Abrasive Blasting Checklist

Abrasive blasting is widely used across various industries, including shipbuilding and automotive manufacturing. Thanks to abrasive blasting, companies can efficiently clean and prepare surfaces for painting or applying sealants. However, because abrasive blasting involves significant force, safety measures are crucial to prevent accidents and injuries.

Employers must ensure workers are equipped with proper safety gear while operating abrasive blasting equipment. Comfortable and protective gear allows employees to focus on their tasks without worrying about potential hazards. Regular inspections of the equipment and using appropriate materials are essential to maintain workplace safety.

We'll outline some of the top hazards related to abrasive blasting and provide a safety equipment checklist to help you and your team avoid serious injuries.

For more information, feel free to reach out to us.

What Is Abrasive Blasting?

Abrasive blasting, often referred to as sandblasting, is a process that uses compressed air or water to shoot a high-pressure stream of abrasive materials onto an object. The purpose of abrasive blasting can vary, from quickly cleaning a surface to removing rust or preparing an object for painting. It's an efficient way to achieve the desired surface finish.

What Materials Are Used for Abrasive Blasting?

There are several materials commonly used for abrasive blasting, each suited to different applications based on the required coating and surface preparation. Here are some of the most popular options:

• Glass beads: Recycled glass materials that are eco-friendly and free of free silica. These abrasives are gentle on surfaces and effective for quick cleaning without damaging the substrate.
• Crushed glass: 100% recycled glass bottles that offer sharp edges for aggressive cutting action, perfect for removing heavy coatings.
• Aluminum oxide: A versatile and medium-density abrasive derived from bauxite. Aluminum oxide is widely used for tasks ranging from rust removal to glass etching.
• Plastic: Lightweight and silica-free, plastic abrasives are less aggressive and suitable for softer substrates.
• Silicon carbide: One of the hardest materials available, silicon carbide provides rapid cutting speeds and short blasting times, making it ideal for preparing surfaces for coatings.
• Steel shot: Designed for heavy-duty applications, steel shot is strong and durable, useful for removing rough edges or corrosion.
• Steel grit: With its angular shape, steel grit creates deep anchor patterns, ideal for supporting coating adhesion in applications like bridge blasting or pipe coating.
• Starblastâ„¢: A general-purpose abrasive made from a blend of staurolite sands with a very low silica content. Known for its uniform blasting patterns and reusability.
• Black Beauty®: A popular coal slag product with less than 0.1% free silica. Available in different grades, Black Beauty is chemically inert and effective for removing surface coatings.
• Ground walnut shells: A lightweight and biodegradable option, ideal for applications requiring gentler abrasion without harming the substrate.
• Ground corn cobs: Similar to walnut shells, ground corn cobs are softer and less aggressive, suitable for delicate cleaning tasks like jewelry polishing or boat hull maintenance.

What Are Some Hazards of Abrasive Blasting?

Abrasive blasting is significantly faster and less labor-intensive than manual sanding or brushing. It plays a vital role in preparing items for painting or protective coatings. However, the materials used often produce a large amount of dust, which can be harmful if inhaled. Workers need to take precautions to protect themselves from air contaminants and other hazards when using abrasive blasting equipment. According to the Occupational Safety and Health Administration (OSHA), the following are potential hazards associated with abrasive blasting:

• Air contaminants: Exposure to toxic particles in the air poses the primary health risk. Materials like silica sand can cause breathing issues and increase the risk of lung cancer, while toxic metals such as arsenic, lead, and nickel are also concerning.
• Loud noise: Operators are exposed to noise levels that can lead to hearing loss if proper protection isn't worn. OSHA’s permissible exposure limit for noise is 90 A-weighted decibels (dBA). Abrasive blasting typically generates noise levels of 112 to 119 dBA.
• Powerful particle streams: Operators risk being struck by high-speed blasting materials, which can embed in the skin or eyes, causing burns or cuts.
• High-pressure water or air streams: Operators or bystanders could suffer severe injuries if they come into contact with high-pressure air or water streams, especially if they're unaware of their surroundings or improperly trained.
• Static electricity: Abrasive blasting equipment can generate static electricity. If not grounded properly, employees face the risk of electric shock.
• Vibration: Prolonged use of equipment exposes operators to hand and arm vibrations, leading to conditions like vibration syndrome, characterized by tingling, numbness, and pain.
• Slips: Operators are at risk of slipping due to abrasive particles creating slippery surfaces.
• Heat: Operators are susceptible to heat-related illnesses from wearing personal protective equipment (PPE) for extended periods or working in hot environments.

Safety Equipment Checklist

 

Using the correct personal safety equipment can greatly reduce the risks associated with abrasive blasting. At Finishing Systems, we offer reliable, comfortable, and high-quality safety equipment and accessories to protect you and your employees from potential hazards. Here's the safety gear you should include on your abrasive blasting checklist:

• Respirator: A respirator protects operators from toxic particles in the air. We offer a range of air-supplied respirators to fit various jobs. Additionally, some respirators come with built-in hearing protection within the helmet for added safety.
• Climate control device: Prevent prolonged exposure to heat and heat-related illnesses with a climate control device. For instance, the RPB® C40â„¢ Climate Control Device combines a lightweight belt with a simple lever to adjust the temperature inside the respirator, allowing operators to work comfortably and safely in any environment.
• Eye and face protection: Workers around abrasive blasting areas should always wear proper eye protection.
• Gloves: Choose heavy-duty safety gloves made from durable materials like canvas or leather that protect the entire forearm. The material should prevent particle abrasion and, ideally, reduce the impact of vibrations.
• Apron or blast suit: Protect your body from abrasive particles by wearing an apron or coveralls. For maximum protection, opt for a breathable yet heavy-duty blast suit that covers the arms and the front of the body.
• Safety shoes or boots: Footwear should shield operators from particulate matter and be made of tough material. Steel-toe boots are durable and protect toes from falling objects and punctures. Slip-resistant features are also important.
• Hearing protection: If your respirators don't include hearing protection, it's essential for employees to wear comfortable ear muffs or properly rated earplugs to safeguard their hearing.

How to Begin Every Project Safely

Every abrasive blasting project should begin with a safety inspection to ensure the equipment is ready for use. Below is a checklist to help you and your team inspect blasting equipment, surroundings, and personal protective equipment (PPE) for safety.

Blasting Equipment

A typical abrasive blast system includes an air compressor, air supply hose, abrasive blaster, blast hose, and blast nozzle. These components work together to deliver a powerful stream of abrasive material. Before starting, inspect the following components:

Air Compressor

An air compressor powers the abrasive blasting equipment. Consider the following before beginning:

• Is the air compressor maintained and serviced?
• Is it equipped with a pressure relief valve?
• Does the air compressor meet your air supply requirements?
• Is the air compressor located upwind of blasting operations?
• Is the air compressor at a safe distance from the blasting equipment?

Blast Vessel

The blast vessel, also called the pressure vessel, is the tank filled with compressed air and abrasive material. Answer the following:

• Is the inside and outside of the blast vessel free of corrosion, cracks, dents, bulges, or other damage?
• Is the inside of the blast vessel free of moisture and debris?
• Does the blast vessel contain any leaks?
• Has the blast vessel been depressurized before loading the abrasive?

Valves, Hoses, Pipes, Wires, and Fittings

Machine parts undergo significant stress during blasting applications, so it's critical to check these components for wear and tear regularly. Ask yourself the following:

• Are all valves, hoses, pipes, wires, and fittings in good condition and free of leaks, cracks, holes, or other damage?
• Are there any soft spots in the blast, air, or remote control hoses?
• Are blast and air hose gaskets free of leaks and visible wear?
• Are whip checks and safety pins installed on all connections?
• Is the size of the blast hose three or four times the size of the nozzle orifice?

Blast Nozzle

The blast nozzle size determines the amount of airflow and abrasive material required. Check the following:

• Is the blast nozzle thread or jacket damaged?
• Is it sized appropriately for the job's requirements?
• Has the nozzle’s orifice size increased by 1/16 inches, and if so, will it be replaced?

Abrasive Materials

Consider the abrasive materials you plan to use for blasting applications before you begin, and be sure you can answer the following questions:

• Is the abrasive material meant to be used with the blasting equipment?
• Is the abrasive material free of trash or other debris?
• Have you reviewed the Material Safety Data Sheet for the abrasive you plan to use?
• Is the material non-toxic, or does it contain an acceptable level of toxic substances according to OSHA?
• Is the material dry?

Objects

Inspect the blast objects and check for the following:

• Is the object adequately secured?
• Is the object used to store non-flammable materials only?

Environment

Consider the job site and your surroundings. Answer these questions:

• Have you established a hazardous blasting zone?
• Have you protected electrical lines in the area from blasting applications?
• Is the site free of tripping, falling, or crushing hazards?
• Is the work area well-lit?
• Is the blasting area adequately ventilated?
• Is the blast machine on level ground?
• Are there measures in place to discharge static electricity from the blast nozzle?
• Is the atmosphere free of flammable fumes?
• Is the carbon monoxide monitor tested and calibrated routinely?

PPE

All workers must wear appropriate PPE to protect themselves from the abrasive blast stream and dust. Be sure to inspect PPE before blasting, and check off the following:

• Does the respirator meet the standards set by the National Institute for Occupational Safety and Health?
• Does the respirator cover the neck, head, and shoulders?
• Does the respirator include air filters that meet the requirements for OSHA’s Grade D breathing air?
• Is the respirator free of damage?
• Are eye protection items in good condition and free of damaged or missing components?
• Are footwear and gloves free of tears, rips, and punctures?
• Is proper ear protection available such as earplugs or earmuffs?

Practicing Personal Hygiene Habits During Projects

To keep workers safe during and after projects, establish personal hygiene habits. OSHA recommends including the following in your safety plan:

• Do not allow workers to eat, drink, or smoke in blasting areas.
• Provide wash stations so employees can clean their hands and faces frequently.
• Ask workers to vacuum or remove contaminated clothing before eating, drinking, or smoking.
• Offer showers and change areas for workers to use at the end of their shifts.
• Ask workers to keep contaminated PPE and clothes out of clean areas.

Contact Finishing Systems for Your Abrasive Blasting Needs

Abrasive blasting quickly cleans objects of rust, paint, coatings, and other materials, providing a clean surface for the next application. By using the right PPE and regularly inspecting your equipment, you can enjoy the efficiency and power of abrasive blasting without compromising safety, production levels, or worker satisfaction. Keeping workers on the job and your customers satisfied is possible when you use quality equipment and prioritize safety.

At Finishing Systems, we offer everything you need to perform abrasive blasting operations safely, from our selection of high-quality abrasive mediums to portable blast equipment. We’re your abrasive blasting experts committed to finding solutions and helping our customers succeed. To learn more about our abrasives, equipment, or services, contact us today!

 

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