Abrasive Blasting System Components Checklist

- Blasting Components
- Safety Components
Handy Hints and Tips that could help your profits
- Compressor Size
- Hose Lengths: Shorter is Better
- Air Hose Sizes
- Blast Hose: Whip Hose
- Blast Hose Sizing
- Checking Nozzle Pressure
- Abrasive Consumption: Metering Valve Settings
Abrasive Blasting Technical Data Tables
- Air Consumption per Blast Nozzle
- Nozzle Pressure vs Efficiency
- Hose Size Selection Guide
- Typical I.D-O.D. Relationship in Common Blast Hose Sizes
- Imperial < to > Metric Conversion Chart of Common Dimensions
Nozzle Pressure vs Blasting Efficiency Chart
Blast Cleaning Cost Calculation Formula
DISCLAIMER: All and any tables, calculations, factors, formulas, procedures, data, information, photographs, pictures, illustrations, lists, references,
summaries, text, descriptions, methods, tests, comparisons, checks, charts, graphs, figures etc., in this Technical Reference section, are a guide only and
shall not be taken as either approved nor standard nor complying for any of the topics or aspects , and neither is any claim made as to the completeness
or accuracy of the information. It is the responsibility of the reader and/or users of this 'information' to separately determine and verify the correct method,
formula, factor, procedure, data, etc. for determining any such topics or aspects as directed or required or indicated in or by any work specifications and/or
standards. Blastmaster expressly disclaims any liability for the use or misuse of the information.
TECHNICAL REFERENCE
ABRASIVE BLASTING
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COMPRESSOR SIZE IS VERY IMPORTANT
Keep your productivity up
Maximize compressed air volume and pressure. A blast cleaning operations productivity level directly depends on the volume and
pressure of the air passing through the nozzle. In operations with slow production rates, theres usually not enough air volume
(cfm) and pressure (psi). A larger compressor will provide
moreair to support a larger nozzle, and a larger nozzle gets
the job done faster.
SHORTER IS BETTER
Dont lose pressure
Keep your air hose and blast hose lengths short. Put your
compressor as close to the blast pot as possible, and
keep your pot near your blasters to shorten the distance
the air has to travel and keep pressure drops to a
minimum. Its especially helpful to keep blast hose length
short since pressure drops are even greater than in air
hose because youre pushing abrasive and compressed
air through the line.
BULL HOSES
Get the most productivity from yourair hose
Use a large I.D. size. When it comes to air compressor hose, bigger is always better. Running large I.D. air line (1 1/2 or 2) from your
compressor to your blast pot reduces the friction pressure loss caused in smaller, more restrictive sizes. Air pressure drops have a
large impact on production. One 2 hose is better than 4 x 1 hoses!
Handy Hints & Tips that could help your profits...
Minimum Compressor
Air Line Sizes
Nozzle Orifice Minimum
size Air Line ID
1/4 (6.5mm) 1 (25mm)
5/16 (8mm) 1-1/4 (32mm)
3/8 (9.5mm) 1-1/2 (38mm)
7/16 (11mm) 2 (50mm)
1/2 (12.5mm) 2 (50mm)
5/8 (16mm) 2-1/2 (64mm)
3/4 (19mm) 3 (76mm)
Undersized Air Supply Hose
Technical Reference Section
284
Blastmaster Catalogue Section 14
14
Technical Reference Section
285
Section 14 Blastmaster Catalogue
14
BLAST HOSE
Get the best production possible
Make sure your blast hose is large enough to make the most of your nozzle. You know that
to get the highest, fastest production out of your blasting set-up you need to run
the largest blast nozzle that your air source can support. But, dont forget the blast hose.
It wont do you much good to run small blast hose to a large nozzle or vice versa.
WHIP HOSES
Dont go too small on your whip
If the operator finds the standard blast hose too heavy to work with all day, a short length of flexible, lighter weight, blast hose called a
whip - can be used near the nozzle. But be careful of using hose which is too small. By decreasing the I.D. of the blast hose, you increase
friction losses and decrease productivity.
Handy Hints & Tips that could help your profits...
Main Blast Hose Size Whip hose Size % of reduction of
internal area
1 1/2" ( 38mm) 1 1/4" ( 32mm) 31%
1 1/2" ( 38mm) 1" ( 25mm) 56%
1 1/4" ( 32mm) 1" ( 25mm) 36%
1 1/4" ( 32mm) 3/4" ( 19mm) 64%
1" ( 25mm) 3/4" ( 19mm 44%
Comparative Percentage Hose Area Reduction
Technical Reference Section
286
Blastmaster Catalogue Section 14
14
WORK UNDER PRESSURE
Check nozzle pressure for productivity
Use a hypodermic needle pressure gauge kit, and insert the needle
into the blast hose slowly, a few inches back from the nozzle. Point
the needle toward the nozzle, and at a slight angle. Insert slowly until
you get a constant reading. Are you getting 100psi?
See page 45 for ordering details
Handy Hints & Tips that could help your profits...
Create the best mixture by starting off with no abrasive
and slowly open up the metering valve, until you can only just
start to see the colour change in the air exiting the nozzle.
Thats all the abrasive you need for fast blasting.
ABRASIVE SETTINGS
Dont lose valuable abrasive
Make sure your abrasive metering valve is set properly.
How can you tell? Look at the abrasive flow coming out of your
nozzle. An efficient air/abrasive mixture will be only slightly visible,
appearing as a coloured haze in the air stream.
If you see a lot of colour in this flow, theres too much abrasive (and
not enough air) in the mixture. Why? Your abrasive metering valve is
open too far. When this happens, your cleaning efficiency is lowered,
valuable abrasive is wasted and youre losing money.
c
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Check your Blasting system right through and find where your
pressure losses are located.
Test the pressure at both ends of a long length of hose -
you'll be amazed to see how much pressure can drop!
We recommend getting two pressure test kits, to test air
going into your blast pot versus air pressure coming out.
If you are losing excessive pressure, it may be equipment,
accessory or compressor related.
NOZZLE PRESSURE VS EFFICIENCY
Blast Approximate Approximate
Nozzle Pressure Abrasive Velocity Efficiency Factor
100 psi 675 kph 100%
95 psi 640 kph 93%
90 psi 585 kph 86%
85 psi 530 kph 80%
80 psi 430 kph 74%
75 psi 225 kph 69%
70 psi 300 kph 64%
AIR CONSUMPTION (CFM) PER BLAST NOZZLE USING GARNET ABRASIVE
Nozzle Size Nozzle Pressure
50 psi 60 psi 70 psi 80 psi 90 psi 100 psi 120 psi* 140 psi*
No. 2 1/8 14 17 19 21 24 26 30 34
No. 3 3/16 32 37 42 47 52 57 67 77
No. 4 1/4 57 66 75 84 93 103 119 136
No. 5 5/16 89 103 117 131 145 158 186 214
No. 6 3/8 129 149 169 189 209 229 269 309
No. 7 7/16 176 203 230 258 285 312 367 422
No. 8 1/2 229 265 300 336 371 407 478 549
No. 10 5/8 356 412 468 524 580 632 744 856
No. 12 3/4 516 596 676 756 836 916 1076 1236
Efficiency 47% 55% 64% 74% 86% 100% 130% 165%
*Ensure equipment is rated for these pressures.
TYPICAL ID - OD RELATIONSHIP
IN COMMON BLAST HOSE
Standard Hose Supa/Whip Hose
ID OD ID OD
mm inch mm inch mm inch mm inch
13 1/2 33 1-5/16 13 1/2 30 1-3/16
19 3/4 40 1-1/2 19 3/4 33 1-5/16
25 1 48 1-7/8 25 1 40 1-1/2
32 1-1/4 55 1-5/32 32 1-1/4 48 1-7/8
38 1-1/2 60 2-3/8 38 1-1/2 55 2-5/32
Imperial/Metric CONVERSION CHART
3/16 5mm 1-1/4 32mm
1/4 6mm 1-5/16 33mm
5/16 8mm 1-1/2 38mm
3/8 10mm 1-9/16 40mm
7/16 11mm 1-3/4 44mm
1/2 13mm 1-7/8 48mm
5/8 16mm 2 51mm
3/4 19mm 2-5/32 55mm
1 25mm 2-3/8 60mm
1-3/16 30mm 2-1/2 64mm
Technical Reference Section
287
Section 14 Blastmaster Catalogue
Technical Data
14
HOSE SELECTION GUIDE FOR BLASTING AT 100 PSI NOZZLE PRESSURE
Nozzle Number No. 4 No. 5 No. 6 No. 7 No. 8
Nozzle Size 1/4 5/16 3/8 7/16 1/2
CFM at 100 psi 103 158 229 312 407
Air Hose ID minimum 25mm (1) 38mm (1 1/2) 38mm (1 1/2) 50mm (2) 50mm (2)
Blast Hose ID minimum 20mm (3/4) 25mm (1) 32mm (1 1/4) 32mm (1 1/4) 38mm (1 1/2)
Did you know???
increasing your nozzle
pressure to 100 psi will
boost your efficiency
substantially!
60 70 80 90 100 110 120 125 130 140 150
Nozzle Pressure (psi)
170
160
150
140
130
120
110
100
90
80
70
60
50
Blast
Efficiency
(%)
HIGH
EFFICIENCY
LOW
EFFICIENCY
POOR
PRESSURE
EXCELLENT
PRESSURE
High
Pressure
Rated
Equipment
Technical Reference Section
288
Blastmaster Catalogue Section 14
14
Nozzle pressure vs Blasting Efficiency
The Golden Rule of Thumb
Every 1 psi below 100 psi pressure
at the nozzle equates to a 1.5%
LOSS of blasting efficiency*
from 94 psi to 100 psi achieves* 9.4% increase
90 psi 100 psi 16%
80 psi 100 psi 35%
70 psi 100 psi 57%
its quite amazing!!
*
approximate calculated efficiency actual efficiency realised will vary, depending on abrasive
type, abrasive size, nozzle size, nozzle type, nozzle wear, hose size, hose wear, moisture
content of compressed air, temperature of the compressed air, etc
CALCULATING THE TRUE COST OF BLAST CLEANING IN
DOLLARS PER SQUARE METRE.
Blast Cleaning
True Cost ($/m
2
) =
A.(B+C) + D + E
x
where A = Abrasive consumption rate (tonne/hour)
B = Abrasive cost delivered to site ($/tonne)
C = Abrasive cleanup and disposal cost ($/tonne) including cartage, landfill
D = Blasting labour cost ($/hour) including holidays, super, WorkCover, etc.
E = Equipment cost ($/hour) compressor, blast unit, truck, safety,
access equipment, fuel, power, insurance etc.
x = Cleaning production rate (m
2
/hour)
Comparative Example
Abrasive A costs $90/tonne, a 6 cu ft pot lasts for 30 minutes
(ie 600kg per hour)
and blasts 15m
2
steel in an hour
Abrasive B costs $300/tonne, a 6 cu ft pot lasts 1 hour
(ie 300kg per hour)
and blasts 20m
2
steel in an hour
common costs are : cleanup and disposal $40/tonne (conservative)
labour cost $40/hour (conservative)
equipment costs $60/hour (conservative)
True Cost (Abrasive A) = 0.6(90+40) + 40 + 60 / 15 = $11.86/m
2
True Cost (Abrasive B) = 0.3(300+40) + 40 + 60 / 20 = $10.10/m
2
CALCULATE THE TRUE COST USING YOUR FIGURES
AND OVERHEADS
True Cost =
consumption x (abrasive cost + disposal cost) + labour + equipment
cleaning speed
= $ /m2
Technical Reference Section
289
Section 14 Blastmaster Catalogue
14
Cost Effective Blast Cleaning