FAQs - Understanding Abrasive Blasting

What is sand blasting?

Sand blasting is a generic term historically used to describe the process of cleaning or preparing a surface by propelling sand at high velocity. The term originated when silica sand was the most commonly used abrasive material. Today, the industry prefers the broader term abrasive blasting, which covers the use of various safer, non-silica abrasives.

Is sand blasting banned?

Yes. The use of silica sand in blasting is banned due to the high health risks it poses. Free crystalline silica particles can cause severe respiratory diseases such as silicosis, lung cancer, and other occupational health hazards. For this reason, regulatory authorities prohibit the use of natural silica sand in blasting operations, recommending use of non-silica abrasives.

Then why is it still used?

In modern practice, the term abrasive blasting refers to processes that use safe, non-free-crystalline-silica abrasives such as garnet (non-silica garnet), copper slag, steel grit, aluminum oxide, glass beads, plastic, agro-grit (walnut shell), dry ice, etc. These alternatives eliminate the free crystalline silica hazard while ensuring effective cleaning and surface preparation.

Why is abrasive blasting necessary?

Abrasive blasting is a highly productive and effective surface preparation method for large-scale production, serve critical industrial use cases for cleaning, finishing, roughening, de-burring, etc. The process is mandatory for various  infrastructural surface preparation applications. An abrasive blast cleaned surface serve effective bonding of paints and coatings to increase their service life multiple times, ensuring corrosion protection and structure sustainability. 

Abrasive Selection and Usage

Unfortunately, some contractors may illegally use silica sand due to lack of awareness, cost-cutting, or untrained labor making compliance awareness critical, putting operator's health at risk. While in some industries and regions, the old term “sand blasting” continues to be used out of habit. Both the cases need proper awareness and monitoring. 

What are the safe practices in Abrasive Blasting?

Most manufacturers design enclosed abrasive blasting machines equipped with proper abrasive recycling and dust collection system eliminating the risk of high dust generation and abrasive slippage, and meeting the air emission norms for suspended dust particles. We recommend proper mask, goggles, gloves, PPE for operators. In-situ operators performing abrasive basting inside a blast room, or at infrastructural site in open are recommended to wear Abrasive Blaster's Helmet with filtered air breathing, and PPE.

Types of Abrasive Blasting

The mechanism of propelling abrasives with high velocity and kinetic energy on to a surface defines the type of process.

Air Operated / Pneumatic Blasting: Uses compressed air to propel abrasives out of blasting nozzle through a rubber hose. Facilitate flexible and visible cleaning, easy maneuvering in manual - automatic manner. Can regulate air pressure for soft/thin components. Pneumatic Blasting is further classified as Suction Blasting (syphon feed propelling), Pressure Blasting (Pressurized feed propelling) and Wet Slurry (Slurry feed) methods. Machines are available in varying sizes and features to adjust size of component, with required number of Blast Nozzles, and are fitted with Abrasive Recovery and Dust Collection Systems.

Airless / Centrifugal Wheel Blasting: Propel abrasive with centrifugal wheel. Used for high kinetic energy - high abrasive feed - high production of rigid components - casting, forging, sheets, plates, structures, etc. Machine types are Tumble (batch components) Table type, Hanger type, Tunnel Type (through pass),  and available in varying sizes to adjust size of component, required number of Blast Wheels, and are fitted with Abrasive Recovery and Dust Collection Systems.

Safety, Regulations, and Compliances?

Technically, Shot Blasting refers to use of shots - spherical media for abrasive basting. Practically, owing to the risk of self-wear abrasion, balancing and vibration in high RPM centrifugal wheels, the Airless / Centrifugal Wheel Blasting process is recommended to use only shots (not Grit), thus the wheel blasting process is in general termed as Shot Blasting.

Similarly, other blasting processes are termed as Grit Blasting, Glass Bead Blasting, Dry Ice Blasting, and so on.

What is the proper method for surface preparation?

There are various factors to be considered for selecting a right abrasive for any application.

Material: Outdoor Abrasive Blasting on infrastructural sites face recovery and re-use challenge, thus use low cost abrasives like garnet or copper slag having maximum two re-use cycle, while enclosed machines are designed for 50 - 100 recycle reuses of low breaking abrasives like steel grit, steel shots, aluminum oxide, glass beads, etc.

Shape: Sharp multi-edge particles are called Grit, spherical particles are called Shot.

Size: All abrasive are available in their grade - mesh number, in respective (ASTM/ISO) international and (IS) national standards for particle size classification.

Selection of abrasive type depends on the required surface finish and application served. Selection of its particle size range depends on surface roughness to be created for the needed application. Selection of abrasive material, particle size, type of blasting process, operating parameters, and the roughness created needs proper R&D trials, inspections, and process set up by experts, or as recommended by principal. 

What is Shot Blasting?

Eliminating the use of Silica Sand Blasting as a banned process, all other forms of abrasive blasting media, machines and processes are a vital part of progressive industrial surface treatment requirements, used for component finish, safety, longevity, refurbishment, reuse, contributing in service life, circular economy, sustainability, and are safe to use under required compliances:

1. SPM Dust emission is to be under specified air emission limits

2. Noise - from Dust Collector Fan Blower, Compressor - or process to be within industry standards.

3. Waste Disposal - of used abrasives and metal dust to be controlled as per industry standards

4. Liquid discharge (only for slurry blasting) is to be monitored or disposed after drying as dry waste.

5. Chemical and Other Non-Hazardous Wastes - Not Applicable

6. Occupations Health and Safety - of operators to be monitored by providing proper PPE, awareness, and guidelines.  

7. For Open Blasting at Infrastructural / Fabrication Sites or Structural Repair Maintenance Works - additional provisions are to be made by contractors for Dust Suppression - Dust Collection, Abrasive Recovery, Slippage Prevention, Waste Disposal, and for Operators PPE.  

What is the solution for safe processes?

The solution lies in adopting:

• Regulatory Compliance – adhering to Pollution Control Board standards, permissible emission limits, and occupational safety regulations.

• Engineering Controls – avoid open blasting, use proper design machines with abrasive recycling, dust collectors, and ensure proper local area ventilation.

• Safer Practices – using approved non-silica abrasives, protective equipment, and trained operators.

• Machine Maintenance and Servicing - ensure better operating conditions, filter cleaning, choking, waste disposal, machine wear and abrasion, spare parts, and operation and usage training. 

• Consulting and Guidance – engaging expert advisory services like KSBE to design compliant blasting systems, adopt alternative abrasives, and implement best practices.

Why Compliance Matters

Addressing safety and environmental impacts of abrasive blasting and dust generation processes in abrasive blasting

Environmental Effects

High risks from abrasive blasting and untrained labor handling processes.

Regulations & Guidelines

National and international compliance standards for abrasive blasting activities.

Consulting Services

Solutions offered by KSBE for compliance with safety and environmental regulations.

Our Services

At KSBE, we deliver actionable, results-driven consulting and industrial services that help manufacturers enhance performance, reduce operational waste, and achieve sustainable growth. Our decades of on-ground manufacturing experience, combined with strategic foresight, allow us to address both current industrial challenges and future readiness without overcomplicating the journey. Led by decades of industrial fieldwork, KSBE helps industries scale quality, efficiency, and sustainability globally.

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Why Compliance Matters

Addressing safety and environmental impacts of abrasive blasting and dust generation processes.

Environmental Effects

High risks from abrasive blasting and untrained labor handling processes.

Regulations & Guidelines

National and international compliance standards for abrasive blasting activities.

Consulting Services

Solutions offered by KSBE for compliance with safety and environmental regulations.

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