Industrial sandblasting guide

Industrial sandblasting is a surface treatment method where compressed air propels abrasive particles at high speed onto a workpiece. The impact of these particles removes contamination or modifies the surface profile.

Although the term suggests the use of sand, modern industrial blasting very rarely uses natural silica sand because of health and environmental concerns. Instead, a range of alternative abrasives is used, chosen according to the base material and the desired finish.

In a typical compressed air blasting system:

1. An air compressor supplies compressed air at the required pressure and flow.

2. Abrasive media is stored in a blast pot or hopper and is metered into the air stream.

3. The air and abrasive mix passes through a blast hose to a nozzle.

4. The operator directs the nozzle at the surface to remove contaminants or create the required texture.

5. Spent abrasive and removed material are collected, separated, or disposed of.

A complete sandblasting system includes several key components, each serves a specific function in the process:

• Air compressor – provides the compressed air needed to propel the abrasive. The required pressure and airflow depend on the nozzle size and application.
• Dryer and filtration – guarantees the compressed air quality is dry and clean, with a dew point low enough to prevent moisture-related issues like nozzle clogging. The air should be filtered to remove oil and solid particles, as contamination can damage the system and negatively impact the work quality and safety. 
• Blast pot (pressure vessel) – stores the abrasive media and meters it into the air stream at a controlled rate.
• Nozzle – shapes and directs the mixture of air and abrasive onto the workpiece. Nozzles are made from wear-resistant materials such as boron carbide.
• Blast cabinet or blast room – an enclosed environment for blasting. Cabinets are used for smaller parts, while blast rooms are designed for large items such as vehicles or steel structures.
• Portable systems – mobile sandblasting units, often powered by diesel compressors, are used in shipyards, construction sites, and other remote locations.

Together, these elements form the basis of any media blasting compressed air system, ensuring the abrasive is delivered with sufficient speed and accuracy for the intended surface treatment.

While the term "sandblasting" suggests the use of sand, modern industrial applications utilize a wide variety of abrasive media due to health concerns associated with inhaling silica dust, which can cause serious respiratory illnesses. The choice of abrasive depends on the surface material, the desired finish, and the specific application.

Common abrasive media include:

• Aluminum oxide - A sharp and hard abrasive ideal for surface preparation and etching. It can be reused multiple times, making it cost-effective.
• Steel grit and shot - These are used for aggressive cleaning and surface profiling due to their rapid stripping capabilities.
• Crushed glass - Made from recycled glass, this is a non-toxic and safe abrasive used for removing coatings and surface contamination.
• Sodium bicarbonate (baking soda) - A mild abrasive used for gentle cleaning and rust removal without damaging the underlying surface.
• Organic abrasive materials - like walnut shells and corn cobs are used for delicate cleaning applications.

The properties of the abrasive media, such as shape, size, density, and hardness, play a crucial role in the final surface finish.

• Automotive – rust removal on body panels and frames, surface preparation before painting.
• Construction – cleaning concrete, masonry, and steel reinforcement.
• Shipyards and marine – hull maintenance, coating removal, and corrosion protection.
• Manufacturing and fabrication – deburring, edge rounding, and pre-coating surface treatment.
• Oil and gas – cleaning and preparing pipelines, pressure vessels, and offshore platforms.

These varied uses show why sandblasting remains an essential process in heavy industry, fabrication, and maintenance.

The air compressor is the core of any sandblasting system, as it provides the airflow and pressure required to propel abrasive media. Different blasting environments demand different compressor technologies.

The performance of a sandblasting system depends on matching the air compressor to the nozzle size and pressure requirements. Undersized compressors reduce efficiency, while oversized nozzles demand more air than available.

Key factors influencing airflow include:

• Nozzle size – larger bores require higher airflow to maintain pressure.
• Operating pressure (PSI/bar) – higher pressures remove coatings faster but demand more air volume.
• Hose length and diameter – restrictions in the air line increase losses, raising compressor demand.

A balanced media blasting compressed air system ensures consistent results and reduces strain on equipment. Learn more about how to choose the right air compressor for sandblasting.

Sandblasting must be carried out with care to protect both operators and the surrounding environment. Silica sand is no longer used due to health risks, and safer abrasives are now standard. Operators are expected to wear protective clothing, respirators, and helmets to guard against dust, noise, and vibration.

Dust collection or wet blasting methods are often applied to reduce emissions, while spent abrasive and coatings should be disposed of responsibly. International and national standards, such as ISO specifications and health and safety regulations, provide guidance for safe and compliant operations.

Our specialists can review your air demand, nozzle size and working hours and suggest suitable compressor solutions.