Specialist Cleaning

Sponge blasting

Solutions for delicate cleaning and restoration for historic surfaces

The dust-free, environmentally friendly cleaning and micro-abrasive technology of sponge blasting is the specified choice of architects, protectors of historic buildings and masonry professionals for the precision cleaning and removal of surface contaminants from delicate and extremely delicate substrates, while at the same time protecting the surrounding environment.

Benefits of sponge blasting

- Sponge Media traps the majority of the dust without having to use water
- Controllable blast feed for precision cleaning/paint removal
- Facilitates inspection and superior visibility during the blasting process
- Sponge Media is recyclable, which can reduce the waste by more than 90%
- Up to 20 times faster than cleaning by hand or with powered tools
- Better visibility during blasting
- Selective stripping of coatings and removal of contaminants
- Specialized equipment facilitates controlling the media flow with a pressure
   of 0.1-7 bars (2-100psi)
- Damage caused by rebound is practically eliminated
- Cleaning and degreasing without water or liquid cleaning abrasives
- No leaching of chemical substances or leachable components
- Considerably less airborne emissions than with other conventional abrasives

Contaminants and substrates

- environmental contaminants
- paint/graffiti
- efflorescence/exfoliation
- soot/carbon deposits
- mold/biological growth
- hard metal alloys/soft metals
- cast iron/carbon steel
- copper/tin/bronze
- granite/terracotta/sandstone
- bricks/masonry blocks/concrete

The heart of the sponge blasting system

The heart of the sponge blasting system is Sponge Media. This patented technology combines the absorbing properties of urethane sponge with the cleaning and cutting power of conventional abrasives.

The pliant nature of sponge blasting abrasive allows its particles to flatten at impact (figure 1), exposing the abrasive.
After impacting on the surface, the media expands creating a vacuum which traps the rebound, as a result of this the cleaned substances which would normally be released in the air are trapped, (figure 2). This is known as the MicroContainment™ of Sponge Media.

Figure 1: Conventional blasting

Figure 2: Sponge blasting

The sponge blasting process:

1. Sponge Media abrasives come in more than 20 ranges for all applications. All ranges offer dry, dust-free abrasive with low abrasive rebound.

2. Sponge Feed Units deliver the Sponge Media abrasives to the surface. The blast pressure and media feed is controlled via a central panel, this allows for precision adjustment.

3. Sponge Media (displayed here at 3 x the actual size) traps contaminants immediately on impacting the surface.

4. Sponge Recyclers sort and clean the Sponge Media abrasives for reuse. The blasted media are collected and processed through either an electrically or pneumatically powered sifter, which separates reusable Sponge Media into coarse grit and fines (spent media and contaminants).

5. Up to 95% of Sponge Media can be recycled for reuse

Sponge blasting is better for the environment and your profits

Sponge blasting is better for the environment and your profits.
The sponge blasting technology suppresses airborne emissions and abrasive rebound, which could result in costly downtime and dangerous conditions at the workplace.

From delicate cleaning to aggressive removal of coatings and profiling of industrial substrates, Sponge blasting offers a range of solutions (and benefits) in the area of surface preparation.

From left to right: conventional blasting and dust-free blasting with sponge blasting

The dust-free, recyclable process of sponge blasting with low abrasive rebound offers
the following benefits:
- less airborne emissions
- less exposure and tiredness for staff
- less injuries to eyes and other body parts
- better visibility and higher inspection percentages at first quality check
- less defects and rework resulting in no delays to projects
- high-quality surface preparation in delicate environments or closed-off areas
- a solution for preparing surfaces in the vicinity of finish coatings, instruments and equipment
- low incoming and outgoing transport costs
- less pollution, waste, penalties and reporting
- improved relations with the neighbouring community
- other professionals in the vicinity can continue working
- less downtime, better availability of assets
- coatings have a longer lifespan, which reduces maintenance costs
- easier to apply, manage, ventilate and to cleanup afterwards
- less waste, drainage and handling of material

The result?
- Higher production and efficiency
- Less liability, litigation, compliance reporting
- Improved efficiency for both the environment as well as the business end
- Higher profits and production

The ideal solution for every sector

Sponge blasting is a productive, flexible, staff and environmentally friendly solution for
every branch, application or surface preparation project:
- Aerospace industry
- Construction and maintenance of bridges
- Restoration after fire
- Historic restoration
- Lead removal
- Marine industry
- Military
- Mold removal
- Cleanup of radioactive contaminants
- Offshore
- Petrochemical industry
- Power Generation
- Pulp and paper
- Treating of water and waste water

It can save you millions

The clean, dry, dust-free and recyclable technology of sponge blasting will help you realize results while protecting what is important at the same time: the environment, machinery and equipment, your staff and your profit margins

The sponge blasting systems allow you to clean, selectively strip paint (or remove contaminants) and realize profiles from 0 up to 100+ micron (4+mil).

Replace less efficient technologies like conventional abrasives, processes using powered equipment or mechanical tools, high-pressure water blasting and blasting with slurry with higher-quality Sponge Media blasting abrasives for restoration, cleaning and profiling.

Conventional blasting methods cost millions

Airborne emissions and abrasive rebound can result in costly downtime and dangerous conditions at the workplace:

Dangerous emissions
High concentrations of poisonous substances, arsenic and heavy metals have been linked to blasting activities in all sectors. Sponge Media absorbs the majority of the potentially dangerous emissions resulting in less exposure to staff, reduced liability for facilities and lower costs related to complying with tests, litigation, treatment and healthcare in the long term.

Corrosion
The estimated yearly cost of corrosion in the US is put at USD 276 billion. 80% of all cases in which coatings fail are attributed to incorrect preparation of the surface concerned. Sponge blasting ensures an ideal surface preparation in the most difficult environments and in this way extends the lifespan of all coatings, as a result of which the cycle of continuous maintenance and downtime is broken.

Equipment failure
Equipment failure can be a disaster, instruments, electronics and running machinery can all fail prematurely due to exposure to abrasive dust or water. The sponge blasting technology eliminates up to 99% of the abrasive dust, which improves the general reliability of equipment and installations.

Injuries to eyes
Blasting and the related activities are a chief cause of eye injuries. In the American work environment alone, 1,000 eye injury cases per day already costs USD 300 million per year. Sponge blasting does not rebound in the same fashion as other abrasives and in this way reduces one the most important causes of eye or other bodily injuries in the work environment.

Pollution
During a recent study targeting shipyards, blasting was seen as the most important factor for airborne emissions. Dangerous particles (< 10 micron) cause problems with the upper airways, smog and worldwide pollution. The Sponge blasting technology collects up to 99% of these emissions, protecting the environment and public health.

Downtime
Downtime can cost factories more than a million per day. Downtime in relation to surface preparation is always longer, as mechanics, welders, electricians and other professionals cannot work in the vicinity of blasting units. Sponge blasting will enable you to complete your project quicker.