meters it, the blast hose
transports it, and the blast nozzle accelerates it. All are
important, but the abrasive does the work.
Selecting the correct abrasive is crucial to
producing the required finish, on time and within
budget. Selecting the incorrect abrasive may produce
an inferior, or out-of-spec finish, impede production,
require expensive rework, or cause all of the above.
Many coating failures can be traced to the use of the
wrong abrasive. The best possible blast system cannot
compensate for abrasive that is not designed for the
work to be done. Use only high-quality abrasives
intended for blasting.
There are three sources for abrasives that are
used for air blasting–natural, manufactured, and by-
products. Natural abrasives are minerals, such as flint
and garnet, that are found in deposits. Manufactured
abrasives are produced specifically for blasting and
include steel, iron, glass, aluminum oxide, plastic,
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starch, and others. By-product abrasives result from
other manufacturing processes. These include slag
that is left from power generating stations, smelting
operations, and agricultural media from food sources,
such as corn cobs and rice hulls. For detailed
information on abrasive materials, see separate
chapters on metallic and nonmetallic abrasives.
Abrasives are usually classified according to
size, shape, density, hardness, and friability, and each
characteristic must be taken into account when
selecting the abrasive for a specific job.
Blast Operator
Without question, the most important element
of any manually operated, air abrasive blast system is
the blast operator. The best available equipment will
not perform to its potential without trained,
knowledgeable, careful and safety minded operators.
Investing time and money, up front, to train operators
pays off quickly in productivity and reduces the risk
and liability of accidents and injuries.
Air blast equipment operators must develop a
thorough understanding of what the equipment will do
and what will happen if the source of compressed air is
altered. Once they comprehend the value of air
pressure and volume, they will be better prepared to
evaluate the entire blasting system.
Blast equipment manufacturers and
professional organizations can be contacted to provide
technical training programs on specific blasting
equipment and techniques. Once an operator is
completely familiar with the form, fit, function, and
maintenance of everything from the air compressor to
the blast nozzle, the potential hazards that are
inherent to abrasive blasting will pose little danger, if
the operators are properly attired and use safe work
practices.
Equipment Set-Up Procedure
Job Site Conditions
Job sites can present their own set of potential
work hazards. Many hazards are relatively easy to
identify; however, some are inconspicuous. In either
case, close attention must be paid to any chance of
worker endangerment Owners, supervisors, safety
engineers, and workers have a responsibility to identify
safety threats and take necessary precautions prior to
starting any work.
 Prior to setting up the equipment, carefully
survey the job site using a common-sense approach to
locate potential problems. If there is any doubt about
any particular situation, all necessary steps should be
taken to eliminate the hazard.
While it is impossible to list all of the potential
hazards that may exist on any job site, some of the
most common are heat, electrical power lines,
hazardous gases, work surface and noise hazards,
and operator visibility.
Equipment Set-Up
After performing the job site inspection, the
blast equipment may be set in position. For outdoor
work, the air compressor should be placed upwind
from the blasting area to help prevent dust from
entering the compressor air intake. The pressure
setting on the compressor must not exceed the
working pressure of the blast machine(s). Conven-
tional machines have a maximum working pressure of
125 psi (8.6 bar/860 kPa) while other machines have
higher ratings. Check the metal identification plate that
is permanently affixed to the blast machine to deter-
mine its working pressure. Refer to the air compressor
manufacturer’s manual for the proper start-up, opera-
tion, and maintenance information.
Install the components of the blasting system
according to the instructions in the operator’s manuals
that are supplied with the blast equipment.
Lay the air hose and the blast hose in the
most direct line to the blast machine and the work, with
as few bends possible. Since there is less friction loss
in an air hose without abrasaive than in a blast hose
with abrasive, the blast machine should be located as
close to the work as possible.
After laying out all the components required
for the job, hook-up the air hose and the blast hose to
run a test on the remote control system. Do not add
abrasive to the blast machine at this time. Make sure
the air hose and the blast hose are properly connected
and that safety cables are in place at each hose
connection. Also ensure that each blast hose coupling
is in good working condition, includes a firm fitting
gasket, and is equipped with safety locking pins.
Check the blast nozzle and nozzle holder for wear,
paying special attention for cracks in the nozzle liner
and worn threads in the holder. Make sure the nozzle
washer is in place and in good condition.
Carefully inspect the operator protective
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equipment to determine that each component is in
perfect working order. Check air-fed helmets for any
damaged or worn parts, being especially attentive to
broken head bands, cracked helmet breathing air
hoses, over-stretched inner collars, damaged outer
capes, leaking window gaskets, broken window
frames, and clogged air supply valves. Check the air
filter cartridge for cleanliness, as described in the
owner’s manual. Carbon monoxide (CO) monitor and
alarm systems should include field calibration
equipment.
Remember that no dust, from any source, is
safe to breathe. Blast operators may be well protected
while using approved, filtered, air-fed helmets during
the blasting process, but they need to safeguard their
respiratory systems before and after the blasting
process as well. A great danger is often posed by early
removal of operator and bystander respirators in dust-
laden abrasive blast areas.
Cycle the air on and off several times to
ensure that the remote control system is functioning
properly. Do not use the blast machine until the remote
control system operates as designed and according to
its instruction manual.
When all equipment is assembled and given a
thorough check, the machine may be loaded with
abrasive and work can begin.
Equipment Tear-Down
Once the job is completed, or at the end of the
workday, follow the shut-down procedures described in
the equipment owner’s manuals. All personnel in the
blasting area during shut-down and abrasive clean-up
must wear NIOSH-approved, properly rated, supplied-
air respirators. Clean-up can be more hazardous than
blasting because of the high concentration of
pulverized abrasive.
The blast machine should be emptied of all
abrasive. Leaving abrasive in the machine overnight
could cause moisture absorption. One effective
method for emptying the machine is to uncouple the
blast hose from the machine outlet, adjust the
metering valve to its full open position, close the
pusher line choke valve, reduce the air pressure to
approximately 40 or 50 psi, and pressurize the blast
machine until empty.
Upon completion of abrasive clean-up, the
safety engineer should test the blasting zone
atmosphere with a dust monitor for the presence of
dust. When the air is clear of dust, the blast operator
and all personnel in the blasting zone should vacuum
clean their clothing. After removing the vacuum-
cleaned respiratory protection equipment, inspect it
for wear or damage, immediately replacing worn parts
as necessary using the owner’s manual as a guide.
Turn off the air compressor and bleed-off the
air receiver tank. Hearing protection should be worn
during this process. Bleed accumulated water from
moisture separators, air dryers, and after-coolers
following the manufacturer’s instructions. Continue to
refer to the owner’s manuals that the manufacturers
have provided in order to keep the blast system
components operating safely and efficiently.

Acknowledgements
The author and SSPC gratefully acknowledge the
participation of Hugh Roper and Steve Dobrosielski in
the peer review process for this chapter.

About the Author

Scott Blackburn
Scott Blackburn has worked in the abrasive blast and
paint spray equipment industry for the past 34 years.
Currently vice president of sales at Clemco Industries
Corp., he has also served as a field sales and service
representative in the Midwest and managing director
of Clemco’s Southeast Asia operations based in
Singapore, during his 28 years with the company.

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