BLASTING & COATING SAFETY

NPC TRAINING PROGRAM

STUDENT HANDOUT

Presented by Frank Palmer

Calgary Tel 1-403-221-8077 Fax 1-403-221-8072 E-mail: info@seal.ab.ca Website: www.seal.ab.ca

Table of Contents
IDENTIFICATION & SELECTION OF MATERIALS & EQUIPMENT FOR ABRASIVE CLEANING ................................................................................................. 1 RATIONALE ...................................................................................................................... 1 OUTCOME ........................................................................................................................ 1 PREREQUISITES ................................................................................................................ 1 OBJECTIVES ..................................................................................................................... 2 RESOURCES ...................................................................................................................... 2 EVALUATION ................................................................................................................... 2 OBJECTIVE ONE............................................................................................................ 3 AIR COMPRESSOR ............................................................................................................ 3 AIR HOSES ....................................................................................................................... 5 BLASTING MACHINE ........................................................................................................ 5 BLASTING HOSE ............................................................................................................... 6 NOZZLES .......................................................................................................................... 8 VENTURI DESIGN ............................................................................................................. 9 NOZZLE LENGTH .............................................................................................................. 9 TUNGSTEN CARBIDE OR NORBIDE LINING ....................................................................... 9 OBJECTIVE TWO: ....................................................................................................... 10 OBJECTIVE THREE: ................................................................................................... 11 OBJECTIVE FOUR:...................................................................................................... 12 CHARACTERISTICS OF ABRASIVES ................................................................................. 12 Size ............................................................................................................................ 12 Hardness ................................................................................................................... 12 Breakdown Characteristics....................................................................................... 12 Shape......................................................................................................................... 13 pH.............................................................................................................................. 13 TYPES OF ABRASIVE MATERIALS................................................................................... 13 Natural Oxides .......................................................................................................... 14 Metallic Abrasives .................................................................................................... 14 Slag Abrasives........................................................................................................... 14 Synthetic Abrasives ................................................................................................... 15 OBJECTIVE FIVE:........................................................................................................ 16 ANGLES OF ATTACK ...................................................................................................... 16 NOZZLE TO SURFACE DISTANCE .................................................................................... 16 OBJECTIVE SIX: .......................................................................................................... 18 SSPC-SP-5 - WHITE METAL BLAST CLEANING ............................................................. 18 SSPC-SP-10 - NEAR-WHITE METAL BLAST CLEANING ................................................ 19 SSPC-SP-6 - COMMERCIAL BLAST CLEANING .............................................................. 20
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SSPC-SP-7 - BRUSH-OFF BLAST CLEANING ................................................................. 21 MODULE EXERCISE ................................................................................................... 22 SAFETY IN PAINTING OPERATIONS..................................................................... 23 RATIONALE .................................................................................................................... 23 OUTCOME ...................................................................................................................... 23 PREREQUISITES .............................................................................................................. 23 OBJECTIVES ................................................................................................................... 23 RESOURCES .................................................................................................................... 24 EVALUATION ................................................................................................................. 24 ACKNOWLEDGEMENTS................................................................................................... 24 INTRODUCTION .............................................................................................................. 25 OBJECTIVE ONE: ........................................................................................................ 26 OBJECTIVE TWO: ....................................................................................................... 28 OBJECTIVE THREE: ................................................................................................... 30 OBJECTIVE FOUR:...................................................................................................... 33 OBJECTIVE FIVE:........................................................................................................ 37 SUPPORT OPERATIONS ................................................................................................... 37 HIGH PLACES ................................................................................................................. 37 CONFINED SPACES ......................................................................................................... 39 REMOTE LOCATIONS ...................................................................................................... 39 OBJECTIVE SIX: .......................................................................................................... 40 CLOTHING ...................................................................................................................... 40 SUMMARY ..................................................................................................................... 44 MODULE EXERCISE ................................................................................................... 45

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IDENTIFICATION & SELECTION OF MATERIALS & EQUIPMENT FOR ABRASIVE CLEANING

Rationale
Why is it important for you to learn this skill? As an industrial applicator, you will be required to prepare surfaces to standards developed and published by international organizations. (Internal linings of pipelines and tanks all require an abrasive-blasted surface for a coating to adhere to the surface.) You will also be required to assemble and operate an abrasive unit.

Outcome
When you have completed this module you will be able to: Select the materials and equipment necessary for abrasive blasting.

Prerequisites
Module 1.1 Course Orientation Module 1.2 Responsibilities of an Applicator Module 4.1 Identification of Initial Conditions Module 5.1 Identification of Surface Preparation Module 5.2 Surface Preparation Standards Module 5.3 Identification and Selection of Materials and Equipment for Solvent Cleaning

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Objectives
List the major components of abrasive equipment. List the sizes of hoses and nozzles. State the cfm and psi required for operating an abrasive unit efficiently. Describe abrasive properties, and list the natural and synthetic abrasives. Describe the correct procedures required to use an abrasive unit. Identify the four levels of surface preparation obtained using an abrasive unit.

Resources
Society for Protective Coatings. Steel Structures Painting Manual, Volume 1 Good Painting Practice. Society for Protective Coatings. Steel Structures Painting Manual, Volume 2 Systems and Specifications.

Evaluation
Obtain 75% on a supervised written test.

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OBJECTIVE ONE
When you have completed this objective you will be able to: List the major components of abrasive equipment. The typical rig for abrasive blasting has five basic parts: air compressor, air hose, blasting machine, blast hose, and nozzle.

Air Compressor
The air compressor provides the high pressure and volume of air needed to propel the abrasives through the nozzle onto the surface, with sufficient force to clean it. The continuous and constant supply of an air stream of high pressure and volume is one of the most critical parts of the blasting operation. The compressor works by taking in, filtering and compressing a large volume of air by rotary or piston action and then releasing it into the blasting machine. The capacity of a compressor is measured in cubic feet per minute (cfm) of air, and is directly related to its horsepower rating. The relationship between horsepower (HP) and volume is shown in Table 1.

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Table 1 - Horsepower and cfm Rating Compressor HP Rating 15 HP (x 4.5 =) 20 25 30 40 50 60 75 100 Volume (cfm) 68 90 112 135 180 225 270 338 450

Typically, a flow of 170 to 220 cfm or 90 to 100 psi (pounds per square inch) nozzle pressure air is necessary for blast cleaning steel plates. This can be achieved with a 50 or 60 HP compressor. Proper compressor maintenance is necessary to control wear of parts, which can cause a drop in output. Oil and water traps are used to remove those contaminants that would otherwise be transferred to the blasted surface. The traps must be inspected, cleaned and adjusted frequently for continuous effective operation. The rate of blast cleaning is directly proportional to both the air pressure and volume exiting from the nozzle. The larger the compressor, the larger the nozzle Interior Diameter (ID) that can be used and thus the higher the cleaning rate. Typically, blasting at 90 to 100 psi and 170 to 220 cfm is accomplished with a 3/8 nozzle. Table 2 lists the cleaning rates on panels blasted with the same equipment for the same amount of time at different nozzle pressures. The rapid decrease in cleaning rate with nozzle pressure can be seen.

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Table 2 - Cleaning Rates Nozzle Pressure (psi) 100 90 80 70 60 Cleaning Rate (standard for comparison) 100% 82% (approx.) 78% (approx.) 60% (approx.) 50%

Air Hoses
The air hose delivers the air from the compressor to the blasting machine. It is not as rugged as the blast hose because it does not carry the abrasive materials (which erode the inner lining), nor is it dragged on the ground. The air hose should have an inside diameter of four to five times the inside diameter of the abrasive nozzle.

Blasting Machine
The blasting machine or sand pot is a container that holds the abrasives. A valve at the bottom, sometimes called a carburetor valve, measures and controls the amount of abrasive material fed into the blast hose. The essential parts of a typical gravity-fed blasting machine are: moisture separator removes moisture from compressed air, exhaust muffler reduces the noise made when the abrasive pot depressurizes, concave head holds the abrasive until it flows into the blast pot; metering valve meters the abrasive into the compressed air stream, and hose/tank coupling these internal couplings allow for even flow.

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The capacities of blast machines vary from 50 pounds to several tons of abrasive material. Smaller machines require more frequent refilling, and thus reduce blasting efficiency. It generally requires about 30 to 40 minutes to use 500 to 600 pounds of abrasive, and from 5 to 10 minutes to refill a hopper with this amount. Thus, 20% of the time may be required for refilling. A double-hopper setup can provide for continuous, uninterrupted blasting. Efficient blasting also requires a continuous, uniform flow of abrasive from the pot into the air stream. Some pots have an automatic metering valve that adjusts the flow of abrasive with fluctuating air pressure.

Blasting Hose
The blasting hose, which carries both the air and abrasive from the blasting machine to the abrasive nozzle, must be sturdy, flexible and have an outer cover that dissipates static electricity to prevent electric shock. (The friction of the abrasive traveling through the abrasive hose generates static electricity.) Abrasive hoses are sold in various lengths that may be joined together with external couplings. As a safety feature, these couplings, when connected, have a safety cable attached to prevent damage to the couplings. The couplings also have holes in their rims to insert a safety pin, which prevents the couplings from coming apart. Most important is the inside diameter of the blast hose which, as with the compressed air hose, has to be four to five times the diameter of the orifice in the blast nozzle. A sturdy, four-ply blast hose with the correct inside diameter is recommended for minimal frictional losses of pressure. Table 3 shows details on the frictional loss related to air hose diameter and length.

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Table 3 - Frictional Loss Related to Air Hose Diameter and Length Hose ID Size (inches) (coupled end) 0.75 Line Pressure (psi) 60 80 100 110 60 80 100 110 60 80 100 110 Loss of Pressure (psi*) for Different cfm of Free Air Passing Through 50-Foot Lengths of Hose 40 1.2 0.8 0.6 0.5 60 2.8 1.9 1.4 1.3 0.6 0.5 0.4 0.3 0.2 0.1 80 5.2 3.6 2.7 2.4 1.2 0.8 0.6 0.6 0.3 0.2 0.2 0.2 100 8.6 5.8 5.5 3.9 2.0 1.4 1.0 0.9 0.6 0.4 0.3 0.3 120 8.8 6.6 5.9 3.3 2.0 1.5 1.3 1.0 0.6 0.4 0.4 150

1.00

11.1 9.9 7.2 3.5 2.4 2.1 1.0 0.7 0.6

1.25

NOTE: * Pressure drops for other lengths in direct proportion to the multiple of length.

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A short length of light, flexible, two-ply, 3.4 ID hose, called a whip, is sometimes joined in at the nozzle. It permits easier handling, particularly in areas with many angles, pipes and stiffeners. Whips are essential in confined or tight locations as it is impossible to bend a regular abrasive hose. If two or more lines are run off the same compressor, a pressure gauge reading may be in the desired range of 90 to 100 psi, but the pressure may be much less at the nozzle because of leaks and frictional losses.

Nozzles
Nozzles are available with a variety of lengths, sizes of openings and lining materials. A control valve is mounted on the nozzle for starting and stopping the blasting without returning to the pot. The deadman valve has a safety feature so that blasting can occur only when the valve is depressed; if the operator should drop the nozzle, the flow is immediately shut off. A hypodermic needle gauge is used to measure air pressure near the nozzle. It is inserted in the direction of the abrasive flow to minimize damage to the gauge. The measurement is made while the abrasive is flowing to give a mix that hits the surface. Table 4 provides more information on minimum air volume requirements. Table 4 - Minimum Air Volume Requirements Nozzle No. 4 No. 5 No. 6 No. 7 No. 8 Size of Orifice 4/16 () 6.5 mm 5/16 8.0 mm 6/16 (3/8) 9.5 mm 7/16 11.0 mm 8/16 () 12.5 mm Volume of Air 81 2.3 137 3.9 196 5.5 254 7.2 338 9.6 Plus Helmet 20 0.5 20 0.5 20 0.5 20 0.5 20 0.5 Plus 50% (reserve) 50 1.4 79 2.2 108 3.0 137 3.9 179 5.0 Minimum Air Required 151 cfm 4.2 m/min 236 cfm 6.6 m/min 324 cfm 9.0 m/min 411 cfm 11.6 m/min 537 cfm 16.1 m/min

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A loss in nozzle pressure of only 10 psi means a 15% loss in production. Contamination of the air supply can be detected by a simple blotter test. A plain, white blotter is held 18 in front of the nozzle with only the air flowing for 1 to 2 minutes (the abrasive flow is turned off). Stains on the blotter indicate contamination of the air supply that requires corrective action. The better nozzles have the following characteristics.

Venturi Design
The tapered shape of the lining of a venturi nozzle is significantly more effective than a cylindrical shape in concentrating the stream of abrasive. It results in abrasive speeds up to 450 mph and creates a larger, more uniform blast pattern. It can increase cleaning rates by as much as 30 to 50%.

Nozzle Length
Nozzle length is usually as great as practical for optimum efficiency. Nozzles from 5 to 8 in length are recommended for removing tightly adhered rust deposits and mill scale. Shorter nozzles (3 or less) are best used behind beams or in other inaccessible areas where one might use a whip.

Tungsten Carbide or Norbide Lining

The nozzle lining, particularly at the opening (generally called the orifice), is worn away by the abrasive. The enlarged opening reduces the cleaning efficiency. Nozzle liners should be replaced when wear increases the original diameter by 50%. Properly handled, tungsten carbide and norbide liners may have a service life of 300 hours and 750 to 1000 hours, respectively. Abuse of the brittle nozzles by dropping or banging causes further damage. Despite the higher initial expense of tungsten carbide and norbide liners, their costs per hour of service are less than the cheaper cast iron nozzles. Tungsten carbide liners may be used with all common abrasives except hard, angular aluminum oxide and silicon carbide; norbide liners may be used with any abrasive.

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OBJECTIVE TWO:
When you have completed this objective you will be able to: List the sizes of hoses and nozzles. The orifice size of a nozzle is chosen according to the volume of air available from the compressor. The largest practical size that can be used on that job should be chosen. A No. 4 nozzle with the proper air supply may clean four times as much area as a No. 5 nozzle with an improper air supply. However, too large a nozzle for the air flow may result in pressure loss. Table 5 shows the efficiency of different nozzle sizes. Table 5 - Nozzle Size and Efficiency Nozzle Size Nozzle No. (inches) 4 1/4 5 5/16 6 3/8 7 7/16 8 1/2 Work Efficiency (sq.ft.) 100 157 220 320 400

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OBJECTIVE THREE:
When you have completed this objective you will be able to: State the cfm and psi required for operating an abrasive unit efficiently. The air hose should have as large an ID and as short a length as practical because airflow through a hose creates friction. The ID is usually four to five times that of the nozzle orifice. A functional pressure loss of 1 psi results in a cleaning rate loss of 1.5% (i.e., a 10 psi loss causes a 15% loss of cleaning rate). Thus, lines over 100 feet in length should have an ID five to six times that of the nozzle orifice. A 1 ID air hose is generally used when the hose is less than 50 feet in length, although a 1.25 ID hose is recommended for production work. Table 3 (earlier in this LOG) provides data on frictional loss related to air hose diameter and length. As can be seen from Table 3, the compressor should be located as close to the abrasive pot as practical to further reduce frictional losses. Manufacturers of abrasive equipment and professionals in the industry strongly recommend that the compressed air hose should be the longer of the two (the air and abrasive hoses). There is less friction in the air hose, as it is not carrying abrasives. Observing this rule is not always possible if working at a height or in a confined space; for example, in the hold of a ship, the blast pot may be stationed far from the surface being cleaned. To compensate for this problem, use a larger compressor than normally required. As well, both air and abrasive hoses should have a larger inside diameter. The increase in pressure can be determined by using a hypodermic needle gauge at the nozzle to measure the pressure. Further details on this type of testing are found in the LOG entitled Material Application and Inspection. Exterior couplings are preferred to interior couplings for joining hoses because the latter decrease the hose ID and increase frictional losses. Also, as few couplings as possible should be used to minimize the number of possible air leaks at unions.

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OBJECTIVE FOUR:
When you have completed this objective you will be able to: State the cfm and psi required for operating an abrasive unit efficiently.

Characteristics of Abrasives
The proper abrasive is one that provides the necessary cleanliness and profile. (Profile is the peaks and valleys obtained when the abrasive is propelled to the surface by the abrasive nozzle.) The characteristics of such an abrasive related to performance include the following.

Size
A large-size abrasive grain will cut deeper than a smaller size grain of the same composition and shape. However, the greatest cleaning rate is generally achieved with as small a size as possible to give the desired surface condition. Too small an abrasive size will result in a faster cleaning rate, with a sacrifice in cutting power. Abrasive particles larger than 16 to 18 mesh may gouge the metal surface and thus have a slow cleaning rate. However, fine particles (100 mesh size or finer) cannot achieve the 1.5 to 2.6 mil profile usually desired for high-performance coatings. Particles in the 40 to 50 mesh range are most commonly used.

Hardness
Hard abrasives generally cut deeper and thus faster than softer or brittle abrasives. A hard but brittle abrasive will shatter on impact, reducing its cleaning power.

Breakdown Characteristics
Abrasive grains striking the work surface at high speeds damage themselves. The way in which they fracture (break) and/or change shape and size is called the breakdown characteristic. This is particularly important when the abrasive is recycled and reused because it limits the amount of recycling possible without adversely affecting cleaning
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rates. A breakdown rate of more than 10% in one use results in a significant increase in dust, requires extra cleaning of the surface for removal of breakdown deposits and limits the number of times the abrasive can be reused.

Shape
The shape and size of abrasive grains determine the type of surface profile received from the blasting. Because it is round, shot opens the surface to give a wavy profile. Shot is particularly effective in removing brittle deposits such as mill scale. Grit is angular, and blasting with grit produces a jagged finish that is generally preferred for coating adhesion. A wide variety of surface patterns are available from different grits. Use of sand and slag abrasives, which are semi-angular, result in a pattern somewhere between that of shot and grit.

pH
A neutral pH (6 to 8) is recommended for the abrasive. It should not be washed with seawater or contaminated water.

Types of Abrasive Materials

The four types of abrasive materials commonly used in blasting facilities are: natural oxides, metallic abrasives, slag abrasives, and synthetic abrasives.

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Natural Oxides
Silica is the most widely used natural oxide because it is readily available, low in cost and effective. However, recently the hazards of silicosis, as well as the OSHA1 and U.S. EPA2 regulations have restricted its use in many areas. Another natural abrasive, Starblast, has also received attention. It is efficient, is quick cutting, has less dusting, has a lower breakdown rate and may be recycled.

Metallic Abrasives
Steel shot and grit abrasives are efficient, hard and dust free. While their initial costs are high, they may be recycled several times to make them cost effective. A mixture of both shot and grit abrasives in blasting may combine the advantages of both. Care must be taken to prevent rusting during storage of metallic abrasives. The impact of steel shot may cause small slivers called hackles to form on the surface. They may be up to 6 mils in height, and must be removed mechanically by sanding or grinding before coating to avoid pinpoint corrosion of the metal projecting through the coating.

Slag Abrasives
Copper and nickel slags are by-products of the ore smelting industry. They are fast cutting, but have a high breakdown rate and cannot be recycled.

Occupational Health & Safety Administration, U.S. Department of Labour. The standards can be found on the internet at http://www.osha.gov. 2 U.S. Environmental Protection Agency. The standards can be found on the internet at http://www.epa.gov. BLASTING & COATING SAFETY S.E.A.L. International 14

Synthetic Abrasives
Aluminum oxide and silicon carbide are nonmetallic abrasives with cleaning properties similar to the metallics but without the problem of rusting. They are very hard, fast cutting and low dusting, but are costly and must be recycled for economical use. New abrasives should be kept in their originally sealed bags until ready for use. They should be stored off the ground on wooden palettes and, if left outdoors, covered with a sheet of plastic. Similarly, care should be taken to prevent contamination of recycled abrasive. The cleanliness of an abrasive can be determined by placing a small amount of it in a glass jar filled with water. Upon shaking, any oil present will rise to form a film on the surface of the water. Contaminated abrasive should be cleaned or discarded.

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OBJECTIVE FIVE:
When you have completed this objective you will be able to: Describe the correct procedures required to use an abrasive unit. Experience is the best teacher for blasters. Test blasting at different angles and distances when starting a new job will determine which are the most effective for that surface condition. Once the most efficient angle and distance are determined, the blaster should remain at that position throughout the entire operation. NOTE It takes only one painter to keep up with four blasters.

Angles of Attack
The angle of the nozzle to the surface may range from 45 to 90, depending upon the work. To remove rust and mill scale, the nozzle should be held 80 to 90 to the surface. This is also preferred for cleaning pitted surfaces. A slight downward angle will direct the dust away from the operator and will ensure better visibility. A sharp angle of attack (45 to 60) allows the operator to peel heavy coats of old paint and layers of rust by forcing the blast under them. General cleaning is usually best accomplished at a 60 to 70 angle.

Nozzle to Surface Distance

The closer the nozzle is to the surface, the smaller the blast pattern (area hit by the abrasives) and the more abrasives to strike it. With the nozzle closer to the work, the cleaning force becomes greater but the area cleaned becomes smaller. A distance of only 6 may be necessary for removal of tight scale, while a distance of 18 may effectively remove old paint at a much faster cleaning rate.

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Each pass should occur in a straight line at the same distance from the surface. Arcing or varying the distance from the surface will result in a non-uniform surface. No more surface area should be blasted at one time than can be primed the same day, since significant rusting can occur overnight. In humid areas, rust bloom or flash rust may be seen on the exposed surface within hours. Brush blasting to remove such rusting before painting is an unnecessary expense.

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OBJECTIVE SIX:
When you have completed this objective you will be able to: Identify the four levels of surface preparation obtained using an abrasive unit. Abrasive blasting is usually the preferred method of preparing steel and other surfaces prior to the application of an industrial coating. The hardness of the abrasive and the high velocity of the abrasive particles can completely and efficiently remove tight mill scale, rust and old coatings. The other important aspect of abrasive blasting is that it produces a surface profile or texture that assists in coating adhesion to the surface. When cleaning steel substrates, abrasives such as silica sand, slag and metal shot are used, depending on the size of the profile required. With softer metals such as aluminum, softer abrasives (such as plastic beads) are used. Harder abrasives will damage a soft substrate. The following four abstracts on surface preparation have been reprinted with permission from the Society for Protective Coatings (SSPC). For full text, please refer to Steel Structures Painting Manual, Volume 1 Good Painting Practice and Steel Structures Painting Manual, Volume 2 - Systems and Specifications.

SSPC-SP-5 - White Metal Blast Cleaning

White metal blasting is the most expensive type of surface preparation carried out in industry today. This surface preparation standard is used for substrates that are found on the inside of tanks or vessels, railway cars and anywhere the environment is hostile. A hostile environment is one that will severely damage a substrate if it becomes exposed. A method of preparing a metal surface for painting or coating by removing all mill scale, rust, rust scale, paint or foreign matter by the use of abrasive propelled through nozzles or by centrifugal wheels, to the degree hereafter specified. A White Metal Blast Cleaned Surface Finish is defined as a surface with a greywhite, uniform metallic colour, slightly roughened to form a suitable anchor
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pattern for coatings. The surface, when viewed without magnification, shall be free of all oil, grease, dirt, visible mill scale, rust, corrosion products, oxides, paint and any other foreign matter. The colour of the clean surface may be affected by the particular abrasive medium used. Photographic or other visual standards of surface preparation may be used as provided in the Appendix of the Steel Structures Painting Manual, Volume 2 - Systems and Specifications to further define the surface, if specified in the contract.

SSPC-SP-10 - Near-White Metal Blast Cleaning

Near-white metal blast cleaning is the second highest level of cleanliness. A method of preparing metal surfaces for painting or coating by removing nearly all mill scale, rust, rust scale, paint or foreign matter by the use of abrasives propelled through nozzles or centrifugal wheels, to the degree hereafter specified. A Near-White Blast Cleaned Surface Finish is defined as one from which all oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint or other foreign matter have been completely removed from the surface except for very light shadows, very slight streaks or slight discolourations caused by rust stain, mill scale oxides, or slight, tight residues of paint or coating that may remain. At least 95% of each square inch of surface area shall be free of all visible residues, and the remainder shall be limited to the light discolouration mentioned above. Photographic or other visual standards of surface preparation may be used, as provided in the Appendix of the Steel Structures Painting Manual, Volume 2 - Systems and Specifications to modify or further define the surface, if specified in the contract. Further details regarding surface preparation can be found in the Steel Structures Painting Manual, Volume 1 - Good Painting Practice.

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SSPC-SP-6 - Commercial Blast Cleaning

Commercial blast cleaning is a method that allows for 66% of each square inch to be completely free of all visible residues. This type of standard would not suit a substrate that would be in immersion service. A method of preparing metal surfaces for painting or coating by removing mill scale, rust, rust scale, paint or foreign matter by the use of abrasives propelled through nozzles or by centrifugal wheels, to the degree hereafter specified. A Commercial Blast Cleaned Surface Finish is defined as one from which all oil, grease, dirt, rust scale and foreign matters have been completely removed from the surface, and all rust, mill scale and oil paint have been completely removed, except for slight shadows, streaks or discolourations caused by rust stain or mill scale oxides, or slight, tight residues of paint or coating that may remain. If the surface is pitted, slight residues of rust or paint may be found in the bottoms of pits. At least 66% of each square inch of surface area shall be free of all visible residues and the remainder shall be limited to the light discolouration, slight staining or light residues mentioned above. Photographic or other visual standards may be used to modify or further define the surface, if specified in the contract. Slight residues of rust and paint may remain on the bottoms of pits.

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SSPC-SP-7 - Brush-Off Blast Cleaning

Brush-off blast cleaning removes all visible dirt, dust, loose mill scale, rust and paint. This standard of surface preparation would be used with coatings that have an excellent wetting ability and will be located in a mild environment. A method of preparing metal surfaces for painting or coating by rapidly removing loose mill scale, loose rust and loose paint, to the degree hereafter specified, by the impact of abrasives propelled through nozzles or by centrifugal wheels. It is not intended that the surface shall be free of all mill scale, rust and paint. The remaining mill scale, rust and paint should be tight, and the surface should be sufficiently abraded to provide good adhesion and bonding of paint. A Brush-Off Blast Cleaned Surface Finish is defined as one from which all oil, grease, dirt, rust scale, loose mill scale, loose rust and loose paint or coatings are removed completely, but tight mill scale and tightly adhered rust, paint and coatings are permitted to remain, provided that all mill scale and rust have been exposed to the abrasive blast pattern sufficiently to expose numerous flecks of the underlying metal, fairly uniformly distributed over the entire surface. Photographic or other visual standards of surface preparation may be used, as provided in the Appendix of the Steel Structures Painting Manual, Volume 2 Systems and Specifications to further define the surface if specified in the contract.

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MODULE EXERCISE
1. Use a separate page to answer the following questions. 2. List, by name, the main components of an abrasive blast unit. Give a brief description of their functions. 3. Describe how the efficiency of abrasive blasting may be improved. 4. Describe the relationship between horse power and volume. 5. How is pressure at the nozzle measured? 6. How large should the inside diameter of the abrasive hose be in relationship to the orifice on the nozzle? 7. Identify the recommended length of an abrasive air hose if the length is less than 50 feet. 8. Identify the reason for using exterior couplings on an abrasive hose. 9. Describe profile. 10. List the synthetic abrasives. 11. What is the advantage of synthetic abrasives? 12. Identify the disadvantages of: a) natural oxides b) slag abrasives c) metallic abrasives 13. Describe the rules of motion that an operator must observe when abrasive blasting a surface. 14. Using your own words, define the four abrasive methods of cleaning a surface.

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SAFETY IN PAINTING OPERATIONS

Rationale
Why is it important for you to learn this skill? As an industrial applicator, the equipment and materials you will use can be a threat to your safety if not handled correctly. Applicators are required to perform their job-related tasks at extreme heights and in confined spaces, as well as while operating dangerous equipment and handling dangerous materials.

Outcome
When you have completed this module you will be able to: Describe safety requirements essential in painting operations.

Prerequisites
Module 1.1 Course Orientation Module 1.2 Responsibilities of an Operator Module 8.1 Occupational Health & Safety Regulations Module 8.2 Identification of Procedures of Handling Hazardous Materials

Objectives
Obtain relevant information on the hazards of products used in the coating industry. Describe the hazards of using toxic materials. Describe the hazards associated with surface preparation. Describe the hazards associated with the application of coatings. Describe the hazards of working in different environments.

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Describe basic personal protective equipment. Understand the relevant sections of the Occupational Health & Safety Act.

Resources
Government of Alberta. Occupational Health & Safety Act. 1980 (can be found at www.gov.ab.ca/qp/ascii/acts/002.TXT). Government of Alberta. General Safety Regulation. AR 448/83 (can be found at www.gov.ab.ca/qp/ascii/regs/1983_448.TXT). U.S. Department of Labor, Occupational Safety & Health Administration. Occupational Safety & Health Standards (29 CFR 1910) (can be found at www.osha-slc.gov.OshStd_toc/OSHA_ Std_toc_1910.html)

Evaluation
Obtain 75% on a supervised written test.

Acknowledgements
The technical information in this module has been obtained from the Society for Protective Coatings, Pittsburgh, and Occupational Health & Safety, Alberta, Canada. Photographs courtesy of the Society of Manufacturing Engineers, Association for Finishing Processes.

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Introduction
Painting operations have many inherently unsafe conditions. It is the objective of this module to describe these conditions, as well as how to legally and safely minimize these hazards. Because of changing standards, no attempt will be made to list safe levels of exposure or other information likely to be changed in the near future. Rather, general concerns will be discussed, much as they are discussed for safety paint application in the Society for Protective Coatings Standard SSPC-PA3 Paint Application for Field Work. The latest information on acceptable exposure levels should be available through company safety offices. These offices are responsible for providing all necessary safety support and it is important that all workers interact freely and positively with them in a total safety program. Attitude is everything in ensuring a safe working environment. Every operation that involves any type of hazard should have a standard operating plan and a safety plan, whether the work is conducted by in-house or contract personnel. All personnel have the right to: learn of any unsafe or unhealthful conditions or operations they will be involved with, and receive all training or equipment necessary to conduct their work safely.

Personnel must also be able to report hazardous conditions and conditions suspected of being hazardous without fear of retaliation. Workers, on the other hand, also have the responsibility of conducting their work in a safe and healthful manner, correcting or reporting unsafe or unhealthful conditions and wearing appropriate personal protective equipment. This includes limiting unsafe or unhealthy exposures as much as possible. No worker who is working in hazardous conditions should work without the correct protective clothing. A safety program is a vital part of every shop conducting cleaning or painting operations. Each routine operation should have a standard operating procedure that includes a safety plan. Each non-routine operation should have a special operating plan that includes safety. Each worker should receive periodic training to keep him/her aware of pertinent government regulations, potential health hazards and measures that may be taken to minimize these potential hazards.

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OBJECTIVE ONE:
When you have completed this objective you will be able to: Obtain relevant information on the hazards of products used in the coating industry. The best way to protect yourself from hazardous chemical products used in painting operations is to know their identifications, the hazards associated with them, and their proper and safe uses. Every employer must provide this information to its employees. All containers must have labels identifying the chemicals inside. Unlabelled products should never be used. Other important information on chemicals, including health & safety data, precautions for handling, and emergency and first aid procedures, can be obtained from the appropriate Material Safety Data Sheets (MSDSs). These sheets must accompany hazardous materials when they are shipped, stored or used in any operation. Finally, the organization must have a written program that provides personnel with information about the hazardous chemicals used in each operation and an inventory of all hazardous chemicals onsite. Employees must also be provided with appropriate safety training. Labels should be replaced if torn, lost or illegible. When materials are transferred to other containers for easier use, these containers must also be properly labeled. Labels usually contain the following information. Complete identification - may include several alternative names. Basic warnings - lists hazardous chemicals and precautions. First aid requirements - what to do when splashed on eyes or skin. Fire actions - how to properly extinguish fires. Treatment of spills - equipment and materials for cleaning up spills. Handling and storage procedures - safety equipment and practice for proper handling. Disposal procedures - describe methods for safe and legal disposal.

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Material Safety Data Sheets (MSDSs) provide the following information. Chemical identification - identifies all chemicals present. Hazardous ingredient data - lists hazardous chemicals and safety procedures. Physical data - describes odour, appearance, etc. of the chemicals. Fire and explosion data - lists flashpoint and extinguishing methods. Health hazards - symptoms of over-exposure and emergency actions. Reactivity data - stability and reactivity with other chemicals. Spill or leak procedures - cleanup and disposal procedures (always notify the Safety Officer). Special protection - necessary respirators, clothing, eye protection, etc. Special precautions - special handling precautions, including safety signs and standby cleanup kits.

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OBJECTIVE TWO:
When you have completed this objective you will be able to: Describe the hazards of using toxic materials. Toxic materials are used for both paint applications and cleanup. They can enter the body via three different routes: inhaled into the lungs, ingested through the mouth, and/or absorbed through the skin.

Toxic vapours or suspended particles inhaled into the lungs may be rapidly assimilated into the rest of the body. Limiting exposure, proper ventilation and use of proper respirators can provide adequate protection. Individual solvent blends in paints vary widely levels of human toxicity as it is not possible to readily determine the concentration of each substance. Ingestion through the mouth usually occurs from contaminated hands (not washed before eating, drinking or smoking). Hands should be washed before these activities, even when gloves are worn to prevent contamination. Skin absorption can only occur through contact. This can be minimized through the use of proper protective clothing. All contaminated clothing should be removed and disposed of at the job site or completely cleaned, and the person working with the contaminants should thoroughly shower before leaving the job site. Toxic substances fall into four major categories. Irritants - inflame eyes, nose, throat and lungs. Asphyxiants - interfere with oxygen assimilation (e.g., carbon monoxide). Nerve poisons - attack nervous system (e.g., acetone, lead compounds). Systemic poisons - affect heart, liver or kidneys.
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There are four types of respiratory hazards in painting operations. Dusts - dry particles from grinding and blasting operations. Mists - liquid particles from cleaning and spraying operations. Gases and vapours of liquids - evaporated cleaning or paint solvents. Oxygen deficiencies - especially in confined areas.

Dusts include smoke particles from combustion. Gases and some particles may not be seen by the naked eye. A cartridge-type respirator may be necessary when working with any of the above-noted products resulting from painting operations. The MSDSs can provide this information. As wells, the MSDSs must always be accessible when using chemical products.

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OBJECTIVE THREE:
When you have completed this objective you will be able to: Describe the hazards associated with surface preparation. Painting procedures may include one or more of the following hazardous operations: high pressures and airborne particulates from abrasive blasting; sparks and metal particles from grinding; acids, alkalis, solvents and steam from cleaning; and/or lead, chromate and other heavy metals from removing old paint.

Abrasive and water blasting are by far the most dangerous operations in surface preparation for painting. High-pressure nozzles (over 100 psi for abrasive and over 30,000 psi for water blasting) pose major threats. Hoses, couplings and the pot pressure must be checked for soundness and to ensure that the maximum allowable pressure is not exceeded. The blast nozzle must have a deadman valve so that it will automatically shut off if it is dropped by the blaster. No attempt should be made to override this or other safety devices. No safety omissions should be permitted, even for very small blasting jobs. The blasting area should be posted for No Admittance and the pot tender located in a protected area behind the blaster so that no one is in the vicinity of the blaster. Each worker should wear the proper safety equipment, including an air-supplied respirator for the blaster. Isolation from the blaster and use of deadman valves are also important during waterblasting. All electrical operations should be shut down at that time to prevent electrical shock. Care should be taken to avoid slipping on wet surfaces. Enclosed areas being cleaned or painted should be well ventilated to prevent the accumulation of toxic or combustible airborne contaminants. Mechanical equipment should be grounded, and conductive substrates should be cleaned or coated to prevent sparking.
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Grinders, sanders and other powered cleaning tools require special attention to meet the safety provisions of Subpart B of the U.S. Department of Labor, Occupational Safety & Health Administration (OSHA) Occupational Safety & Health Standards (29 CFR 1910). They should have safety shields or devices to protect eyes and fingers. OSHA regulations do not permit the use of faulty hand or power tools, such as cracked grinders and wheels or damaged rotary brushes. Power tools should only be operated as recommended by the supplier. Chemical cleaning is inherently dangerous and requires special precautions. Chemicals must be properly labeled, stored and used. Proper eye, face and skin protection should be provided by using appropriate clothing, skin cream and equipment, and by following recommended operating procedures when working with caustic chemicals or solvents. Contaminated personnel or the work areas should be appropriately cleaned and treated as soon as possible. Spill kits and instructions for their use should be available. Protection of workers and the environment from lead or chromate compounds in dust generated during removal of old paint are described in SSPC courses on this subject.

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The following excerpt is from the Safety Update Newsletter3.

Remote Controls are Safe, Convenient & Required by Law The Occupational Safety and Health Administration (OSHA) began requiring remote controls on blast machines more than two decades ago. Possibly driven by the same attitude that leads people to blast without wearing respirators, some contractors still prefer manually operated blast machines. While OSHA might impose a fine, the laws of physics can inflict a far more costly punishment. At 80 to 100 psi, air and abrasive exit the blast nozzle at nearly 400 miles per hour. The abrasive, by itself, can tear through clothing and cut your skin to ribbons in seconds. But the real threat to your life is the high-pressure, highvelocity air. Travelling at almost supersonic speed, the air can pass through your skin and become imbedded in your flesh. Air that reaches a vein or artery can form a bubble, called an embolism, which interrupts blood flow. Depending on the size and location, an embolism can cause anything from minor pain and weakness to a severe stroke and death. If talk of disability and death cant convince a contractor to switch to modern remote controls, maybe cost savings will. Without remotes, the contractor must run back and forth to turn the machine on and off, or pay a laborer to tend the pot. Every minute the machine runs without blasting wastes compressor fuel, wastes abrasive, and adds to the abrasive load that must be cleaned up later.

Safety Update, Clemco, Summer 1999, p. 2. 32

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OBJECTIVE FOUR:
When you have completed this objective you will be able to: Describe the hazards associated with the application of coatings. Hazards include: toxic solvents, flammable solvents, toxic or allergic resins (urethane, coal tar, epoxy, etc.), toxic pigments (lead, chromium and other heavy metal pigments), and/or high pressures in airless spray.

Coating materials should be stored under cover in well-ventilated areas away from sparks, flames and direct sunshine. Eye protection, gloves, protective skin cream, and other appropriate equipment and clothing should be used during paint mixing and application. Individual solvents blended with paints vary widely both in solvency and in human toxicity. They can remove moisture and natural oils from the skin to make the skin more sensitive to other irritants. Paints should not be stored, mixed or applied at temperatures near or above their flashpoints (the minimum temperature at which a liquid gives off enough vapour to become ignited in the presence of a spark or flame). Flammable liquids such as turpentine and toluene have flashpoints below 100F; combustible liquids have flashpoints of 100F or greater. The flashpoints of individual solvents vary greatly; so do the explosive limits and concentration ranges in air at which combustion may occur. When mixing and applying paints, the following precautions should be observed: protect eyes, face, hands and skin; keep paint well below flashpoint; keep outside explosive limits;
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use slow-speed stirrers; permit no matches, sparks or flames in the work area; and ground equipment and work.

When applying coatings with spray equipment: equipment and metal work should be grounded; only non-sparking tools should be used; and no matches, open flames or smoking should be allowed in the area.

Airless guns should only be used by trained personnel and with protective guards. They should never be pointed at any part of the body since they can penetrate flesh. Figures 1 and 2 show the effects of paint injection into the body. The nozzle guards should never be removed. Reversible tips simplify removal of clogs.

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Figure 1 Injection Site is Right of White Spot on Finger Tip

Figure 2 Finger Surgery Necessary Airless spray equipment, material hoses and spray guns are rated for different pressures3000 and 5000 psi.

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Check the pressure that the machine is operating at by multiplying the amount of air being used by the pump ratio. For example, using a 56:1 ratio pump with an in air pressure of 80 psi results in: 56 x 80 psi = 4480 psi at the tip In this example, you must use a material hose and spray gun rated at 5000 psi. If the in air pressure is 40 psi: 56 x 40 psi = 2240 psi at the tip A hose and gun rated at 3000 psi would be acceptable.

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OBJECTIVE FIVE:
When you have completed this objective you will be able to: Describe the hazards of working in different environments.

Support Operations
Tall structures - towers, bridges, etc. Scaffolding and other aids in reaching high places.

High Places
Safety requirements for ladders, scaffolding and stages can be found in the OSHA Occupational Health & Safety Standards (29 CFR 1910), Sections 1910.25 (Portable Wood Ladders), 1910.26 (Portable Metal Ladders), 1910.28 (Safety Requirements for Scaffolding) and 1910.29 (Manually Propelled Ladder Stands and Scaffolds [Towers]). General requirements for ladders used in painting operations include: all loose, bent or split steps or rungs should be replaced immediately; safety shoes should be used on all straight and extension ladders; metal ladders should never be used near power lines; never use ladders as horizontal scaffold members; and use only when the top of the ladder extends at least 3 feet above the point of support. General requirements for scaffolds include: hold scaffolding securely in place; use rigid guard rails (never ropes) and toeboards or rails; scaffolding should be clean and free of abrasive, mud, grease and other debris;

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no unnecessary equipment should be on the scaffolding; platforms should be level at all times; and regular inspection and repairs should be performed, as necessary.

Additional requirements for swing (suspended) scaffolds suspended by block and tackle are: secure life lines to personnel on scaffolding; never allow scaffold to swing freely; limit the number of personnel on scaffolding to two; and follow OSHA requirements for suspension.

Additional requirements for rolling scaffolds are: always set caster brakes when in a fixed position; never ride on a rolling scaffold when it is being moved; and remove all materials from the platform before moving.

Permanent scaffolding should be built for routine maintenance operations on aircraft or other standard configurations. Many contractors buy or rent powered lift platforms or boom machines to reach high places. Some extend as high as 100 feet. Scissor-lifts, the most common type, only go straight up. Booms can provide greater access where there are obstructions. Power stages should have free-fall safety devices with hand controls in case of power failure. When painting bridges, towers or other tall structures where there are no scaffolds or lifts, safety nets or harnesses should be utilized. They not only provide safety, but also result in better workmanship. Safety harnesses are preferred to safety belts because they distribute the force imposed by the safety line during a fall. A variety of safety harnesses are available.

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Confined Spaces
Confined areas such as fuel storage tanks, boilers and utility tunnels may have the following hazards: flammable or explosive atmospheres or materials; toxic atmospheres or materials; insufficient oxygen to support life; and/or excess oxygen, creating a fire or explosion hazard.

Confined spaces with limited ventilation and access may have hazards that are not easily detected. An engineer should check a confined space for safety before anyone enters it. Paints with safety solvents (relatively high flashpoints) should be used in these areas. Hand and power tools, and other electrical equipment (including lighting) should be nonsparking and explosion-proof. Because paint solvent vapours are heavier than air, ventilation of confined spaces requires exit of contaminated air from the lowest point. Safety harnesses and lines leading to a worker outside the confined area should be used to permit rescue in the event of an emergency.

Remote Locations
When doing fieldwork at remote locations, personnel should be prepared to respond to possible accidents. Access to a telephone and medical treatment should be established. Knowledge of first aid, especially CPR, is also beneficial for immediate action.

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OBJECTIVE SIX:
When you have completed this objective you will be able to: Describe basic personal protective equipment. Hazards in painting operations can be greatly reduced by the use of personal protective clothing, respirators and other personal protective equipment.

Clothing
Protective garments must resist chemical attack from three different routes of entry. permeation chemical works its way through the suit, penetration entry through physical imperfection (damage), and/or degradation properties of material chemically degrade the suit.

Contaminated clothing should be discarded at the job site or thoroughly cleaned before reuse. Personnel exposed to contamination should thoroughly shower and put on clean clothes before leaving the work area. Torn clothing should not be worn because it can get caught in machinery or on structural projections. Trouser cuffs and ties present similar problems. Protective headgear can prevent devastating injuries to the head. Selection of the proper head protection for different hazards is especially important. Protective headware includes: hard hats, bump hats, and hair covers.

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Hard hats are made of rigid, impact-resistant, nonflammable materials such as fibreglass or thermoplastic. A network of straps and harnesses holds the shell on the head and serves as a cushion. A full-brimmed hard hat provides general protection to the head, neck and shoulders while the visored brim (which does not provide this protection) is often used in confined spaces. Bump hats, made of lightweight plastic, protect only against minor bumps. They should be worn when there are only minor head hazards. Hair covers made of breathable fabric or lightweight materials are intended to prevent hair from becoming caught in moving machine parts. They are adjustable to ensure proper fit. Eye protection is available in many forms to protect eyes from flying particles, dust, sparks, splashes and harmful rays. The appropriate type of eye protection should be used for each job. Safety glasses have impact-resistant frames and lenses that meet OSHA and American National Safety Institute (ANSI) standards. They may also have side shields, cups or tinted lenses to provide additional protection. Safety glasses with prescription lenses should be available from all company safety offices. They should be cleaned as described by the supplier and stored in a clean, dry place. Safety goggles are also impact resistant. They form a secure seal around each eye to provide protection from all sides. They may have direct or indirect ventilation to eliminate fogging. Safety shields or helmets are used for splash protection, or when grinding, welding or working with molten materials. They are ordinarily worn with goggles or safety glasses. Hearing protection can prevent loss of hearing that may occur over time from repeated exposure to excessively loud noises. Muffs, plugs and canal caps offer a variety of devices to protect our hearing.

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Muffs come in a variety of styles. Most have spring-loaded head bands to secure them in place, covering the entire ear. They can reduce noise levels by 15 to 30 decibels. They are even more effective when used in conjunction with ear plugs. Ear plugs of reformable rubber or plastic materials are positioned in the outer part of the ear. They may be disposable or reusable. The latter should be cleaned and properly stored after use. They may reduce noise levels by 50 decibels. Canal caps (headband plugs) close off the ear canal at the opening. A flexible headband ensures a close fit. They must also be cleaned and properly stored after use. Safety shoes can reduce the approximately 12,000 accidental foot injuries that occur each year. Steel-reinforced shoes are designed to protect feet from common machine accidentsfalling or rolling objects, cuts and punctures. The entire toe box and insole are usually reinforced. Safety boots offer more protection from splash and spark hazards. Neoprene or nitrile boots are often required when handling caustics, solvents or oils. Quick-release fasteners may permit speedy removal in case a hazardous substance gets in the boot. Slip-resistant soles are required for both shoes and boots, if a slip hazard is present. Safety gloves come in different designs, lengths and chemical compositions. The length should provide full protection and the material should be resistant to the chemical materials with which it will come into contact. Selection of the right work glove can protect you from unnecessary injury or contamination. Commonly used protective gloves include the following. Disposable gloves - usually lightweight plastic; protect from mild irritants. Fabric gloves - cotton or other fabric; improve grip, minimal protection from contaminants. Rubber gloves - may also be of different plastics; protect from chemical contamination. Leather gloves - protect from abrasion.
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Metal mesh gloves - protect from cuts/scratches; used with cutting tools. Aluminized gloves - insulate hands from intense heat.

Respirators and ventilation can minimize hazards of exposure to toxic materials. Respirators include the following types. Disposable dust masks/filters - fibre mask over nose and mouth; filter particulates. Half masks - fit over nose and mouth; cartridges absorb gases and vapours, select cartridge for particular vapour or gas. Air-supplied respirators - air from line or self-contained; positioned air pressure in helmet, provides greatest protection. Personnel using respirators must do the following for full protection from respiratory hazards: obtain knowledge of respiratory hazard; obtain proper respirator training; get proper respirator fitting and testing; keep respirator clean and properly stored; use the right respirator/cartridge for the job; and receive periodic medical monitoring.

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SUMMARY
There are many hazardous operations involved in coating industrial structures and equipment. Everyone involved in these operations must also be involved with safety. Management is responsible for proper communication of hazards to field workers. Management is also responsible for providing worker safety training and equipment. Workers must conduct their operations in the manner written into standard operating procedures. They must also follow safety plans prepared for their protection.

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MODULE EXERCISE
Use a separate page to answer the following questions. 1. 2. 3. 4. 5. 6. 7. 8. In detail, list the information found on labels of coating products as it relates to contents. In detail, explain how toxic substances can enter the human body. What are respiratory hazards? List, from your personal experience and this module, the hazards of surface preparation. Describe the hazards of applying coatings by airless and air-assisted spray methods. What components require grounding when applying material with an airless spray unit? List the hazards related to working in different environments. List the protective equipment required for each of the following: a) b) c) surface preparation mixing of materials applying materials by brush, roller or spray

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