Professional Media Blasting & Abrasive Surface Preparation

Media selection depends on substrate material, required surface profile, and coating specifications. Steel grit (G25-G40) provides aggressive profiles for heavy rust on steel. Garnet (30-80 mesh) works well for aluminum, fiberglass, and multi-substrate projects. Aluminum oxide suits precision aerospace work. Glass beads create smooth peened finishes for stainless steel. Crushed glass offers an economical, silica-free option for concrete. We analyze your substrate and coating requirements to select optimal media.

Yes, when performed with proper controls. We implement full containment systems capturing all media and debris, preventing environmental contamination. HEPA-filtered dust collection maintains air quality. Workers use supplied-air respirators, blast hoods, and hearing protection. We avoid silica sand (causes silicosis) in favor of safer alternatives. All waste is properly characterized and disposed of according to EPA regulations. For lead paint removal, we follow EPA RRP requirements with additional containment and worker monitoring.

When performed by trained professionals with proper equipment, media blasting is safe for substrates. We control multiple variables: air pressure (typically 80-100 PSI for steel, 40-60 PSI for aluminum), nozzle distance (12-18 inches optimal), blast angle (70-90 degrees), and media selection. Softer substrates like aluminum, fiberglass, or thin metals require gentler media (glass beads, plastic media) and reduced pressure. Our experienced operators continuously assess the surface to prevent over-blasting while achieving specified profiles.

Surface profile (anchor pattern) ranges from 0.5 to 5+ mils depending on media type, pressure, and technique. Standard industrial coatings typically require 2-3 mil profiles (achieved with garnet or steel grit at moderate pressure). Heavy-duty epoxy and zinc-rich primers need 2.5-4 mil profiles. Thin-film coatings may only need 1-1.5 mil profiles (glass beads or fine aluminum oxide). We verify profile using SSPC comparators or replica tape, documenting measurements for quality records and coating manufacturer compliance.

Containment systems vary by project scope and location. Indoor facilities use full enclosures with negative air pressure (maintaining 0.03 inches WC negative), HEPA filtration, and dust collection. Outdoor projects employ tarp enclosures, ground covers, and portable dust collectors. For hazardous materials (lead paint), we install double-layer containment, air monitoring, and decontamination stations. Bridge and elevated work uses specialized scaffolding enclosures. All containment is designed to capture 100% of blast media and debris for proper disposal.

Dry blasting uses compressed air and abrasive media for maximum cleaning power and surface profiling—ideal for heavy rust, mill scale, and coating removal. Wet blasting (vapor blasting or dustless blasting) adds water to reduce dust by 90%+, making it suitable for occupied areas, sensitive environments, or where dust control is critical. Wet blasting provides gentler cleaning for delicate surfaces and eliminates static discharge risks. Trade-offs include potential flash rusting on steel (requiring rust inhibitors) and slightly slower production rates.

SSPC (Society for Protective Coatings) standards define cleanliness levels: SP-5 (White Metal) removes all visible rust, mill scale, and coatings—used for immersion service. SP-10 (Near-White Metal) removes 95%+ of contaminants—standard for industrial coatings. SP-6 (Commercial Blast) removes most visible contamination—acceptable for many architectural coatings. SP-7 (Brush-Off Blast) removes loose material only. SP-14 defines industrial blast standards. We document achieved cleanliness with visual standards and provide photographic verification for each project.

Media blasting costs range from $1.50-$6.00 per square foot depending on: substrate condition (heavy rust vs. light oxidation), required cleanliness level (SP-5 vs. SP-6), containment requirements (open vs. enclosed), access difficulty (ground level vs. elevated), and hazardous material presence (lead paint adds $2-4/sq ft). Standard industrial steel blasting to SP-10 typically costs $2.50-$4.00/sq ft. Prices include media, labor, containment, and waste disposal. We provide detailed estimates after site inspection.

Yes, we're EPA RRP certified for lead paint removal with extensive experience on pre-1978 structures. Lead blasting requires specialized protocols: Type 3 containment (full enclosure with negative pressure), worker medical monitoring, air sampling, HEPA filtration, and proper waste characterization and disposal. We perform XRF testing to confirm lead presence and levels before work begins. All lead waste is manifested and transported to licensed disposal facilities. Complete documentation is provided for regulatory compliance and property records.

Project duration depends on surface area, condition, and cleanliness requirements. Production rates vary: 100-200 sq ft/hour for heavy rust to SP-10, 200-400 sq ft/hour for light oxidation to SP-6. A 10,000 sq ft steel structure typically requires 3-5 days including setup, blasting, and cleanup. Factors affecting timeline include: containment installation (1-2 days), weather conditions (outdoor work), access challenges, and coordination with coating application (primer within 8 hours of blasting to prevent flash rust). We provide detailed schedules during estimation.

Professional blasting contractors should hold: SSPC-QP1 (Field Application) and QP2 (Shop Application) certifications demonstrating quality systems. NACE/AMPP coating inspector certifications (CIP Level 2+) ensure proper quality control. EPA RRP certification is required for lead paint work. OSHA 10/30 hour training covers general safety. State contractor licensing with proper insurance coverage is essential. Our crews maintain all required certifications and participate in ongoing training to stay current with evolving standards and technologies.

Media blasting prepares virtually any hard surface: steel and iron (structural, tanks, equipment), aluminum and non-ferrous metals (with appropriate media), concrete and masonry (surface profiling, coating removal), fiberglass and composites (gel coat removal, repair prep), wood (paint stripping, surface cleaning), and stone (restoration, cleaning). Each material requires specific media selection and pressure settings. We evaluate your substrate and recommend appropriate blasting methods, or alternative preparation techniques when blasting isn't suitable.

Flash rusting (oxidation within hours of blasting) is prevented through: immediate primer application (within 4-8 hours maximum, same day preferred), humidity control (maintain below 85% RH, substrate 5°F above dew point), rust inhibitor application (temporary protection when immediate coating isn't possible), dehumidification equipment (for enclosed spaces), and proper scheduling (blast only what can be primed same day). We monitor environmental conditions continuously and coordinate closely with coating crews to ensure primer application within the critical recoat window.

Complete PPE for blasting operations includes: NIOSH-approved supplied-air respirator or pressure-demand airline respirator, blast hood with replaceable lens, leather or heavy-duty gloves, hearing protection (noise levels exceed 100 dB), full-body protective suit (leather or canvas), steel-toed boots, and dead-man switch. Support personnel within blast areas need respiratory protection and hearing protection. We supply all required PPE and conduct daily equipment inspections. Workers are trained in proper use, maintenance, and emergency procedures.

Yes, but cold weather requires additional considerations: steel temperature must be 5°F above dew point to prevent condensation and flash rust—heated enclosures may be necessary. Air lines need adequate moisture separation as cold air holds less moisture but compressed air generates condensation. Some coatings have minimum application temperatures (typically 40-50°F). Production rates may decrease due to worker comfort and equipment performance. We adjust procedures for winter work including heated staging areas, heated enclosures when needed, and optimized scheduling around temperature windows.