The major componentsof a properly planned blastfacility are sizedfor efficient operation and maximum return on investment.
More and more companies chemicalsis reduced. Chemical Yet even for theselarge projects,
are turning to indoor blasting as an disposalcosts are eliminated. In most statesrequire that temporary
alternative to chemical stripping or many cases,processingtimes and structuresbe erectedto contain the
outdoor blasting. Blast cleaning labor costsare reducedas well. dust and abrasive.
with abrasivemedia removes old Switching to blasting can reduce
Bringing blasting indoors
coatings, rust, and other unwanted chemical stripping VOCs (Volatile
results in substantialsavings,
material from a surface,and creates Organic Compounds)by 100
particularly when you switch from
an anchor pattern to allow new percent,becausethe processis dry.
coatings to adherebetter. Blasting
Blasting technology has been sandor mineral slag, to recyclable
with peening media increasesthe
around sincethe late 1800s,though abrasives.
fatigue life of many materials,
the dust generated blasting, and
including steel and alloys. Indoor blasting allows you to
the cleanuprequired afterward
Manufacturerswho turn to relegatedit to use outdoors.
weather,time of day, or other
blast cleaning as an environmentally
Today'sever-tightening nearby activities.
stripping processes, often realize An efficient, high-production
restricted the useof outdoor
substantialcost savingsas well. blast facility can pay for itself in as
blasting to structuresand other
Employeeexposureto toxic little as one year.
items too large to bring indoors.
Becauseconditions and applications vary, every blast room is customized
to some extent. Careful planning will maximize the benefits of a new blast
facility or extend the useful life of an existing facility. The componentsyou
selectdetermine the return you can expect from this investment.
This guide has beenpreparedto presentyou with options and assistyou in
making the best choices for your specific needs.The function of each major
componentis explained and comparisonsare presentedfor the options available.
Clemco and its worldwide network of distributors will assistwith every
step in planning, installation and start-up. Clemco is the only manufacturerthat
offers a complete line of pneumatic and mechanical conveyancesystemsfor
abrasiverecovery. Clemco can even show you how to breathenew life into an
aging, inefficient blast facility.
Use the Request Quotation form in the center of this book to record the
information your Clemco, ZERO, or Aerolyte Distributor win need to help you
get the best system at the best price.
Blast Equipment 5
Blast machines,Compressed air supply,
Operator safety equipment
Recovery System 6-8
Flat- Trak, Flo-FlorTM,
Screw Floor, M-Section
Abrasive Cleaner 9
Dust Collector 10
Workpiece Handling 11
Forklift, Work car, Rails,
C/emcos txptritnctd staff of designtrs and tngint'ers and our worldwide nttwork of
distributors and dealersht'tp you gt't tht' mostfrom your blastfacility.
The enclosurekeepsin the If you plan to build your own enclosure,get your Clemco, ZERO, or 18
abrasiveand dust and keepsout the Aerolyte Distributor involved before the fIrst drawings are made. While Clemco
elements. This allows the abrasiveto can adapt equipment to an existing enclosure,it is far more cost effective to plan
be cleanedand reused,often hundreds for recovery, ventilation, lighting, controls, and blast machinesin the original
of times. Efficiently recycling the drawings even if all of thesecomponentsare not budgeted.
abrasivecan make your blast facility
The size of the part being pro-
cessedand the production rate desired
will dictate the size of the enclosure.
Allow room for the part, plus four feet
on all sides for the blast operator to
To increaseproductivity, you can
build a bigger enclosure,increasing the
number of operatorsand/or the number
of parts in the enclosure at one time.
This also increasescapacity require-
ments for other blast facility compo-
nents -- such as the dust collector and
The enclosure'scubic capacity
influences the size of the dust collector.
In planning the facility, balancethe
convenienceand productivity of the
arger enc osure WI
.th th tra
e ex expense
Column-boltenclosures for InclusIon an overhead
of the larger dust collector.
To begin planning your enclosure, Column- Bolt
describe part or partsyou anticipate
blastcleaning.Includeasmuch Clemcooffersblastenclosures two construction
m styles. In a column-bolt
informationaspossible aboutthepart facility, prefabricatedsteelpanels bolt to a structural
steelframe. This design
it allowsfor widerroomsandwill supportanoverhead monorailfor partshandling.
Makesureyou indicatethe dimensions . .
f th I t art I t bl t For most applIcations,the enclosurewalls are made of 10- to 14- gauge
0 e arges p you p an 0 as, I If th f .Ii ill d th I k ' f ' all . .
includingproducts in planningthat s~e.
still e aCI ty w o~erate faun e ~ oc . o~1.especi y aggre~s~ve media
may be part of production. will be used, rubber curtains on the wall will minimiZe wear. The addItional
investment for the curtains, and for their periodic replacement, will greatly extend
thelife of theenclosure.
In a flange-bolt facility, the wall
panelsbolt directly to each other,
without the support of a frame.
Flange-bolt construction limits the
room to 14 feet wide and 14 feet high,
though the length is not restricted.
If your facility can be 14 feet
wide (or less) and does not need to
support a monorail, the flange-bolt
design could result in substantial
savings when comparedto a column-
bolt enclosureof the samesize.
Flange-bolt room with reclaimer and reverse
pulse dust collector:
Bright, well-positioned lights The parts handling doors must
11 Dry-strip boothidealfor automotive
jobs, increaseproductivity in the blast open with sufficient clearancefor the
room, The amount of light needed part and your work handling equipment.
Dry-Strip Booth dependson the type of work being
Additional doors at the rear of the
The flange-bolt room is also done, Typica~lybetw~en 50 and 80
facility let you pa.~s
parts through en-
available for lighter applications in the foot candlesIS sufficIent.
route to the paint booth or finishing area.
form of the dry-strip booth which has Lights may be mounted in the
walls of lighter gauge steel, and is ceiling or walls, Most blast rooms Personneldoors, required by
suitable for use with lightweight blast have flush-mounted ceiling fixtures, OSHA every 30 feet in large facilities,
media such as plastic and wheat starch. but a tall component may block allow easyentry and exit without havin~~
to open the main doors. Position the
Pre- Assem hIed ceiling lights. Wall-mounted lights
illumina- personneldoors for the best work flow,
such as allowing quick access control
can tion on verticalsurfaces.
pre-assembled readyto set
-- panels,media storage,and changing
" For a smaII to medlum sIzed
m place at your site. A pre-assembled rooms.
. , bl as t room, rfull ' ht t d
dim . f 7 ~ powe Ig s moun e
room has mtenor enSlons 0 leet
.d 14 teet 1 and 8 teet hIg h.
. at an angle where the walls meet the
WI e, ong,
li ' d II ill . . Work Stations
sow... t e room to truc e .
Thi all h be k d cel ng provl e exce ent Uffilnation
, . ,, on the top and sIdesof the part, A work station, built into the wall,
mtact, Once the room ISpoSItionedon
M ounting the IIght modu1 hi gh
SIte, the dust collector, abrasIve
. pro te c ts th em fr om ma d ve rt en t
allows you to usethe blast room as a
cleaner, and blast machine are con- bl '
blast cabinet. It consistsof a view
th fl . asting. window, work rabIe,and rubber-lined
nected, Because e recovery oor IS
built in, no excavation is required for a To ensureadequatelight levels gloves.
pre-assembled room, but it can be in a room fitted with wear curtains,
placed in a pit to reduce entry height, If consider ordering optional light-
necessary, room can easily be
the colored curtains instead of the
relocated. standardblack rubber.
Compressedair supplies the Clemco offers single and
power for the blast machine, pulses the multiple operator packages. Multiple
dust collector cartridges, provides operator packagesinclude additional
breathing air for operators,and in blast machinesand a storagehopper to
somesystems,powers the recovery channel media from the reclaimer or
abrasivecleaner into the blast ma-
chines. Using multiple blast machines
The orifice size of the blast allows the blast operatorsto work
nozzles, the type of recovery floor, and independently. Oversized blast
the type of respirators worn by the machinescan be ordered.but they
blast operatorswill greatly affect increasethe abrasive storagecapacity
compressedair consumption. without increasing production rates.
Most problems associatedwith If you plan to use plastic, wheat
blasting can be traced to the air supply. starch or other lightweight media, you
Blast cleaning requires an abundant must use a blast machine specifically
supply of clean, dry air. Your Clemco, designedfor such material.
ZERO, or Aerolyte Distributor can
Blast machinescan be ordered
determine whether your existing plant complete with remote controls, 50 ft.
compressorcan power your new
coupled blast hose, nozzle and mois-
facility or if you need an additional
ture separator.In addition, the system
compressor. includes operator safety equipment;
Apollo helmet with Climate Control
Tube, breathing air filter, large blast
suit and leather gloves.
Aerolyte blast machinesat McCk/Jan AFB.
According to OSHA and NIOSH
regulations, operator safety equipment,
including air-fed respirators, air filters,
carbon monoxide monitors and alarms,
and abrasiveresistant clothing is
required for all blast operators. Plan to
provide equipment storagelockers and
a changing areanear your blast room.
Improper use of abrasiveblast
cleaning equipment can causesevere
injury, terminal illness, or death. Read
and follow the instructions in all
owner's manuals and warning labels,
and obtain proper training before using ~
Blast suit, glovesand respirator. this equipment. Clnnco's CPF-20 breathing air filter:
With open air blasting, cleaning
up the dust and abrasiveis usually the
most labor-intensive, time-consuming
part of any project. Picking up,
packing, and disposing of spent
abrasivecan easily account for 60
percent or more of a project's cost.
Recovery systemsperform two
. Catch the media for delivery
to a recovery point.
. Transport the media to a
For a truly high-production blast
facility, use as much of the floor for
recovery as possible. This reducesthe
labor costs associatedwith abrasive
cleanup and makes for fewer interrup-
tions to blasting.
Clemco makesfour types of Some applications call for built- remove abrasivefrom crevices or
recovery systemssuitable for full or in vacuum recovery systemsto remove containers,plan to include vacuum
partial floor areainstallation. These abrasivefrom the inside of tank cars or recovery in addition to your floor
four systemsare either pneumatically other containers. If you needto recovery system.
or mechanically powered.
Pneumaticrecovery works best
with lightweight media, such as
agricultural, plastic, glass bead,or
aluminum oxide. In Clemco's M-
Section pneumatic recovery system,
dust and media fall through funnel
shapedholes into channelsbeneaththe
floor. High-velocity air carries this
media and dust to the reclaimer.
Becausethere are no moving
parts, pneumatic floors are simple to
operateand maintain. Pneumatic
recovery requires the use of a
reclaimer --a type of cyclone separa-
tor -- to separateblast media from the
dust, debris, and rmes.
The efficient and easily maintained M-section pneumatic float:
Flat-Trak Floor The Flat-Trak floor requiresless
maintenance dian other mechanical
Clemco's exclusive Flat-Trak floors which contributesto its greater
system,the newesttype of recovery operationaleconomy.
floor, usespneumatic power and a
Additionally, the Flat-Trak takes
ladder-like arrangementof steel vanes
lesstime to install than other mechani-
to move the blast media. The vanes
cal systems. This featurehelpscut down
push the media on the forward stroke. on lost productiontime when the Flat-
then ride up and over the mounds on Trak is installedas a replacement
the backstroke. systemin an existing enclosure.
Developedinitially for steelgrit Because Flat-Trak is offered
and shot.the Flat-Trak works well with in standard-sizemodules,most compo-
most blastmedia. Its key advantages nentsare readily availablefrom stock.
includea low profile. requiring little or This recoverysystemis available
no excavation. low purchase and exclusivelythroughClemco,ZERO,
installationcosts,and readyavailability. Installing the F/at- yak air lint's
drive module Vanes
Stationary I "'"
The innovative F/4t- Trak offin efficient, low-profile recowry. easeof installation, and low maintenance
Screw floors move the heaviest
abrasiveswith ease,and are often used
for steel grit and shot. They operate
quietly, even in high production
applications. Due to their complexity,
screw floors require a diligent mainte-
Depending on the number and
size of the screws,thesefloors are
generally more expensiveto purchase
and require deeper,more expensive
Screwfloors conveyheavy media at high production rates.
Manual recovery, via a sweep-in
or wall-mounted hopper recovery
system,requires periodic shutdown for
media cleanup. If you plan to blast
intermittently, the low initial cost may
outweigh the increasedlabor costs for
blowing or shoveling the media into
Pan floors moveangular abrasive easily. Sweep-in systemscan be
mechanical (with a grate over the feed
to a bucket elevator) or pneumatic
(with a grate over a single M-Section
In pan floors, such as Clemco's at the rear of the blast room). If site
Ao-AorTM, abrasivefalls into long conditions preclude excavation, a wall-
pans that are continuously rocked by mounted systemmay be the only
rotating cams at one end. This rocking option for manual recovery.
motion moves the abrasiveand dust A sweep-in systemis inexpensiveto install.
slowly toward a crossoverpan or a
screw conveyer,which transportsit to
a bucket elevator.
Pan floors are durable and
simple to operate.They work best with
The efficiency with which
reusablemedia is separatedfrom dust
and fines affects the cost per media
cycle and the life expectancyof the
dust collector's fIlter elements.Too
much usableabrasivereaching the dust
collector may wear out the filter
Clemco'sAbrasive Cleaner is a
gravity-fed air wash cleaner designed
to be used with mechanicalrecovery
A rotating scalping drum culls
debris from the media stream. The
spentmedia. dust, and fines cascade
over a seriesof baffles. A high-
volume streamof air is drawn through
the falling media to remove dust and
fines. Reusablemedia is carried either
to a storagehopper or drops directly
back into the blast machine.
Designed into the product is its
ability to spreadthe media into a
uniform curtain as it cascades each
baffle and, control of the flow of air """
passingthrough that curtain of media.
This design keepsthe media curtain
from developing gaps.If the curtain is
not uniform, the air will remove dust
and fines unevenly.
A reclaimer is a cyclone separatorthat spins the heavier media particles in
the air streamto the outside of a cyJinder,while dust and broken media are
drawn out with the exhaustair. RecJaimers work best with pneumatic recovery
systemsusing Jightweight media. A reclaimer can be precisely tuned to mini-
mize the amount of usable media carried over into the dust collector. If alumi-
num oxide or other aggressiveabrasiveswill be used, order the reclaimer with
optional rubber-lined wear-plates.
Reclaim"s are usedin pneumatic systems.
Most blast facilities built or The requirementsfor blast room of filter element. This is commonly
refurbished during the past 10 years ventilation vary from state-to-state. referred to as the air-to-cloth ratio,
have included a reversepulse cartridge The size of the room, the condition of though modern filter cartridges use
dust collector. The dust collector has a the part being blasted,the amount of pleated polyester/paperto trap the dust.
powerful exhaustmotor to draw dust- dust from the blast media, the airflow Clemco dust collectors provide a 2-to-l
laden air out of the enclosure and trap required for the media reclaimer or air-to-cloth ratio, though the filter area
the dust in filter elements. abrasivecleaner -- all will affect the can be increasedfor especially dusty
The cylindrical cartridges of the size of the dust collector needed. applications.
reversepulse dust collector are open at At a minimum, the dust collector The dust collector is among the
one end and have a reinforced pleated must generate50 feet per minute of air most expensivecomponentsof a blast
paper filter element. The advent of flow through the enclosure.Dusty facility. Paying for more dust collection
pleated,high-efficiency filter elements applications or those that generate than you needis wasteful; buying an
greatly reducedthe size requirements hazardousmaterial, may require flow inadequatecollector can be disastrous.
of blast facility dust collectors. rates of up to 100 fpm.
Your Clemco, ZERO, or Aerolytf:
To extend the life of the filter The dust collector's filtering Distributor can recommendthe appro-
cartridge, the dust that collects on the capacity is measuredby amount of air priate size of dust collector for your
filter element must be removed flow in relation to the total squarefeet application.
periodically. Modem dust collectors
clean their cartridges with a pulse of
compressedair that momentarily
reversesthe flow of air through the Pulse jet air Reverse pulse
manifold - - jet valves
filter element. This pulse knocks the
caked-on dust into a hopper or dust
drum below. Clean exhaust
If the pulse cleaning is auto- Dirty
matic, the dust collector can operate incoming Dust filter
for long periods without stopping. air --- cartridges
Clemco provides only automatically
pulsed dust collectors. The pulse can Dust laden
be actuatedby a timer or by sensing air
devices that detect dust build up by
measuringthe difference in pressure Heavy debris
betweenthe clean and dirty side of the particles
Position the dust collector as Magnahelic
close to the blast enclosureas possible Controlpanel- gauge
for maximum ventilation efficiency
and reducedinstallation costs. Locat-
ing the dust collector outside simpli-
fies emptying dust hoppers and saves
valuable plant floor space.
Dust Collector Size
The dust collector must be -- Debris barrel
sufficiently powerful to ventilate the
room and have filtering capacity to
trap the dust generatedduring blasting.
A cartridge dust collector cleansits filter elementswith periodic blastsof compressed
Forklifts, rail-mounted work
cars, overheadmonorails, and other
common systemsthat already exist or
are planned for your plant can be
integratedinto a Clemco blast facility.
For parts weighing more than 5,<XX>
pounds,modifications in the enclosure
floor or roof beamsmay be required.
If you plan to drive equipment into the
blast room, tell your Clemco, ZERO,
or Aerolyte Distributor so that special
load-bearingfloors or heavy-duty floor
gratescan be incorporated.
A blastfacility can take advantage of any existing or newly installed work handling
equipment -from forklifts to monorails to work cars with and without tracks.
To co-ordinate the operation of
the various components,most blast
rooms include a central control panel.
Controls range in complexity from
simple on/off buttons to computer-
controlled parts handling systems.
The control panel enclosure
servesas the interface betweenyour
existing power supplies and the blast
room. Standardblast room control
panels meet NEMA-12 specifications.
Explosion-proof panels or other
special power requirementswill affect
componentsbeyond the panel itself,
and must be specified in the request
Control panels serve as the interface betweensources power and the blastfacility.
Clemco has establisheda profes-
sional relationship with a group of
experiencedblast facility installation
contractors throughout the U.S. and
Canada. These contractors can prepare:
the site, install the blast room, and
connect your existing work handling
system to the blast room's. Complete
or partial installation can be included ill
the price of the blast facility.
Some companieselect to use their
own employeesor to hire local contrac-
tors to perform all or part of the
installation. Clemco provides complete
drawings for site preparation, equip-
ment arrangement,electrical and sheet
metal connections,and finish work.
Installation by our t'xpmenced contractorscan be included in the price of your facility;
Training is frequently overlooked
as an important component of a new or
refitted blast faciljty. Even experi-
encedoperatorsmust learn how the
systemswork, how to troubleshoot,
and how to work safely.
supervision for major new components
and complete facilities, and training
for employeesnew to abrasiveblast-
Clemco conductsmost new-
facility training on-site, in conjunction
with the startup of the facility. Also,
Clemco has a fully equipped training
center at its Washington,Missouri,
Ckmco can provide completetraining and start-up supervision.
These adjoining blast room
modules combine to form a 72-foot
enclosurefor blasting large parts on a
regular, but not daily, basis. The
modules are capableof operating
independentlyfor smaller parts or
linking to handle large parts. Work
cars ride on rails set into a concrete
slab flanked by Clemco's FIo-FiorTM
recovery pans. The slab remains
relatively clean during blasting. What
little abrasivedoes land on the slab is
blown into the pans before the doors
Each module has its own blast
systemand dust collector. The
installation runs two shifts a day, with
two bla...terseach shift.
In Clemco's own plant, partiany
assembled product.~ move through
finishing and final assemblysus-
pendedfrom an overheadmonorail.
This 120 square-footroom is manned
by a single operator free to walk
anywhereon the Flat-Trak's 250 lb./ft?
man-load grating. Becauseproducts
are suspended from the monorail, the
fun floor catchesthe abrasivescattered
throughout the room. Shedplates
along either side direct media into the
recovery floor. The modules are
~-o ~ ~
Customer Built Enclosure
A remanufacturerof "piggyback" railroad cars built its own lOO-foot
", enclosureusing Clemco's specifications and components. The cars move along
a spur track into the blast room, then to a paint facility, and on to rejoin the
The cars are blasted thoroughly, including the undercarriages,which
meansa substantialamount of abrasivefalls under the cars. The huge facility
has a full floor recovery system,including the area under the tracks. Recovery
is fully automated,so the two blasters spendtheir entire shift blasting, with no
interruptions for abrasivecleanup.
~b... ) ~o~ ~
~ ~ ~ ,.,
Wall-mounted light modules
... . -
; .' .. (")~
n~v-n illuminate all areasof the railcars
... ~ '>~~:
during blasting. A centrally located
panel controls all start/stop functions
(except actual blasting). Two dust
collectors, representingmore than
~,",6-6 ~p 10,000 squarefeet of filter cloth,
maintain ventilation and visibility.
We have manufacturedquality abrasiveblast cleaning equipment for more than 50 years. You will find our products
available through more than 450 independentClemco, ZERO, and Aerolyte Distributors in the U.S. and Canada. Clemco
International, Inc., operatesa worldwide network of subsidiaries,licensees,and distributors.
In addition to blast facilities, we offer the most complete line of blast cleaning equipment. We are proud of our
worldwide reputation, a reputation basedon the quality, innovation, and value engineeredinto all our products.
Becausewe engineer and manufacture all of the componentsthat go into your blast facility, and becausethe parts are
designedto work together, the result is a balancedsystem,free of the compatibility problems found in someblast rooms.
We can even show you how to breathenew life into an aging, inefficient blast facility.
A blast facility is a major investment. Our staff will work closely with you to plan and create a facility that provides
lasting value and maximum return on investment. We keep you informed at each step and rely on your direction to make
sure we are producing a systemcapableof doing the job. Our comprehensiveinstallation, operation, and maintenance
manualshelp your employeeslearn how the systemworks and how to keep it operating at peak efficiency for years to come.
Stock No. 09292 Job No. 115-0877 . Date of Issue; August. 1977 . Rev. B; (X)/94