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PAINTSQUARE.COM

JOURNAL OF PROTECTIVE COATINGS & LININGS

A JPCL eResource

SURFACE PREPARATION & SAFETY

2005-2015 Technology Publishing Co.

Surface Preparation & Safety

Copyright 2005 by
Technology Publishing Company
2100 Wharton Street, Suite 310
Pittsburgh, PA 15203
All Rights Reserved

This eBook may not be copied or redistributed

without the written permission of the publisher.

2005-2015 Technology Publishing Co.

ii

Contents
v

Introduction

1 Safety Monitoring and Remote Control Systems

3 OSHAs Proposed Rule for Silica Hits the Streets

By Alison B. Kaelin, CQA, ABKaelin, LLC

5 Shipyard Regulatory Update

By Alison B. Kaelin, CQA, ABKaelin, LLC

10 On the Time Between Blasting and Priming

11 Safety Considerations for Abrasive Blasting Operations
15 Setting Up Air Blasting Equipment
19 Surface Preparation: Adventures in Frustration

By Peter Bock, CorrLine International

2005-2015 Technology Publishing Co.

2005-2015 Technology Publishing Co.

Introduction
This eBook features articles from the Journal of Protective Coatings &
Linings (JPCL) about surface preparation and safety. All information about
the articles is based on the original dates of publication of these materials
in JPCL. Please visit www.paintsquare.com for more articles on these and
other topics.

2005-2015 Technology Publishing Co.

Safety Monitoring
and Remote Control Systems
for Blasting in Shipyards

last cleaning is a critical process to remove mill scale,

slag, and pre-existing coatings on steel surfaces and to
prepare substrates for the subsequent application of a
protective coating. Dry abrasive blast cleaning is known
to provide the best surface roughness for an ordinary
organic or inorganic coating, although it is considered a very
dangerous process.
In shipyards, dry abrasive blast cleaning is especially dangerous. Modern shipbuilding practice is to construct vessels
as a series of blocks, coat these, and then join up to finish
the build. Workers must contend with a very poor environment because of a mist of paint debris, spent abrasive particles, noise, and the danger from blasting media traveling at
a high speed. Also, their work can involve moving through
narrow access holes (600 mm x 800 mm hole) in the steel
blocks. Moreover, blasters work alone for a long time. There
is virtually no visibility inside these steel blocks during blasting, so developing a safety system for blast cleaning workers
is more essential than for many other types of projects.
Basing a remote workers safety and contact system on
wireless technology is more difficult to develop than such
a system for other work areas because of the possibility at
shipyards of wireless data transmission errors by reflection,
refraction, and diffusion of the radio waves in the blasting
area (cell). There are also technological limits in building
the safety system for shipyard job areas, but developments
in IT (Information Technology) and RFID (Radio-Frequency
Identification) technology have made remote control safety
systems possible.
This article summarizes work carried out by Won-Jun
Yun, Byung Hun Lee, and Dong-Min Kim of Hyundai Industrial Research Institute, Hyundai Heavy Industries, Co. Ltd.
Korea, and Young-Shick Ro, School of Electrical Engineering,
University of Ulsan, Korea, into such a system. The summary will concentrate on the features of such a safety system,
rather than on the technical aspects.
The summary is based on a presentation given at PACE
2010, the joint conference of SSPC and PDCA, held Feb.
710, 2010, in Phoenix, AZ. The full paper is published in the
Proceedings (www.sspc.org).

The Safety System Features

The complete safety system is composed of three sub-systems: the monitoring system for checking the blast workers
safety, the remote control system of the blasting nozzle(s),
and the special bone conduction ear-set system for voice
communications among workers and managers. Additionally, the safety system has a function to analyze the actual
result of a blast cleaning job.

In shipyards, dry
abrasive blasting
is especially dangerous.
The Safety Monitoring System
The safety monitoring system features emergency call signaling, sensing vibration data, and checking location data for
blast cleaning workers in the blasting cell.
When the worker with a 2.45GHz RFID active tag is working in the blasting cell, the safety system works as follows:
information about working conditions is transmitted from
the active tag through a network to the monitoring system,
where the manager can check workers safety using computer-analyzed emergency signal data with the workers location information.
The monitoring system consists of three functions to
check workers safety and to send the emergency signal to
the manager. First, its a function for storing and analyzing
information; second, its a function for monitoring workers
location and their safety information; and third, its a function for sounding a buzzer and sending SMS (Short Message Service) to the manager. Also, it can give an alarm by
analyzing the vibration sensor on a worker, including direct
emergency calling. Finally, it can monitor remaining battery
capacity of the active tag and temperature of the working
conditions.
The Remote Control System for Blasting Nozzles
The remote control of blasting nozzle(s) is integrated with
2005-2015 Technology Publishing Co.

the safety monitoring system to cut compressed air when an

emergency situation occurs. Managers also can check the
blasting nozzle status and turn it off remotely using PC when
emergencies occur. The remote control system can control
the blasting nozzle valve directly after checking the condition
of blasting nozzles one by one or altogether.
The Special Bone Conduction
Ear-Set Communication
The special bone conduction ear-set system with neck microphone is necessary to communicate about blast working
conditions in the cell with a person in the managing office.
Working conditions in the blasting cell and protective
clothes for blast cleaning work are not conducive to easy
voice communication. So it is more difficult to communicate
using normal methods inside the steel block. Thus, a special
system that the worker can use while wearing a mask, earplugs, and a helmet had to be developed.
For communication among workers and managers during
the blast cleaning job, the special voice communication
system using the existing infrastructure with TRS (Trunked
Radio System), which can communicate with a group, was
used. Workers wearing masks and earplugs can still listen
with the aid of the bone conduction mechanism and speak
using a neck microphone, which makes communication possible through the vibration of vocal cords.
Because blast cleaning workers must pass through small
access holes to work in the steel block, the developed system is small and has the added conveniences of portability
and noise interception.

Operation Procedure of the Safety System

To confirm workers safety, there are three ways to check the
emergency signals from workers in the blasting cell: sensing
the active tag emergency call, analyzing a sensed danger
signal automatically by vibration sensor, and using voice
communication with a special bone conduction ear-set.
The monitoring system can sense various emergencies,
ring alarms, and send the information about the emergency to managers. After the manager checks the SMS or the
emergency signal on the monitoring system, he or she
can reconfirm the workers safety by having a conversation through the bone conduction ear-set. If an emergency
occurs, the blasting nozzles can be controlled remotely by a
manager. Also, actions can be taken for workers to be safely
evacuated from the life-threatening emergency, as well as
for the urgent rescue of nearby co-workers. Emergency signals can be transmitted to all managers to prevent sudden
accidents and to inform them of the rescue process.
This innovative safety system for workers blasting in shipyards allows managers to communicate with workers in real
time and thus also allows managers to properly distribute
the workload and make a contribution to the improvement in
productivity.

2005-2015 Technology Publishing Co.

OSHAS Proposed Rule

for Silica Hits the Streets

others discussed in the proposal: abrasives such as mineral

slags as well as sand, paints, concrete, portland cement,
silicates, and soil.
As part of the rulemaking, OSHA performed an extensive
analysis entitled Respirable Crystalline SilicaHealth
Effects Literature Review and Preliminary Quantitative Risk
Assessment. The available evidence indicated that employees exposed to respirable crystalline silica at concentrations
well below the current PELs (of 100 and 250 g/m3) have
an increased risk of lung cancer and silicosis. Occupational
exposures to respirable crystalline silica also may result in
the development of kidney and autoimmune diseases and in
death from other nonmalignant respiratory diseases, including chronic obstructive pulmonary disease (COPD).

Summary of the Proposed Rules

By Alison B. Kaelin,
CQA, ABKaelin, LLC

n August 23, 2013, the U.S. Occupational Safety and

Health Administration (OSHA) unveiled its long-expected proposed rule for protecting workers against respirable crystalline silica. OSHA issued two versions of the
proposed rule, one for general industry and shipyards
(1910/1915) and one specific to construction (1926).
The proposed rule reduces the current permissible exposure
limit (PEL) for general industry, shipyards, and construction
to 50 micrograms per cubic meter of air (g/m3). The current
PEL for general industry and shipyards is 100 g/m3, and the
current PEL for construction is 250 g/m3.
Once published in the Federal Register, OSHA will accept
comments for 90 days, as part of a rulemaking process. A
hearing will be held in early March 2014, and the final rule
will be issued sometime after. The proposal and related information can be read on https://www.osha.gov/silica/index.
html.
While no conclusions on the actual requirements should
be drawn based on a proposed rule, the proposed provisions
do provide insight into likely approaches that will be considered by OSHA when the final rule is issued. Employers
should consider the requirements of the proposed rule as
they apply to their operations, and plan how to implement
the requirements when the rule is final. Background on
respirable crystalline silica, including its health effects, and a
summary of the proposal follow.

Background
Silica is a compound composed of the elements silicon and
oxygen (chemical formula SiOz). Respirable crystalline silica
means airborne particles that contain quartz, cristobalite,
and/or tridymite. The respirable portion is determined by a
respirable-particle-size-selective sampling device.
The proposed rule estimates that exposures to crystalline
silica can occur in more than 30 major industries and operations. Silica can be present in the following materials and in

Among the aspects of the proposed rule that may be of interest to the coatings industry are the following.
Requirements to comply with applicable ventilation standards (e.g., 29CFR1926.57) for abrasive blast cleaning. While
the ventilation standards have long been in place, they have
not been fully implemented in many containment systems.
Requirements for laboratory analysis of respirable silica
samples by an ISO 17025-accredited laboratory.
Construction industry exemption from exposure monitoring for specific operations if engineering and work practice
controls and respiratory protection are implemented.
Options for establishing regulated areas or developing a
written access plan (which appears to be very similar to the
worker protection plan required by the Lead Standard).
Addressing training requirements via the Hazard Communication Standard.
The paragraphs in the proposed rule address similar topics
(e.g., methods of compliance) of other comprehensive health
standards.
The box on p. 53 gives a brief summary of the proposals
for General Industry and Shipyards and for Construction.
The box highlights some similarities and differences between the two proposals.
Alison B. Kaelin, CQA, has more than 25 years of public
health, environmental, transportation, and construction management experience in the coatings industry. She is the owner of ABKaelin, LLC, a Pittsburgh,
PA-based provider of outsourced
quality assurance, auditing, training,
consulting, and related services
to the protective coatings, construction, fabrication, and nuclear
industries. She is a certified quality
auditor, a member of SSPC, and a
NACE-certified coating inspector.
She was a 2012 JPCL Top Thinker,
a 2012 JPCL Editors Award Winner, and an SSPC Technical
Achievement Award winner in 2005.
(See table on next page)
2005-2015 Technology Publishing Co.

2005-2015 Technology Publishing Co.

Shipyard Regulatory Update

Whats Happening with Enforcement, Regulation,
and New OSHA Guidance Documents

iStockphoto/milarka

By Alison B. Kaelin, CQA,

ABKaelin, LLC

his article reviews OSHA enforcement on shipyard ac-

Respiratory protection

tivities and recent guidance on illumination and ventila-

Wiring design, protection, methods, components, and

tion related to ship repairing, shipbuilding, and ship-

equipment for general use

breaking that fall under OSHAs Standards for Shipyard

Guarding of deck openings and edges

Employment (29 CFR 1915). It also discusses new OSHA

Welding and cutting (arc, gas, and oxygen-fuel)

information on abrasive blasting hazards and potential Cal/

Hazard communications

OSHA Lead Standard changes that are applicable to shipyard

Toxic metals

and many other industrial painting sectors.

Painting

Shipyards are fixed facilities with dry docks and fabrication

Abrasive wheel machinery

equipment capable of building a ship, defined as watercraft

Occupational noise

typically suitable or intended for uses other than personal

Hand and portable powered tools and equipment

or recreational. Activities of shipyards include the construc-

Confined space

tion of ships, their repair, conversion and alteration, and the

Lighting

production of prefabricated ship and barge sections.

Lockout/tagout

OSHA Enforcement Summary

OSHA Shipyard Fact Sheets Illumination

Review of the most frequent OSHA citations for NAICS Code

In November 2013, OSHA issued a Fact Sheet on Safe Light-

336611Ship Building and Repairing from October 2012

ing Practices in the Shipyard Industry. It elaborated upon

through September 2013, and OSHAs enforcement data

29 CFR 1915.82, Subpart F, General Working Conditions:

for NAICS 336611 and 29 CFR 1915, indicates the following

Lighting, and provided the minimum lighting requirements

areas of non-compliance resulting in citations. Areas are

(Table 1).

ordered from highest to lowest, and some similar areas were

Note that the values in Table 1 differ from SSPC-Guide 12,

grouped by the author.

Guide for Illumination of Industrial Painting Projects, which

2005-2015 Technology Publishing Co.

itime (1915) does not have specific ventilation requirements.

OSHA General Industry Standard Ventilation standard (1910.94, Ventilation),
published in the 1970s, established the first
requirements for abrasive blast booths as
(1) exhaust-ventilated to provide continuous
air flow at all openings during blasting operations, (2) capable of preventing escape
of abrasives into adjacent work areas, and
(3) able to provide prompt clearance of dust
when abrasive blasting ceases.
The Industrial Ventilation: Manual of
Recommended Practices, published by the
American Conference of Governmental
Industrial Hygienists, provided the basis
for the design of blast booths for the stated
purpose of operator visibility and to control escape of contaminants into adjacent
work areas. It established the minimum
air flows (60100 feet per minute), transport velocities in ductwork (3,500 feet per
minute), and design criteria with inward air
flow exhausting to a remotely located dust
collection system, as shown in Figure 1.
SSPC-Guide 6, Guide for Containing
Surface Preparation Debris Generated
During Paint Removal Operations, relies on
the Industrial Ventilation Manual criteria as

suggests that a higher level of lighting is required for work,

surface preparation, and inspection activities. SSPC-Guide
12 recommendations are shown in Table 2.
Use of a portable light meter can help assess the adequacy
of lighting. Be sure to use it frequently to re-verify that lighting levels remain constant. Make sure your light meter is
capable of taking measurements in the range of your lights

Fig. 1: Typical blast booth

design
Source: Reference 10.80.3
and 10.80.4; American
Conference of Governmental Industrial Hygienists, Abrasive Blasting
Room, 02-91, VS-80-01

and that it meets your accuracy needs. Most light meters

have an accuracy range from 5% up to 18% and even higher.

OSHA Ventilation in Shipyard Employment Guide A Shift in Approach?

OSHA 3639-04 2013: Ventilation in Shipyard Employment
provides a review of basic principles of ventilation and
provides methods for selection, installation, and use of ventilation systems to reduce contaminants during shipyard operations. While it primarily focuses on confined and enclosed
spaces, it provides guidance applicable to any industry.
Unlike General Industry (1910) and Construction (1926), Mar-

SECTION THROUGH TYPICAL ROOM

Q = 60100 cfm/ft2 of floor for downdraft with typical choice 80 cfm/ft2
Q = 100 cfm/ft2 of wall for cross draft
Lower control velocities may be used depending on toxicity of the contaiminant, object and blasting media, and the size of the blasting room.
Notes: 1. The above ventilation is for operator visibility and to

control escape of contaminants into adjacent work areas.

2. Operator in an abrasive blasting room is required to wear

appropriate NIOSH-certified respiratory protection.

3. For rotary tables, use 200 cfm/ft2 of total opening (taken

without curtains).

4. For blasting cabinets, see VS8002.
2005-2015 Technology Publishing Co.

the basis of its ventilation requirements for abrasive blast-

(4) There is no need to collect the air contaminant.

ing containments. In industrial field painting, it generally

If we apply the four factors to industrial painting and abra-

involves bringing duct work to the face of the containment

sive blast cleaning in the construction, marine, or shipyard

system or just inside the containment wall and having air

industries, where the quantity of contaminants are high and

inlets generally across from them, mimicking the design of a

non-uniform and many of which are toxic, it would suggest

blast booth (Fig. 2).

that LEV may be more appropriate than dilution ventilation.

This type of venti-

Fig. 2: Efficient method of supplied

ventilation (forced air) with system
away from tank opening.
Source: Edward J. Willwerth, Atlantic
Environmental & Marine Services

LEV is an industrial ventilation system that captures

lation is considered

and removes emitted contaminants before dilution into the

dilution ventilation

ambient air of the workplace.1 While we typically associate

(general exhaust

LEV with vacuum shrouds and vacuum attachments, LEV can

ventilation), which is

include placement of one or more exhaust air ducts in the

a form of exposure

immediate vicinity of where the exposure is occurring. LEV

control that involves

is frequently used in the shipbuilding industry and is the rec-

providing enough air

ommended method when workers are exposed to hazardous

in the workplace to di-

chemicals, when a large amount of dust or welding fumes

lute the concentration

are generated, or during cold weather when increased heat-

of airborne contam-

ing costs from the use of dilution ventilation is a concern.

inants to acceptable

The Shipyard Guide suggests that using ventilation in an

levels.1

exhaust mode and placing the ductwork where contami-

The Shipyard
Guide states that both

nants are released in the air by the operation is an effective

method in capturing the generated contaminants and greatly

general dilution ventilation and local exhaust ventilation

reduces exposure to workers in a space (Fig. 2).

(LEV) at the source are suitable for controlling exposures.

Table 3 (excerpted from Ventilation in Shipyard Employ-

However, it states that local exhaust ventilation is typically

ment), suggests that LEV may be more appropriate for abra-

preferred and more effective.

sive blast cleaning.

The Shipyard Guide also states that dilution ventilation

While the preference for LEV may be specific to shipyards,

involves the reduction of contaminants being generated

all industries should evaluate the hazards and unique char-

in the space through the introduction of

clean outdoor air (through air inlets) and
removal of the contaminants through a
dust collector. It notes that sometimes, this
can cause a supply and exhaust imbalance
that positively or negatively pressurizes the
space or results in short circuiting (when
only a small portion of the space is ventilated). The Shipyard Guide depicts dilution
ventilation as inefficient, requiring a lot of
air and air movement to reduce the level of
hazardous contaminants.
The Shipyard Guide also suggests that
four factors should be considered before
using dilution ventilation for protecting
worker health.
(1) The quantity of contaminant released
should be relatively low and uniform.
(2) Workers should be located far away
from the contaminant source.
(3) The toxicity of the contaminant must be
low.
2005-2015 Technology Publishing Co.

acteristics of the work area to which their employees are

Slags can contain trace amounts of toxic metals such as

exposed and consider all methods for reducing exposures.

arsenic, beryllium, and cadmium.

When working with materials covered by comprehensive

The fact sheet also suggests that when performing abra-

health standards (such as lead) which require the use of

sive blasting to reduce worker hazards from materials, one

engineering controls for the purpose of reducing worker

needs to use nearly identical controls as one would for lead

exposures to as low as feasible, LEV may be more in line

or other toxic metals, including engineering controls (e.g.

with the definition of an engineering control, which focuses

containment and ventilation), work practices (hand and body

on elimination or reduction of the hazard at the source.

PPE and hygiene), and respiratory protection. Some other

Duct Work

observations made in the fact sheet include:

recommending the use of alternative, less toxic blasting

Whether you use dilution or local exhaust ventilation, an

materials such as sponge, baking soda, or dry ice;

integral part of the system is the ductwork. The Shipyard

keeping coworkers away from the blaster;

Guide is consistent with the guidance provided in SSPCs

cleaning and decontaminating tarps and other equipment

C3 Course, and SSPC-Guide 16, Guide to Selecting Dust

at the worksite; and

Collectors, and states that consideration should be given to

scheduling blasting when the least number of workers are

the type and length of the hose and layout of duct work to

at the site.

ensure the greatest amount of air flow.

Take a look at your abrasive blast cleaning operations and

As the length of hose or ductwork increases, the amount

materials and consider what equipment, processes, materi-

of air moved decreases due to frictional losses. Therefore,

als, or worker changes may be necessary to reduce worker

the shortest length of hose or ductwork should be used.

exposures to abrasive blasting material hazards.

Equally important is the amount of bends or turns in

Are We Closer to Revising the Cal/osha Lead Standard?

the ductwork. A greater number of bends or turns greatly

In April 2011, the California Department of Health/Occupa-

decreases the volume of air moved. Try to keep the hose as

tional Lead Poisoning Prevention Program (OLPPP) began

straight as possible. To put this in perspective, one sharp

providing information to support revisions to the 30-year-old

90-degree bend in a 20-inch-diameter duct is equivalent to

Cal/OSHA Construction Lead Standard based on more recent

adding 46 additional feet to the length of the ductwork.

health-based scientific evidence. OLPPP suggests that the

When we install ductwork through manways, small open-

following changes are necessary.

ings, and other limited egress areas, it may impede entry/

Provide medical surveillance, blood lead level (BLL)

exit. The Shipyard confined space standard requires that if

testing, annual blood pressure measurements, and question-

ventilation ductwork blocks access to a confined space, then

naires to all employees likely to be exposed to lead.

all workers must be provided with airline respirators, and

Increase frequency of medical surveillance of BLLs and

a person must be stationed outside the space to maintain

further increases if above 10 g/dL.

communication and to aid in the event of an emergency. The

Remove employee from lead exposure at or above 30 g/

Guide suggests a saddle be used in these cases. A saddle is

dL or if two successive blood lead concentrations measured

a piece of equipment that allows entry/exit without remov-

over a four-week interval are at or above 20 g/dL.

ing the duct work.

Return employee to work when two blood lead tests taken

Abrasive Blasting Hazards

four weeks apart are less than 15 g/dL.

OSHA released a new fact sheet in November 2013, titled,

Lower Permissible Exposure Limit (PEL)/Action Level (AL)

Protecting Workers from the Hazards of Abrasive Blasting

which reflect new medical/toxicological information on

Materials. It outlines the following abrasives and likely

chronic and low-level health effects.

health effects.

Conduct regular testing of surfaces in eating areas and

Silica sand (crystalline) can cause silicosis, lung cancer,

change areas and clean more frequently when lead is found.

and breathing problems in exposed workers.

Establish a quantitative limit for lead on surfaces and specify

Coal slag and garnet sand may cause lung damage similar

sample collection and analysis methods.

to silica sand (based on preliminary animal testing).

Provide quarterly employee training. Training should maxi-

Copper slag, nickel slag, and glass (crushed or beads) also

mize the use of participatory and hands-on methods.

have the potential to cause lung damage.

Post warning signs in areas where lead is present.

Steel grit and shot have less potential to cause lung dam-

Define and require minimum engineering and work prac-

age.

tice controls unless the employer can demonstrate that such

2005-2015 Technology Publishing Co.

controls are not feasible.

References

Do not allow certain high-risk work

1. OSHA Technical Manual.

practices.
In October 2013, the California Department of Public

About the Author

Health (CDPH) made a recommendation to Cal/OSHA for a

Alison B. Kaelin, CQA, has more than 25 years of public

new PEL based on the low level health effects literature and

health, environmental, transportation, and construction man-

new modeling of the relationship between air lead levels and

agement experience in the coatings industry.

blood lead levels.

She is the owner of ABKaelin, LLC, a pro-

CDPH used an updated version of the original model used

vider of OSHA training, quality assurance,

by OSHA to develop the General Industry Standard for lead

auditing, consulting, and related services

and challenged the model using actual BLL and mortality

to the protective coatings, construction,

data obtained over the last 20 years. The modeling and the

fabrication, and nuclear industries.

conclusions support the overwhelming body of recent scien-

Kaelin is a certified quality auditor and

tific evidence indicating the health impacts of very low BLL

NACE-certified coating inspector. She was a 2012 JPCL Top

exposures ranging from 510 g/dL. The modeling focused

Thinker, a 2012 JPCL Editors Award Winner, and an SSPC

on two issues.

Technical Achievement Award winner in 2005. At SSPC 2014,

Estimate the amount of lead in workplace air inhaled by

she was presented the inaugural Women in Coatings Impact

workers without respirators that would result in BLLs of 5,

Award. She is a JPCL contributing editor.

10, 15, 20, and 30 g/dL over a 40-year working lifetime.

Estimate the time it would take for a workers BLL to come
down to 15 g/dL from a higher level once the worker is
removed from workplace lead exposure.
The modeling arrived at the following conclusions.
To keep almost all workers (95%) BLLs below 5 g/dL
over their working lifetime, the amount of lead in the air the
worker is exposed to must not be above 0.5g/m3 averaged
over an 8-hour workday.
The model also shows that the amount of lead in a workers blood climbs very fast in the first few years of workplace
exposure and then climbs much more slowly in the remaining years. Even though a workers BLL does not climb much
during the remaining years, lead levels in the bones continue
to increase. The lead in the bones is slowly released into the
blood throughout a workers lifetime.
The model also estimates the time it may take for a workers BLL to come down to a BLL of 15 g/dL, after removal
from workplace exposure.
The CDPH concluded that based on available scientific
evidence adverse health effects begin to emerge at BLLs of
10 g/dL and likely lower.
Modeling suggests that in order to maintain BLLs of 10 g/
dL over a working lifetime in 95% of workers, the air concentration of lead must not exceed 2.1 g/m3 as an 8-hour TWA
average or to maintain a BLL of 5 g/dL a PEL of 0.5 g/m3
as an 8-hour TWA average.
Cal/OSHA is expected to introduce a final rule by the end
of this year. Industry professionals expect medical removal
levels to be established at 1520 g/dL and a PEL of approximately 20 g/m3 as an 8-hour TWA average.
2005-2015 Technology Publishing Co.

10

On the Time between Blasting and Priming

How long can a blasted
surface be left before
priming under different
temperatures/relative
humidity environments?

and vary from job to job. In Jordan, for example, oxidation

or orange rust may not occur for several hours or days, but
in UAE, you can probably expect to see rust break through in
few hours, depending on the time of the day or night.
It is almost impossible to state the effect of time, tem-

Editors Note: Problem Solving Forum questions are posted

on the free daily electronic newsletter, PaintSquare News,
on behalf of JPCL. Responses are selected and edited to
conform to JPCL style. To subscribe to PaintSquare News,
go to www.paintsquare.com/psn/.

perature, and humidity on all blast-cleaned surfaces. On any

given job, the answer must be the sole responsibility of the
inspector, who conductson-site checks ofthe conditions
such as the following:
Place of work

From Lee Edelman

Air temperatureminimum and maximum

CW Technical Service

Relative humidity

Always attempt to prime the prepared surfaces before the

Dew point

specified surface preparation starts degrading. Most speci-

Steel temperature

fications will address this practice. Humidity and dew point

Necessary ventilation

should be monitored throughout the process, so that when

Type of weather, such as sunlight, rain, wind speed, and

humidity or dew points exceed what the specification al-

direction

lows, there should not be any painting activities.

These on-site checks must be done at least three times per

If the prepared surface has degraded, most specifications

shift. The inspectorshould have the sole right to determine

will require reblasting to the specified degree of surface

the time without deviating from the specification.

preparation.
From Remko Tas
From Richard D. Souza

Futuro SRL

Stoncor Middle East LLC

As a curiosity, flash rust did not occur for 10 days in a dry cli-

How long a blast-cleaned surface can remain uncoated is not

mate at an altitude of 4,000 m (13,000 ft) in Bolivia, hundreds

the issue; rather, the highest criterion is the steel tempera-

ofkilometers away from the influence of saltwater and con-

ture: It should always be at least 3 degrees C (5 F) higher

tamination from industry-generated air pollution. We could

than the calculated dew point temperature. This margin of

still safely paint the interior of the tank in one shot, achieving

safety is sufficient for all type of coatings.

a high efficiency.

A common scenario is that thecontractor blasts all day

long; experiences problems with the compressor or oth-

From Lubomir Jancovic

er piece of equipment; and as a result of the equipment

MSPLUB Inc.

problems, lets the newly blasted steel sit along time before

You have to prime the blasted surface of steel within eight

coating. But the standard requires thatthe surface to be

hours. Otherwise, blasting was for nothing. If the relative

painted must meet the cleanliness criteria set by the client or

humidity is more like 60%, you have to prime thesurface

consultant. These criteria supersede every other judgment

within four hours.

2005-2015 Technology Publishing Co.

11

iStockphoto/ZooCat

Safety Considerations
for Abrasive Blasting Operations

Editors Note: This Applicator Training Bulletin is

an update of an original article written by Walter
Shuler, certified safety professional and safety
consultant; Jeff Theo, Service Painting Company; and Mike McGinness, Custom Process Systems. The article was originally published in the
June 1998 issue of Protective Coatings Europe
(PCE) and was updated for this issue by Dan
OMalley, Manager of the Environmental, Health,
and Safety Group; and Stan Liang, Director of
Health and Safety; KTA-Tator, Inc.

he Occupational Safety and Health Administration

ant that you understand what they are and observe the

(OSHA) writes and enforces regulations that govern

proper safety precautions. The hazards of abrasive blasting

safety and health practices in the work place, with many

include, but are not limited to:

pertaining to cleaning and painting operations. Most

dust,

of these regulations are very specific about how to

noise, and

do a job safely. Their purpose is not to make our job more

equipment.

difficult, but to make it safer. These regulations have been

developed over many years through studies on how and

Dust

why accidents happen, and following these written proce-

The dust produced by abrasive blasting is a very serious

dures and regulations should ensure that we don t make the

health hazard. Dust results from the breakdown of abra-

same mistakes that have injured others in the past.

sives and the pulverizing of surface coatings, rust, millscale,

and other materials on the steel surface being blasted. The

This article will review some of the general requirements

of regulations on abrasive blasting and explain how they can

individual dust particles vary in size from 1 micron (125,000-

help increase job safety.

inch) to 1,000 microns (125-inch) in diameter. Dust larger

than 10 microns may be visible and settles quickly. Dust

Hazards of Abrasive Blasting

smaller than 10 microns, called respirable dust, is invisible,

When you blast clean surfaces with abrasive driven by air,

remains suspended in the air for a longer period of time,

you have to deal with several hazards to your health and

and can pass through the respiratory systems defenses and

safety. Some of these hazards can be lethal, so it is import-

settle in the small air sacs in the lung called alveoli.

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such as lead, arsenic, cadmium, and hexavalent chromium.

One of the most common toxic metal hazards encountered
in the removal of a coatings system is lead, a toxic metal that
can damage the bodys blood-forming, nervous, urinary, and
reproductive systems. Lead also accumulates in the body;
thus, exposure to small doses over long periods of time can
cause great harm.

Exposure to toxic metals can also directly affect the skin.

Metals such as hexavalent chromium can irritate the skin or

cause an allergic reaction. Other metals can have an irritant
effect on the respiratory tract, such as pulmonary edema
(fluid build-up in the lungs) caused by severe cadmium
dust exposure. Entry can also occur via ingestion, typically
caused by poor hygiene practices such as eating, drinking,
and smoking in the work area.

To determine the specific toxic metals likely to be present

in a coatings system, paint chip samples should be collected

from representative areas of the structure. The metals that
the samples should be analyzed for would depend on a number of considerations, such as the type of structure and the
type of coatings system being evaluated. Sometimes, toxic
metal content can be determined based on historical knowledge of the coatings system being evaluated.

Toxic metals can also be present in the virgin abrasive

blast media, such as crystalline silica in silica sand abrasive. However, dust-containing crystalline silica also can be
produced during other abrasive blasting activities, such as
surface preparation of concrete. A study published in the
September 2006 issue of the Journal of Occupational and
iStockphoto/tolgabayraktar

Environmental Hygiene indicated that elevated exposure to

crystalline silica exposure also can result when it is present
in the coatings system being removed.1

Dust of this size cannot be dissolved by the lung fluids.

The Safety Data Sheet should be consulted to determine

what metals may be present in the abrasive blast media.

Because the lung cannot break down or cast out the par-

Recently, OSHA has begun requiring abrasive manufacturers

ticles, it does the next best thing in its defense program,

to list toxic metals in their products, even if they are present

which is to isolate the intruder by building a thick, fibrous

only in trace amounts. Arsenic is commonly found in steel

tissue around it. When too much of this tissue develops, the

grit and coal slag abrasives, while beryllium is commonly

lung is said to be fibrotic, or in a condition of fibrosis.

found in coal slag abrasives.

The routes of entry and the associated health effects de-

When there is exposure to toxic dust, the primary con-

pend on the chemical and physical properties of the dust. If

cern is to control respiratory exposure. Respiratory protec-

the dust is soluble in water and respirable in size, it can enter

tion must comply with the OSHA Respiratory Protection

the alveoli, pass through the walls of the alveoli in the lungs,

Standard (29 CFR 1926.103). This standard requires feasible

and enter the bloodstream. Once in the bloodstream, dust

engineering and work practice controls to be employed be-

can be transported rapidly throughout the body and damage

fore respiratory protection is used by workers. Engineering

various organ systems.

controls include ventilated abrasive blasting containments

and considering alternatives to abrasive blasting, such as

Other health hazards may be present in the dust pro-

duced by the abrasive blasting process. These hazards can

vacuum-shrouded power tools, water jetting, and chemical

result from the removal of coatings containing toxic metals

stripping. Job rotation is an example of a work practice con 2005-2015 Technology Publishing Co.

13

trol. Note that job rotation is not permitted by OSHA in all

Noise

cases (if workers are exposed to hexavalent chromium, for

Most forms of abrasive blasting create the hazard of noise

instance). If such a control is used, a written schedule must

exposure, which will vary depending on the blasting condi-

be developed and followed.

tions. Regardless of the nature, excessive amounts of noise

may require personal hearing protection for blasters and

Respiratory protection may only be used after engineer-

ing and work practice controls are employed and workers

other workers in the general area. Depending on the size of

are still exposed above the OSHA Permissible Exposure

the equipment, the material being blasted, and the location

Limit (PEL) for a given toxic dust. Employers must select,

of the blasting operation, noise levels can range from about

use, and maintain respirators in accordance with a written

90 decibels to more than 110 decibels. OSHAs limit for noise

program (the elements of which are specified by OSHA in

depends on the duration of exposure. For an eight-hour shift

the Respiratory Protection Standard).

of continuous exposure, the limit is 90 decibels. Personal

hearing protection should then be recommended if the level

Blasters typically use a Type CE or helmet-type airline

respirator. Workers in the vicinity of the blasting area, such

and exposure time of the workers exceed the OSHA stan-

as pot tenders and lookouts, are required to wear respiratory

dard. Noise protection must reduce exposure to below the

protection. Workers engaged in clean-up operations should

OSHA limit.

also be equipped with respiratory protection. These workers

are usually assigned a half-mask, air-purifying respirator

some degree of noise protection, but the manufacturers

with high-efficiency cartridges (labeled as N, R, or P 100).

specifications should be checked to see if the degree of noise

However, workers cleaning up abrasive blasting debris when

reduction will be adequate. When there is any question

blasting is still in progress (as is often the case when recycla-

about the existing levels (meaning a noise survey is needed)

ble grit is used) may need a higher level of protection. Such

or the adequacy of hearing protection, a health and safety

workers may need to wear the same type of respirator as the

professional should be consulted.

blasters, as their exposure levels are likely to be similar.

The National Institute of Occupational Safety and Health

Note that some abrasive blasting hoods already provide

Equipment

(NIOSH) conducts research on health issues in the work

The equipment used in abrasive blasting operations can

place, and one of its main functions is to test and certify

create physical hazards that require certain precautions. The

industrial respiratory protection equipment. All respiratory

following are some examples of equipment commonly used

protection equipment used in the workplace must be ap-

during the abrasive blast cleaning process and the respective

proved by NIOSH.

precautions that should be taken during their use.

Deadman control: This is usually a spring-loaded control

Respiratory protection should continue to be worn after

blasting as long as dust-laden air remains. Respirable dust

located near the nozzle end of the blast hose. When de-

in an abrasive blasting booth or containment can remain

pressed, it starts the flow of high-pressure air and abrasive.

suspended for long periods of time after blasting is finished.

When released, it stops the flow. Deadman controls can be

This time period is largely dependent on the effectiveness of

either pneumatic (air-operated) or electric. In either case,

the ventilation system, unless the work is performed out-

the control must be kept depressed by the operator for the

doors.

system to work. This prevents a nozzle from blasting the

operator or nearby workers with abrasive if dropped. Always

A health and safety professional should review all proj-

ects that require abrasive blast cleaning to determine what

verify that there is a Deadman control and that it is operable

precautions, if any, should be taken to eliminate the hazard

before any work is performed.

of chemical exposure. Examples of these precautions include

Hoses: Hoses are subject to severe abrasion from the

disposable clothing, boots, gloves, respiratory protective

high-pressure air and abrasive that moves from the pressure

devices, and hygiene practices. Hygiene facilities that can be

vessel to the nozzle. Ruptures can cause serious injury. Metal

required by OSHA include hand wash stations and showers.

piping carrying abrasive also deteriorates rapidly. Hoses and

OSHA requires provision of a hand wash station when work-

piping should be inspected on a regular basis and repaired

ers may come into contact with toxic materials. Whether or

or replaced periodically as necessary. Hose and pipe cou-

not showers are mandatory depends on which OSHA stan-

plings also should be inspected regularly. Blast hose cou-

dard is applicable. If workers are exposed to lead, showers

plings should be wired together and whip checks should be

are required when exposures exceed the PEL.

used. Whip checks are safety cables that restrain movement

2005-2015 Technology Publishing Co.

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of the hose should the coupling connection become compro-

Summary

mised.

When performing abrasive blasting, safety considerations

Pressure vessels: Pressure vessels for compressed air or

must be given to hazards including dust, noise, and equip-

abrasive under pressure should be checked regularly be-

ment. Once the hazards are determined, procedures for

cause they are also subject to abrasion and deterioration be-

personnel protection can be developed. In addition to being

yond that of normal pressure vessels. Pressurized abrasive

provided with personal protection, workers must be properly

tanks must have a removable plate for internal inspection.

trained in the use, inspection, and maintenance of equip-

All vessels must conform to American Society of Mechani-

ment.

cal Engineers (ASME) boiler and pressure vessel codes.

Valves: All valves and rubber valve parts are subject to

hazards must conform to the OSHA regulations that govern

wear and should be inspected and replaced periodically.

blasting operations. Additional regulations from state or

Fill ports: Pressure vessels for abrasive blasting should

local jurisdictions may be in force. Twenty-three states have

have a funnel-shaped input that is easily accessible to the

their own version of OSHA, and their regulations are at least

operator so that strain caused by lifting bags of abrasive is

as strict and, in some cases, stricter than federal OSHA regu-

avoided.

lations.

Hoseline grounding: Nozzles should be grounded because

the air and abrasive can create enough friction to develop a

analysis of abrasive blasting health and safety. When there

substantial charge of static electricity. This is most important

is any doubt about the nature of the hazard or how to protect

while working inside tanks or in other areas where there is

workers, assistance should be obtained from a health and

potential for explosion.

safety professional, typically someone who is a Certified

Personal protective equipment: In addition to respiratory

Industrial Hygienist or a Certified Safety Professional or pos-

and noise protective equipment, blasters should wear ap-

sesses a degree from a related field of study.

parel to prevent damage to their skin from abrasive blast-

Procedures to control exposure to health and safety

This article should not be considered a comprehensive

ing and ricochet. Such apparel includes safety footwear or

References:

toe guards, coveralls, leather or rubber capes, and gloves.

1. Meeker, John D., Pellegrino, Anthony, and Susi, Pam,

Pant and sleeve cuffs should be secured with tape or other

Comparison of Occupational Exposures Among Painters

suitable fasteners. These clothing rules are most difficult

Using Three Alternative Blasting Abrasives. Journal of

to enforce during hot weather, but despite the discomfort,

Occupational and Environmental Hygiene, Volume 3, Issue 9

they still must be enforced. Protective equipment should be

(September 2006): pp. D8084.

inspected daily and repaired or replaced as necessary. Clean

storage areas should be provided for respiratory protection
and protective apparel. It is most important that blasters
receive proper training in the use of personal protective
equipment.

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Setting Up Air Abrasive

Blast Equipment
Editors Note: This Applicator Training Bulletin is an
update of a previous article written by Joe Fishback of
Custom Blast Services Inc. It was first published in the
November 1989 JPCL and has been updated for this issue
by Bill Corbett and Stan Liang of KTA-Tator, Inc.

Fig. 1: Blast pot

Courtesy of Axxiom Manufacturing
Air compressors are generally identified by output capaci-

n air abrasive blast equipment system is composed of

ty, such as 250 CFM, 325 CFM or 750 CFM. CFM means cubic

several major components, including the following.

feet per minute, which is how the volume of pressurized air

Air Compressor

is measured. The power to run a compressor is usually pro-

Blast Pot (Pressure Blast Tank)

vided by an internal combustion engine (gasoline or diesel)

Abrasive (Blast Media)

or by an electric motor. Selection of a power unit is generally

Blast Nozzle

dictated by the area where blasting is to be done or by the

Moisture Trap

availability of utilities.

Deadman Switch

Before starting the compressor, remember to:

Blast Hood

check the engine oil level;

Interconnect Hoses

check the coolant level; and

Lets take a look at each to see how they work together to

check the belts and hoses for leaks or defects.

provide an efficient abrasive blast system.

Air Compressor

Blast Pot
The blast pot (Fig. 1, p. 17) is a coded pressure vessel gen-

The air compressor provides high-pressure air for the blast-

erally referred to as a pressure blast tank (PBT). Because it

ing operation. This machine takes in atmospheric air at 14.7

is a pressure vessel, it must have a stamp on it showing that

psi and compresses it to a pressure several times higher,

it has been pressure tested. The PBT is further identified by

usually about 120 psi. The heat generated through compres-

size. For example, it may be called a 6-ton PBT or a 6-sack

sion is somewhat dissipated by an air intercooler. The air

pot (based on silica sand), referring to the amount of abra-

then passes through moisture and oil separators to make it

sive it can hold. During operation, the blast pot is pressur-

dry and oil-free as it exits the compressor.

ized and feeds abrasive into the air stream.

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the compressed air continues to cool, additional moisture

condenses in the bull hose. This remaining moisture is
trapped by the moisture separator just before it enters the
PBT. This trapping is done either with a centrifuge-style
separator or with a replaceable filter element-style separator.
Generally, it is necessary to leave an air bleed valve open in
the bottom of the moisture trap when blasting to allow the
moisture to be expelled.

Deadman Switch
The deadman switch (Fig. 2), either pneumatic or electrical,
Fig. 2: Multi-colored deadman switches. Courtesy of SAFE
Systems, Inc.

Abrasive (Blast Media)

allows the blaster to have remote control over the pressurization of the blast hose. With pneumatic operation, this is
accomplished when pressure through the deadman switch
closes the air control valve and opens an escape valve. This

While not usually thought of as abrasive blast equipment,

prevents air from entering the PBT and at the same time,

not much happens to the surface without the abrasive.

it depressurizes the PBT. Electrically operated systems use

Abrasives are generally categorized as expendable (one-time

pinch valves to stop the flow in the blast hose. With electri-

use) or recyclable (multiple uses). The type, size, shape and

cally controlled systems, the PBT is always pressurized when

hardness of the abrasive all affect productivity as well as the

the bull hose is connected and pressurized.

depth and shape of the surface profile or anchor pattern. The

The primary purpose of the deadman switch is safety. It

cleanliness of the abrasive is just as important as the clean-

provides a means to stop the discharge of abrasive from the

liness of the compressed air used to propel the abrasive. A

nozzle when a safety hazard arises. The fact that it allows the

vial test is performed on new or recycled abrasive prior to

blaster to start and stop work at his discretion is a secondary

use. The abrasive is tested for oil according to ASTM D7393

purpose.

and conductivity according to ASTM D4940. According to the

SSPC standards, abrasives cannot contain any visible oil and

Blast Hood

cannot have a conductivity that exceeds 1,000 S.

The blast hood (Fig. 3) is a piece of safety gear that provides

Blast Nozzle

a degree of comfort to the blaster as well. This hood is generally a reinforced plastic shell with a replaceable skirt that

The blast nozzle is a small but important piece of the blasting

covers the torso of the blaster. It has a double-faced shield of

equipment. It is the last item to exert influence on the blast

clear plastic for eye protection and an air feed line to provide

media. Nozzles are identified by their shell composition, their

positive pressure under the hood. The positive air pressure

lining composition, the size of the orifice and length (for ex-

under the hood prevents the entrance of harmful blasting

ample, aluminum shell with tungsten lining, size #7, short).

dust and abrasive. Air coolers are also available. If the air is

The orifice size number relates to the size in 116-inch units

coming from a diesel compressor, an air purifier and carbon

(#7 = 716-inch). The size of the nozzle has a bearing on the

monoxide monitor are required.

amount of air and abrasive used and on the amount of work

completed. The larger the size of the nozzle, the greater the

Hoses

consumption of supplies. Nozzles are chosen for the work to

Hoses vary in size depending on the work to be performed,

be performed.

available air capacity, distance to work area and other con-

Moisture Trap

siderations.
The first in the sequence is the bull hose. This is generally

The moisture trap is a device that allows the compressed

a short hose less than 50 feet long, with an internal diam-

air to shed water. As the air is compressed, heat is gener-

eter (ID) of approximately 2.5 inches or less that provides

ated. As this hot air passes through the heat exchanger to

passage of air from the compressor to the PBT.

lower the air temperature, water in suspension (humidity) is

The next hose is an air-line with an approximate ID of 0.75

condensed. Generally, a compressor is fitted with a moisture

inches or less that provides air first to a moisture trap and

trap. This first trap catches most of the water. However, as

then to the blast hood. The section between the moisture

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trap and the hood is smaller, down to 0.25-inch ID.

Control hoses can be down to 0.20-inch ID and are generally duplex (dual-line) hoses. They run from the control valve
on the PBT to the deadman switch and back to complete the
circuit when the blaster is ready to commence work. Included here is the electrical wiring necessary if the deadman is
electrically operated. It generally operates from a 12-volt DC
source such as the compressor power units DC system.
The last hose in the circuit is the blast hose. It is a thickwall, wire-reinforced hose designed and constructed to
contain the high-pressure air (up to 120 psi) and abrasive
mixture that moves from the PBT to the blast nozzle. The
blast hose is constructed in three layers: an inner wearing
lining, a conductive layer and an outer wrapping. Abrasive
passing through a blast hose builds up static electricity.
The conductive layer is needed so the whole system can be
grounded. As a general rule, the hose should be three times
the ID of the nozzle orifice; ideally, 1.25 inches to 1.5 inches
for optimum production.

Setting Up the System

With the major sub-assemblies identified, we can now set
up our blasting equipment. Position the compressor upwind
from the work area so that airborne grit does not enter the
cooling or air intake systems. The compressor should be
level so that the oil and moisture separators can function
efficiently. The power units lubrication system also depends
on the compressor being level. After fluid levels (oil, coolant
and fuel) have been verified and topped off, the compressor
is ready to start.
The bull hose should be laid out with no kinks and a min-

Fig 3: Blast hood

Courtesy of Bullard

imum of bends. Prior to making connections at the compressor and PBT, the sealing gaskets should be examined

the hose for the deadman switch. The fittings on the ends of

for tears, cracks or other sealing problems. As soon as the

this hose are brass, male/female and threaded. It is neces-

connectors have interlocked, a safety pin or wire should be

sary to use the proper-sized wrench to prevent damage to

inserted to prevent accidental separation of the joint. If this

the brass hex surfaces. As the hose is installed, care should

separation should occur, there is great potential for per-

be taken to lay the hose parallel to the blast hose. The

sonnel or property damage as the hose whips around. The

control line should also be secured to the blast hose by tape

hose should be examined for damaged locking lugs, missing

or other means to minimize possible damage to this less du-

gaskets, soft spots, torn covers or other damage.

rable hose. This is important because air leaks in the control

If any defects are observed, consideration should be given

line will not allow the control valve to pressurize the PBT and

to replacement of the worn or damaged part. If all appears

thus no blasting takes place. The threaded fittings should be

in good condition, make the connections at the compressor

tightened securely but not over tightened.

and PBT moisture trap.

Now, go back to the air source for connection of an air-line

The next step is to lay out the blast hose utilizing the same

to feed the small moisture trap for hood atmosphere. These

inspection procedures used for the bull hose and fittings. If

fittings are usually 0.75-inch crows foot, quick-disconnect

all is in good shape, connect the selected nozzle and pin all

fittings. Inspection of hose gaskets and locking lugs is once

fittings.

again necessary. Be certain to pin all quick-disconnect crows

When the blast hose connection is complete, you can run

feet.
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The hood atmosphere line is the last hose to be hooked

To assure the quality of cleaning, two important checks

up. This hose has brass screwed fittings similar to those on

should be made. The first is a compressed air cleanliness

the control line. The same care in hook-up should be exer-

test, also known as a white rag or blotter test. This test

cised, with particular attention to preventing entry of debris.

determines if the blast air is free of moisture and oil as it

Now, with all hoses connected to their respective fittings,

is delivered to the nozzle. The abrasive valve is closed to

you are ready for pressurized air. Close all air outlet valves

prevent abrasive from entering the air stream. A white rag

on the compressor. Press the shutdown bypass button

or blotter (called an absorbent collector) fastened to a

as well as the start button. The compressor should start

rigid backing is then positioned in the air stream within 24

and run. After the temperature moves up to the operating

inches of the nozzle. A non-absorbent collector such as rigid

temperature, it is time to press the service air switch. At this

transparent plastic may also be used. After a minimum of

time the air pressure gauge should register approximately

one minute, the collector is removed and examined for oil or

110120 psi. If the reading is higher or lower, adjustments

moisture contamination. If evidence of oil is present on the

should be made before beginning the blasting operation.

collector, adjustments must be made to the system, possibly

When the compressor stabilizes at working air pressure,

by service personnel from the supplier of the compressor.

slowly open the valve to furnish hood atmosphere air. After

The second test measures nozzle pressure. This measure-

the quality (oil and contaminant-free) and quantity of this air

ment is taken with a needle pressure gauge. The needle

are verified, slowly open the valve for the bull hose. There

is inserted into the blast hose in the direction of air and

should be no air escape except at the moisture trap bleeds.

abrasive flow. This insertion takes place close to the nozzle

If air leaks are present, they should be repaired. The PBT can

with both the air and the abrasive flowing. Nozzle pressure is

now be filled with abrasive.

read directly on the face of the gauge. Optimum blast nozzle

The blaster should be clothed with sturdy shoes or boots,

pressure should be approximately 100 psi for productive

heavy pants, a long-sleeved heavy shirt and leather gloves

work. Pressures lower or higher than 100 psi may improve

for protection from bounce-back of abrasive. When the blast-

productivity depending on the abrasive being used.

er has been properly suited up, he or she can check opera-

With proper setup of equipment and a thorough knowl-

tion of the blast equipment. He or she does this by opening

edge of good safety practices, your job should be safe and

the deadman valve to pressurize the PBT and thus force

trouble-free.

a quantity of abrasive to enter the air stream to the blast

hose.
Adjustments in the amount of abrasive delivered to the
nozzle can be made with an abrasive valve located close
to the bottom of the PBT. Enough abrasive to do the work
should be delivered, but not so much as to slow the impact
or choke the blast hose or nozzle.

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191

Surface Preparation:
Adventures in Frustration

No, its just not

good enough.
Youll have to
reblast.

By Peter Bock
CorrLine International

Abrasive blasting structural beams

for a coastal petrochemical
project. All photos courtesy of
Mobley Industrial Services Inc.

hese are dreaded words a contractor hates to hear,

(SSPC-SP 5/NACE No. 1) reads as follows:

whether they come from a third-party inspector or from

the contractors own QA/QC manager. Abrasive blasters

blast cleaned surface, when viewed without magnification,

have been hard at work all morning. Just before lunch-

shall be free of all visible oil, grease, dust, dirt, mill scale,

time the blasters shut down. The spent blasting grit and

rust, coating, oxides, corrosion products and other foreign

2.1 White Metal Blast Cleaned Surface: A white metal

the old coating (and rust) blasted from the surface have been

matter.

hurriedly gathered and removed, the blasted surface blown

down or vacuum cleaned to remove blasting dust, and the

it isnt. But its not always that simple. The standard states

inspector summoned.

that the the surface needs to be white when viewed without

The inspector or QA/QC person is not the bad guy he

That should be easy and straightforward its white or

magnification. Does that mean the inspector has a right to

or she is simply following his or her interpretation of the

get his nose half an inch from the blasted surface, or should

project specification and the industry standards used to write

he view it from a more normal range? How visible are

the specification. If there has not been sufficient discussion

the visible contaminants and foreign matter? What about

and agreement about standards and interpretation during

non-visible contaminants?

the pre-bid and pre-job conferences, the QA/QC person, the

third-party inspector and the contractors site superintendent

affect surface cleanliness as defined in Paragraph 2.1 include

may have significantly different opinions of what meets the

variations caused by type of steel, original surface condition,

project surface preparation specification.

thickness of the steel, weld metal, mill or fabrication marks,

heat treating, heat-affected zones, blasting abrasives, and

This article discusses potential ambiguities in visual

2.1.1: Acceptable variations in appearance that do not

surface preparation standards and provides insight into

differences because of blasting technique.

preventing disagreements between owners, inspectors and

contractors, and avoiding delays and costly reblasting.

in fact be several shades of gray, some of them because of

SSPC-SP 5/NACE No. 1, White Metal Blast Cleaning

Acceptable white metal prepared steel surfaces may

abrasive blasting, some of them in spite of it, and white

metal is a somewhat of a misnomer.

Surface preparation standards are almost entirely visual.

7.4: Immediately prior to coating application, the entire

SSPCs definition of a White Metal Blast Cleaned surface

surface shall comply with the degree of cleaning specified...

2005-2015 Technology Publishing Co.

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vacuumed or blown down again and the dread of dreads

the inspector has to be called back to re-inspect. In the
meantime, other previously acceptable areas of blasted surface may have deteriorated, so from a practical viewpoint,
if the inspector turns down a portion, reblasting or at least
resweeping the entire shifts work is often the most cost-effective option.
White Metal Blast
Cleaning, is usually
specified only for tank
and vessel lining and for
critical exterior surfaces. The costs and the
perfection required are
too high for most coating
projects and SSPC-SP 10/
NACE No. 2, Near White
Metal Blast Cleaning,
This blaster is using medium-grade garnet abrasive to obtain
a Commercial Blast Cleaned surface (SSPC-SP 6) and a 2-to3-mil anchor profile.

or SSPC SP-6/NACE No.

An area of staining or discolor- 3, Commercial Blast
ation in SSPC-SP 10 blast.
Cleaning, are specified
Does it pass or fail?
instead. Near White
Metal Blast Cleaning allows 5 percent of a unit area of

Any visible rust that forms on the surface of the steel after

abrasive blasted steel surface to be less than white metal

blast cleaning shall be removed by recleaning

and Commercial Blast Cleaning allows for 33 percent. For

both standards the less-than-white areas can have only ran-

If the inspector thinks that the job has not been done well

enough, the contractor will have to reblast the unaccept-

dom staining consisting of light shadows, slight streaks or

able areas. Because the contractor has already set up for

minor discolorations caused by stains of rust, stains of mill

painting to ensure no more deterioration immediately prior

scale, or stains of previously applied coating.

to coating application, all that effort is wasted. Blasting

equipment has to be brought back in, spent abrasive has to

Therefore, if an inspector finds a 3-inch-square area in which

be once again gathered and removed, the surface has to be

more than 3 square inches are randomly stained, the area

A unit area is defined as a 3-inch-by-3-inch square.

fails Commercial Blast. The math is easy; the stains are

not.

When is a Stain Not a Stain?

Although the SSPC Protective Coatings Glossary defines
a stain as An area of a surface which, when compared to
adjacent areas, has an equal surface profile but is discolored
(usually darker) with a material having no apparent volume;
upon visual assessment, confusion remains about what
constitutes a stain versus actual rust or mill scale left on the
surface. How light, slight or minor do the light shadows,
slight streaks or minor discolorations specified in SSPC-SP
6/NACE No. 3, Paragraph 2.1 have to be to pass, especially
since the following paragraph (2.1.1) of the specification
allows the same steel color variations as for White Metal?
Beam end area has been blasted to a "Near White Metal"
finish (SSPC-SP 10).

Just as for White Metal Blast, Near White Metal

and Commercial Blast require that immediately prior to

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test-blasted areas done as part of the contractor bid qualification or pre-job qualification, there should be a general
agreement between the owner, contractor and third-party
inspector. In advance of the project, a decision should be
reached about what constitutes acceptable visual appearance of the prepared surfaces in order to conform to the
specification standard. Inspection of the days surface preparation work should be an opportunity for agreement, not a
source of frustration, confusion and conflict.

After a commercial or near white blast of aged steel in a

refinery or chemical plant environment (especially at a coastal location where high humidity and salt in the air are almost
constant), it is often difficult to determine whether stains the
inspector finds are allowable, or a result of degradation of
Newly-blasted support beam unit has flash rusted badly after
an unexpected rain shower.

the blasted surface.

According to the inspector, the most straightforward way

to tell is to let the blasted area sit a while and see if the staining gets worse. From the contractors perspective, this can
be perceived as an expensive way for the inspector to force
a reblast. Using an agreed-upon visual comparison standard
up front can help to avoid disagreement.
SSPC-PA 17

Procedure for Determining Conformance to Steel Profile/

Surface Roughness/Peak Count Requirements
Testing of a dry-abrasive-blasted surface for specified anchor
profile can be a non-visual, quantifiable test. The traditional
visual comparator test has been superseded by the use
of profile replica tape, or of depth micrometer testing of the
profile. Both replica tape and depth micrometer testing are
quantitative measurements, but they measure only small
Light flash rusting on steel dry blasted to SSPC-SP 10. This
area needs to be reblasted.

samples of the entire prepared surface. The number of

required anchor profile tests should follow standards as a
minimum or should be specified and agreed upon at the prejob conference. Depth micrometer testing is highly accurate,

coating application, the entire surface shall comply with the

but measures only one pit per reading, so multiple groups

degree of cleaning specified. Any visible rust that forms on

of readings must be done to assure accuracy. The project

the surface of the steel after blast cleaning shall be removed

specification should clearly state the type and frequency of

by recleaning But are the stains the inspector is finding

blast profile tests required.

on newly blasted Near White Metal or Commercial steel

from before blasting, or are they new turning or rerusting of

was blasted and without degradation, the inspector could

the steel?

inspect it and pass or fail the actual preparation work itself,

Get the Picture

If newly-abrasive-blasted steel could be stabilized as it

rather than the preparation that has subsequently been

affected by environmental conditions.

Visual comparison standards for acceptable quality of

dry-abrasive-blasted surfaces (SSPC VIS 1) should be avail-

faces has been known since before coating inspectors were

able at the job site and should have been discussed and

assigned CIP numbers. When the author was first learning

agreed on at the pre-bid and pre-job conferences. Whether

the offshore oil field maintenance painting business in the

using available photographic standards, or digital photos of

late 1970s, there was already a primitive test for salt residue

The presence of salts on White Metal blasted steel sur-

2005-2015 Technology Publishing Co.

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surface or more. The project specification should include

the specific method to be used for testing for soluble salts.
It may also include the number, frequency and location of
tests. There is also a visual component structures tend
to corrode unevenly; verification tests have often shown
widely varying results, indicating that surface contaminants
are unevenly distributed on the prepared surface, tending
to cluster or aggregate. This accounts for the phenomenon
that some areas of the same abrasive blasted surface tend to
flash rust faster and more severely than others.

Both the equipment owner and a seasoned third-party

inspector may have experience indicating where the structure being prepared will tend to corrode, that is, where the
previous coating system failed the earliest or most extensively. Salt tests should be specified to be taken at precise
Moderate flash rusting on steel dry blasted to SSPC-SP 10.

areas which are expected to have the highest levels of residual non-visible contaminants. Without such specificity, there
may be disagreement.

contamination on newly-blasted-steel surfaces. The original

field salt test consisted of licking the newly-blasted steel.

ing or UHP water washing remove some non-visible contam-

At that time the blasting medium was silica sand, and the

inants, but the wet prepared steel surface can quickly flash

steel looked clean when viewed without magnification, so

rust as it dries. There are methods of inspecting a flash-rust-

licking it was safe and sanitary, but you could always taste

ed surface after wet preparation, but these are also entirely

the salt. And, of course, the spot you licked immediately

visual and are even more subjective than the staining

flash rusted. Then the contractor painted over all that salt,

described in SSPC-SP 6/NACE No. 3 or SSPC-SP 10/NACE

because there was no cost-effective way of removing it.

SSPC Guide 15

Wet surface preparation methods like wet-abrasive blast-

No. 2.

The most common method of delaying flash rusting on

dry-abrasive-blasted steel is dehumidification reducing

Field Methods for Extraction and Analysis of Soluble Salts

relative humidity over the newly-blasted surfaces to a level

on Steel and Other Nonporous Substrates

where an electrolytic cell does not exist and flash rusting

Since then, much more sanitary and quantifiable tests have

cannot occur.

been developed for measuring salt residues left on new-

ly-blasted surfaces. Different types of salt test procedures

being dry-abrasive-blasted is relatively simple. There are few

measure different groups of salts and it should be noted that

and relatively small openings, and the steel sides and floor

test results may vary, depending on the test method used.

contain air and hold heat. Exterior structures can be scaffold-

All the tests have in common the facts that they are expen-

ed and tented with plastic sheeting to allow for DH, but such

sive (anywhere from $10 to $40 for the test kit itself, exclud-

tenting can be leaky and requires more DH to accomplish the

ing the cost of the measuring device) and they are slow,

originally desired results. In either case, the cost of running

typically taking 10 to 30 minutes per test. All of the salt tests

the DH system continuously can be very expensive, and if

are also handicapped by two other factors: first, they mea-

the DH is stopped for any reason, the blasted steel can quick-

sure only a tiny area of the blasted surface, typically about

ly flash rust.

one one-hundredth of one percent, which is then assumed to

be uniformly representative of the entire prepared surface,

flash rusting after dry-abrasive blasting is the use of a

and secondly, they do not specifically measure iron sulfides

waterborne inhibitor chemical which changes the pH of

left on the surface, and these are one of the primary causes

the abrasive-blasted steel or leaves a thin residual coat on

of flash rerusting.

the blasted surface, or both. The inhibitor chemical can be

A salt test measures salt concentration on two-to-four

sprayed onto the newly-blasted surface immediately after

square inches of the prepared surface and the test results

blasting is completed or it can be used as a part of a wet-

will be representing several hundred square feet of prepared

abrasive-blast process.

Dehumidification (DH) for the interior of a roofed tank

An alternative and less expensive method of controlling

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23

Use of an inhibitor chemical allows a contractor some

Whichever method is used, determination of the speci-

time to finish abrasive blasting and cleanup, allows the

fied level of surface preparation is predominantly a visual

inspector time for a thorough inspection, and in some cases,

process. To prevent disagreements, delays, frustration and

allows abrasive blasting to continue for several shifts before

costly reblasting; the end user, contractor and third-party in-

shutting down, inspecting, and coating or lining the pre-

spector should agree on visual acceptance standards before

pared surfaces.

surface preparation begins. The best way to reach agree-

ment is to use visual samples, preferably photos of accept-

Inhibitors are frequently used during maintenance work

where the owner or inspector requires Near White Metal

able surface preparation samples, available to all parties at

appearance, but blasting and coating application cannot be

the job site.

done quickly enough to prevent flash rusting. The process is

not recommended by paint companies but is frequently used

About the Author

in the oil and petrochemical maintenance areas.

Peter Bock is vice president and technical service manager

for CorrLine International in Sugar Land, Texas. He is a U.S.

The dried inhibitor film is visually transparent. To the

inspectors eye, the steel appears to be Commercial or

Air Force veteran and has degrees

Near White Metal Blast, (whatever the original standard

from Tulane University and the

and quality of blast), so it fulfills the visual standard.

University of Northern Colorado.

Bock has 37 years of experience with

A third, relatively new method for controlling flash rust

on abrasive-blasted steel is a proprietary waterborne pas-

sales, management and technical

sivation process. Unlike inhibitors, which must be applied

service in oilfield and petrochemi-

before any flash rusting occurs, the passivation process

cal heavy-duty coatings in the U.S.,

claims to remove flash rust, restoring prepared steel to its

Canada, Mexico, Venezuela, Indone-

White Metal stage. Visual inspection and salt testing after

sia, and Taiwan. He has experience

the passivation process are the same as for newly dry-abra-

with on- and offshore production,

sive-blasted steel.

drilling and workover rigs, shipyard work, natural gas and

LNG, pipelines, terminals, refineries, and chemical plants.

Conclusion
Surface preparation is the first and sometimes the most

He is a specialist in elevated temperature systems and CUI

mitigation. JPCL

important part of a successful industrial coating or lining

project. Unfortunately, specification standards for surface
preparation are almost entirely visual and can be somewhat
subjective. After dry-abrasive-blast-surface preparation,
properly prepared surfaces can quickly degrade from their
initial state on completion of blasting, and need to be quickly
inspected, approved and coated.

Field-usable salt contamination tests can determine the

presence of non-visible contaminants on visually-acceptable,

prepared surfaces, but the tests available today are expensive, slow, and measure too small of a percentage of the
prepared surface to be completely reliable.

Flash rusting of a newly-abrasive-blasted surface can be

prevented by dehumidification, which keeps humidity at

the bare steel surface below a level where it can act as an
electrolyte, by the use of inhibitors, or by a steel passivation
process.

2005-2015 Technology Publishing Co.