The different tools for surface conditioning

Conditioning, machining and cleaning metal surfaces exists in many ways. All these forms of surface preparation have one and the same purpose: to remove coatings, mill scale, rust and other dirt, in order to extend the life of a steel object. Often this is done prior to the application of a (possibly new) coating. To do this properly, it is important that the surface is cleaned and prepared so that an adhesive layer is created in the surface. There are various surface conditioning tools to accomplish this. But what are these tools, how do they work, and how do MontiPower power tools play a role in this?

Sandblasting as a surface conditioning tool

One of the best known and most widely used tools for surface conditioning is abrasive blasting. There are different ways of abrasive blasting, which are broadly the same way of working. In surface conditioning with abrasive blasting, an abrasive combined with air is applied at very high pressure to the surface. Because of the high speed at which this happens, the impact of the abrasive causes coatings and dirt to easily come off the object. Originally, the most widely used method of abrasive blasting was sandblasting. The grain of sand had such a good abrasive effect that sandblasting was used in many industries. Over time, however, several disadvantages of sandblasting came to light. For example, sandblasting not only proved to be very harsh on the surface, but also very harmful to human health. It caused sandblasting to be banned in many countries worldwide.

Surface conditioning with other blasting media

After sandblasting was banned in many countries, alternative abrasives for surface conditioning had to be sought, such as bead blasting, wheel blasting and vacuum blasting. These alternatives were found in blasting with glass, corundum and plastic, among others. To this day, these materials are still used as tools for surface conditioning. Yet, despite the fact that these methods of abrasive blasting do not have the dangers of sandblasting, they themselves have their drawbacks. First of all, abrasive blasting is a difficult job to perform as an individual. To ensure the best possible surface finish, it is therefore recommended that this always be done by a professional, which makes abrasive blasting relatively expensive. Also, with abrasive blasting, the abrasive has a very aggressive effect on the surface. This removes coatings, dirt, rust and mill scale in a very effective way, but because of the high speed at which the abrasive is applied to the surface, damage to the object can easily occur. Because of this, vapor blasting, in which water is added to the abrasive, is often used when preparing more fragile surfaces. However, this method of abrasive blasting is not powerful enough when there is heavy soiling.

The tools for surface conditioning from MontiPower

MontiPower’s Bristle Blaster® and MBX® are the revolutionary tools in the field of surface conditioning. The power tools combine all the good things of abrasive blasting with a patented technique, which responds to all the disadvantages they bring. For example, the Bristle Blaster® and MBX® are hand-held tools that are easy to use yourself. In this way, you are no longer dependent on external parties for the conditioning of surfaces and can easily remove coatings, paint, rust and mill scale yourself. Due to the effective operation of the tools, surface conditioning will be a piece of cake from now on. Moreover, the specially designed technology of the tools not only ensures thorough removal of dirt; it also creates a surface profile, which is comparable to the adhesion layer created by the various blasting methods. With our wide range of rotary brushes, you will always find a suitable method of surface conditioning for your own specific situation at MontiPower. It makes the Bristle Blaster® and MBX® the perfect alternative to sandblasting and other methods of abrasive blasting.

How do MontiPower’s surface conditioning tools work?

MontiPowers powertools for surface conditioning work with a rotating brush, which features specially designed curved tips. The rotation of the brush and its points ensures that different types of metal surfaces can be cleaned and prepared quickly and easily. In this rotation of the brush, the bent points are briefly stopped by the so-called “accelerator bar”. This causes a small hiccup in the rotation, so that the bent brush tips – partly due to the high speed – are released with extra large force into the surface. Due to this high force, the brush tips of the Bristle Blaster® and MBX® are immediately released upon contact with the surface. This initially ensures highly effective and precise removal of coatings, rust, mill scale and other dirt, but this is not the only thing. The violent impact of the brush tips into the surface also creates the profile that can be used as an adhesion layer for a new coating.

Surface preparation solutions

Surface preparation exists in many different forms. Whenever a metal surface needs to be stripped of rust, coatings, mill scale or other dirt, there are various possibilities for this. The traditionally best known form of surface preparation is abrasive blasting, such as grit blasting, bead blasting, wheel blasting and vacuum blasting. The surface is cleaned and prepared by applying an abrasive under high pressure. A common form, which has been used for many years, but nevertheless also has the necessary disadvantages. MontiPower, with the Bristle Blaster® and MBX®, responds to these disadvantages and offers the solution for surface preparation with a revolutionary technique.

The disadvantages and solutions for surface preparation

Despite the fact that abrasive blasting has been done for quite some time, several disadvantages of this method of surface preparation have come to light over the years. But what are these disadvantages really? And in what way do MontiPower power tools offer the solution for surface preparation?

Disadvantage 1: abrasive blasting can be dangerous

One of the biggest disadvantages of traditional forms of surface preparation is that they can be very dangerous. Not only are they often hard on the surface, but people, animals and the environment can also be damaged by frequent abrasive blasting. The best-known example of this is sandblasting, which is one of the first forms of abrasive blasting developed and has been the most widely used for many years. This involved the use of quartz sand, which falls apart into very small particles during the blasting process. Research showed that inhaling the particles could have very harmful effects on human health, and in the worst case even fatal consequences. It caused sandblasting to be banned worldwide in numerous countries.

Not only sandblasting; other forms of surface preparation can also be very harmful. Another good example, chemical surface preparation, in which the metal surface is cleaned using an acid solution. This acid – usually hydrochloric acid – is a very aggressive agent, which, when coming into contact with it, can have the necessary harmful effects. Moreover, when using this acid, harmful fumes can be created, which can affect not only people, but also the nearby environment.

How does MontiPower offer the solution for surface preparation?

MontiPower attaches great importance to safety and health. The various power tools are therefore developed in such a way that they are considered safer than the traditional forms of surface preparation. For instance, no processing under high pressure takes place, no abrasives or other (harmful) substances are used and in the design of the Bristle Blaster® and MBX®, ergonomics have also been taken into account. In this way, surface preparation is made easier in a safe and healthy way.

Disadvantage 2: surface preparation is difficult to carry out

Preparing different types of surfaces is a job that needs to be done accurately. On the one hand, it is important that the surface is removed from rust, coatings and dirt as effectively as possible, but when the impact of the abrasive is too strong, damage to the object may occur. The balance in this is difficult to determine when using blasting machines. For this reason, surface preparation is not an easy job for private individuals to perform. For this reason, it is advisable to have the surface preparation with abrasive blasting carried out by a professional company at all times. This will always make you dependent on an external party, and the surface preparation will also be a relatively expensive job.

How does MontiPower offer the solution for surface preparation?

MontiPower’s Bristle Blaster® and MBX® are the only manually operated power tools in the world that can be used for surface preparation. Because the devices are hand-operated and very easy to use, the Bristle Blaster® and MBX® can be easily operated by yourself. The revolutionary technology with which the power tools are equipped ensures that surfaces are prepared and cleaned thoroughly yet accurately, so you do not have to worry about any damage to the object. Because the tools are easily operated by yourself, you are no longer dependent on an outside party.

Disadvantage 3: surface preparation is harmful to the environment and nature

Earlier, we mentioned the fact that the traditional forms of surface preparation can have very negative effects on human health. But not only human beings; also on the environment and the surrounding nature, the different forms of abrasive blasting can have very harmful effects. For example, the environment can be polluted with released abrasives and chemical substances can affect the environment and nature.

How does MontiPower provide the solution for surface preparation?

MontiPower’s Bristle Blaster® and MBX® responds in several ways to the disadvantages of abrasive blasting in terms of environmental and natural pollution. First, MontiPower’s power tools do not use loose abrasives. Also, chemical agents that can be harmful to the environment and nature are not used with the Bristle Blaster® and MBX®. Moreover, the brush belts of MontiPower’s tools can be returned for recycling after use. It makes the Bristle Blaster® and MBX® the solution in the field of surface preparation.

What is corrosion?

Corrosion can be defined as deterioration of metal as a result of a chemical reaction with factors from the environment. This reaction can be caused by various factors, which is why many different types of corrosion can be distinguished. One of the best known forms of corrosion is rust. A brown layer forms on the metal as a result of a chemical reaction between oxygen and damp. Both terms – corrosion and rust – are often used interchangeably. However, the use of both terms is incorrect. Whereas corrosion can be defined as the umbrella term for the deterioration of metal, rust is only one example of this. And although rust is indeed one of the best known forms of corrosion, other forms of corrosion can also be distinguished. But which other forms of corrosion do we know? And how can you best remove corrosion?

Types of corrosion

As said, there are several types of corrosion. Corrosion is caused by a chemical reaction between different factors. In case of rust this is oxygen and damp, but corrosion can also be caused by acid, electrical tension or bacteria. We can differentiate the following ten different types of corrosion:

• Oxygen corrosion
• Uniform corrosion
• Acid corrosion
• Galvanic corrosion
• Stress corrosion cracking
• Stray current corrosion
• Pothole corrosion
• Crevice corrosion
• Intercrystalline corrosion
• Microbacterial corrosion

Would you like to know more about corrosion and its origins? Then read more about the different types of corrosion.

Removing corrosion

There are several ways to remove corrosion. Traditionally, this was mainly done by abrasive blasting. With this method of surface preparation, an abrasive is applied to the surface at high pressure in combination with air, which removes corrosion, but also other dirt such as mill scale and coatings. A well-known example of abrasive blasting is sandblasting. Over time, however, several disadvantages of blasting came to light. For example, several dangers of sandblasting were discovered, and blasting is also a time-consuming and expensive activity.

With the Bristle Blaster® and MBX®, MontiPower offers the revolutionary techniques in the field of surface preparation. The electrically driven tools are easy to operate and have a very fast and effective operation. The Bristle Blaster® and MBX® are characterized by a rotating brush with patented curved brush tips. These brush tips not only ensure effective corrosion removal, but also create a surface profile that can be used as an adhesion layer for a new coating. This makes the Bristle Blaster® and MBX® the perfect alternative to sandblasting and other abrasive blasting techniques.

What is welding and what techniques are used?

Welding is a joining technique used to make two materials into one. When materials are welded, they are joined together under very high temperatures, combined with high pressure. In the process, a small portion of the material is liquefied to allow for the attachment of both objects. By using two virtually identical materials, continuity is created between the two objects. Welding is mainly used when joining steel objects, but can also be applied to stainless steel, aluminum and some plastics, for example. For the welding process to be successful, the materials must at least be fusible.

Different welding techniques

Although in most cases, welding is done in the same way, there are different welding techniques. Which welding technique can best be used in which situation depends on the situation and the purpose of the materials. In order to explain the differences between the various welding techniques, we will take a closer look at the three most common methods of welding.

Electrode Welding

Electrode welding is also known in the world of welding as clad electrode welding or arc welding. This method of welding is mainly used when welding steel and stainless steel. It is unsuitable to use for aluminum. In electrode welding, you use a welding machine in combination with a package of covered electrodes. These electrodes are intended as an additive material in the welding process and will melt to the object as the process progresses. This melting process will then produce slag on the steel object. Slag is a brittle material that, in most cases, is created because the steel material has not been sufficiently cleaned of dirt, rust, paint or other coatings beforehand. This slag can be removed after the welding process is completed. Because the electrodes are coated, the use of a shielding gas, which is often required in other welding methods, is not necessary in this case. This makes electrode welding one of the few blasting methods that can be carried out outdoors. Another advantage of electrode welding is that it is relatively inexpensive and easy to carry out. This makes electrode welding the most suitable welding technique for home improvement projects and quick welding jobs where the appearance of the end result is relatively unimportant.

TIG welding

Another commonly used method of welding is TIG (Tungsten Inert Gas). Whereas electrode is mostly used by home handymen and relatively quick, easy welding jobs, TIG welding is generally labeled as the most difficult welding technique. This is due to the fact that in TIG welding, when adding the filler metal, two hands are required throughout the welding process. While one hand is holding the welding torch, the other is adding the filler metal. This makes TIG welding more difficult to perform and also takes a relatively long time. On the other hand, TIG welding, when performed properly, gives the most beautiful result in terms of appearance. When detailed welding jobs have to be carried out, where appearance is an important factor, TIG welding is the preferred technique. In addition, TIG welding is a very clean way of welding, where slag and other debris will not readily form.

MIG/MAG welding

The welding technique that is generally considered the easiest is MIG/MAG welding. MIG-welding (Metal Inert Gas) and MAG-welding (Metal Active Gas) differ only in the type of gas used, but otherwise they work in exactly the same way. The welding technique is characterized by the use of a constant voltage, which creates an arc between the welding wire and the material. The welding wire serves primarily as an electrode, but when it melts it also serves as a filler material, making MIG/MAG welding a relatively much faster welding technique than the other methods of welding. As a result, MIG/MAG is one of the most widely used welding techniques in the welding industry and at large companies. However, given the fact that MIG/MAG is not allowed to be used outdoors and the material is also relatively expensive, this is not a technique that will be quickly employed by a home handyman. In addition, the amount of dirt is also relatively high compared to, for example, TIG welding.

Welding: the advantages and disadvantages

Welding is not the only way to attach two materials together. A connection with a bolt and a nut, for example, is also a possibility. Nevertheless, a welded joint has several advantages compared to other ways of joining.

First of all, a welded joint is very strong. Because there is continuity in both objects, the connection is hardly noticeable and one can rightly speak of a solid whole. In addition, a welded joint is relatively easy to apply. Whereas, when creating a connection using bolts and nuts, holes first need to be made in the material, this is not necessary when welding.

Although welding has many advantages, there are also disadvantages. A welded joint is permanent and cannot be disassembled. On the one hand, this can be seen as a great advantage, but when the various parts have to be disassembled after some time, it can still turn out to be a disadvantage. In addition, welding is not possible with all materials. As mentioned, welding is mainly carried out with steel, stainless steel and aluminum, but it is only possible when two more or less the same materials are used. When two different materials have to be joined together, welding is not an option. Also, as mentioned earlier, different welding techniques can produce slag and other debris, which must be cleaned after the welding process. Fortunately, MontiPower’s power tools offer the solution.

Welding cleaning with the Bristle Blaster® and MBX® MontiPower

The Bristle Blaster® and MBX® from MontiPower are the revolutionary tools in the field of surface preparation and cleaning. The hand-held tools are not only suitable for removing rust, coatings and dirt, but can also be used in weld cleaning, for removing slag and other residue. The precise and effective action of the rotating brush of the Bristle Blaster® and MBX® ensure thorough contamination without damaging the material. Not only after the welding process has been completed; cleaning of the metal may also be required before welding begins. When the object is covered with mill scale, rust or other dirt, its removal is necessary to achieve a perfect result. The power tools provide, both before and after the welding process, a fast, effective and also very easy cleaning.

What is steel preparation?

Steel is used in various industries for numerous reasons. In order to keep the quality of the steel as high as possible, it is necessary to clean and prepare steel products regularly. Moreover, the preparation of steel is essential before applying any new paint or other type of coating. Before this can be done properly and accurately, you must first remove any mill scale and thoroughly clean and prepare the current steel surface. In this way, the steel object is not only cleaned of rust and other dirt, but an adhesion layer for the new paint or coating is created. This steel preparation can have a major impact on the durability and condition of the steel surface.

Ways to prepare steel

Preparing and cleaning steel consists of several elements. First, steel preparation involves removing rust, mill scale and other dirt that may have developed. Not only dirt, but also any previously applied coating can be removed when preparing steel. There are different methods to achieve this result, each with their own advantages and disadvantages. The best known way of preparing steel is through blasting. This blasting is done with a combination of an abrasive and air under high pressure. The best known form of blasting is sandblasting, where sand is used as an abrasive, but over the years many other ways of grit blasting have been developed. You can think of blasting with glass or corundum, but also wet blasting by means of water. All methods of grit blasting have essentially the same effect. By applying a combination of air and the abrasive with great force on the steel object, an abrasive effect is created on the surface. The high force with which this happens not only removes the coating, mill scale, rust and other dirt from the steel, but also creates a profile on the surface, which serves as an adhesion layer for a new coating.

Disadvantages of steel preparation

Preparing and cleaning steel has been performed in the same ways for quite some time. Despite the fact that this has been done for many years, over the years more and more disadvantages have been encountered with the preparation of steel surfaces. These disadvantages are found in a number of factors. First, cleaning steel with grit blasting could be very damaging. This makes this method of cleaning unsuitable for more vulnerable surfaces. Partly for this reason, grit blasting is not easy to perform as an individual. The advice is to always let a professional do the preparation and cleaning of steel, to be guaranteed of a good result. However, this makes grit blasting a relatively time-consuming and also very expensive job.

Another disadvantage of grit blasting, is that it is not only hard on the steel surface, but also on the health of humans and animals. This is especially true of blasting with sand as the abrasive. As mentioned earlier, the abrasive is applied to the steel with great force. Because this is done with such force, the sand grains disintegrate into small particles. These particles can easily be inhaled by people and animals, causing unpleasant health and respiratory complaints. Partly because of this, blasting with sand has been prohibited in many countries for decades.

Preparing steel with the power tools MontiPower

With the arrival of MontiPower power tools, an alternative to sandblasting and other methods of cleaning and preparing steel is finally on the market. The Bristle Blaster® and MBX®, with their specially developed technology, provide a clean steel surface with also roughness profile comparable to the surface created after grit blasting. In this way, the power tools from MontiPower offer all the advantages of the traditional techniques for the preparation of steel, excluding all the previously mentioned disadvantages that they entail. For example, the manually operated Bristle Blaster® and MBX® are easy to use yourself, so you are not dependent on external parties. Moreover, the operation of the power tools is highly effective and precise, saving you not only money, but also time.

How do the Bristle Blaster® and MBX® work?

Powertools Bristle Blaster® and MBX® work through a patented technology. The power tools are equipped with a rotating brush, which in turn are equipped with specially designed curved brush tips. Through these curved points, the steel is prepared and cleaned with the same effect as with traditional techniques. This works as follows: during the rapid rotation of the brush, the curved brush tips are obstructed by a so-called ‘accelerator bar’. Because of this obstruction, the points are released with an extra large force behind the bar. Due to the great force involved in this process, the steel is accurately and quickly stripped of mill scale, rust, paint and other dirt. In addition, the heavy impact of the bent brush tips creates a new adhesive layer for a new coating.

Cleaning steel before painting

Before a new coat of paint can be applied to a steel surface, it must first be stripped of the old coat of paint. In addition, over time rust and other dirt may have formed on the steel, which will also have to be removed. The question then becomes: with what and how should rusty steel be cleaned before painting? The answer to this question has become a lot simpler with the MontiPower power tools. The Bristle Blaster® and MBX® are the tools for cleaning steel before applying paint, since they create the prefect adhesion layer for a new coating.

Preparing stainless steel before painting

Due to the many advantages that it brings, stainless steel is increasingly being chosen in many industries. A characteristic of stainless steel is that it often has a smoother structure than in comparison with regular steel surfaces. Before applying a (new) coat of paint, it is therefore of great importance to prepare the stainless steel, to allow the new coating to adhere as well as possible. This is where MontiPower comes into play. Stainless steel surfaces can easily be prepared to achieve a surface roughness of at least 50 microns and a minimum cleanliness of grade 2, in accordance with BS 7079:Part 1A. MBX® offers a finer roughness Ra of approximately 10-30 microns. In this way, the stainless steel is easily and quickly prepared for the new coat of paint and also made ready for welding.

Preparing galvanized steel for painting

Galvanized steel is steel that has a layer of metal on the outside. In most cases, zinc, nickel or chromium is used to protect the steel from corrosion and to improve its appearance. Galvanized also needs to be prepared before painting, because the new coat of paint will most likely come off over time. As with regular steel and stainless steel, MontiPower’s power tools offer a solution here as well. Preparing the galvanized steel with the Bristle Blaster® and MBX® effectively prepares the surface for a new coating or paint.

Abrasive blasting: everything you need to know

Abrasive blasting is a technique that has been used for many years. Although using loose abrasives for blasting is a very common practice, this method also has its drawbacks. These disadvantages are a thing of the past with the power tools from MontiPower for spotrepair and maintenance.

In this article, we will tell you everything you need to know about abrasive blast cleaning. And moreover, what are those drawbacks? And how do MontiPower’s power tools serve as an alternative for loose abrasive blasting?

What is abrasive blasting?

What is abrasive blasting exactly? In simple terms, abrasive blast cleaning refers to the process of using pressurized air, combined with either dry abrasive particles or abrasive particles mixed with water, to shoot at a part or surface. This technique is also known as sandblasting or grit (garnet) blasting, because silica sand is (one of) the most popular abrasives. Blasting with abrasives is often used to clean, treat or process different types of surfaces – such as steel or other metals.

Traditionally, sandblasting has been the most commonly used method of blasting. Over the years, more and more different techniques are available to replace this. Think of blasting with, for example, steel grit, glass or plastic. The blasting media, in combination with air, is blasted onto the object with great force. Broadly speaking, all these ways of abrasive blasting work in the same way.

What is abrasive blasting used for?

Now you know what it is, but what is abrasive blasting used for? Due to the impact of the blasting material, a layer gets removed from the surface. The use of abrasives during blasting creates a hammering effect, which can remove rust, mill scale, lacquer and other coatings from the surface. This not only cleans the object, but also creates a structure in the surface, which can serve as an adhesive layer for a new coating. In short, if you’re looking for a way to clean surfaces and prep them, abrasive blasting is a commonly known practise as per the ISO and AMPP standards for thorough cleanliness results.

Health risks and other dangers

The use of sand in blast cleaning is decreasing further and further. This is due to health risks and other dangers, which have increasingly come to light over the years. In some countries, including the Netherlands, it is even forbidden to blast with sand because of the dangers. Research showed it’s harmful for the health of humans and animals.

Due to the great force with which sand is blasted onto the surface, these sand grains break down into minuscule pieces. The particles are so small that they can easily be inhaled, causing respiratory and other health problems.

Alternative tools to abrasive blasting: the Bristle Blaster® and MBX®

The Bristle Blaster® and MBX® from MontiPower are the new developments in the field of surface preparation. Due to the specially developed technology with patented brushes, the power tools are the perfect alternatives for the existing blasting equipment.

With the use of the Bristle Blaster® and MBX® from MontiPower, blasting with different types of loose abrasives is a thing of the past for smaller areas and difficult to access areas. The tools are easy to use, are – unlike blasting – completely safe and very effective. Not only in cleaning surfaces, but also in processing them.
With their impact, the brushes of the power tools create a profile on the surface that can be compared to the surface profile that is created after blasting. In this way, MontiPower tools are the ideal alternative to sandblasting.

How do MontiPower abrasive brushes work?

The Bristle Blaster® and MBX® from MontiPower are hand-operated tools, which are equipped with a rotating brush. These specially designed brushes are characterized by their sharpened flexible tips with kneed ends.
By rotating the brushes at a low RPM, the different types of surfaces are processed and cleaned easily, quickly and effectively. The kneed tips of the brushes play an important role in this. These points are held back for a very short time during the rotation of the Bristle Blaster Brush by the so-called ‘accelerator bar’. Due to this short interruption, the points – partly due to the high speed at which the brush rotates – are released with great power from behind the accelerator bar. This technique ensures that the curved tips of the brushes are immediately retracted upon contact with the surface, effectively cleaning the surface and also providing it with the characteristic micro-structure. It makes MontiPower tools the ideal surface preparation method for many sectors, and a great alternative to blasting with abrasives.

Alternative to blasting with abrasives in different sectors

With their many advantages, our power tools ensure that they are the ideal alternative to cleaning with abrasives for many markets. As mentioned, the traditional ways of blasting can be harmful to humans and animals, but also damaging to the environment. It makes the Bristle Blaster® and MBX® from MontiPower, among other things, an excellent alternative for surface preparation in the maritime and industrial sector.
In addition, the convenience and effectiveness of the various power tools play an important role in many sectors. A good example of this is the work in public infrastructure. The blasting of bridges, tracks and highways, among other things, is a very time-consuming and labor-intensive job, which is subject to a lot of pressure because of the time. When blasting these objects, workers are also exposed to various small particles and possible chemicals. With the use of the Bristle Blaster® and MBX® from MontiPower, abrasive blasting is a thing of the past.

Cordless, a contractor’s delight

During the Press Conference of 8^th of December 2020, Frits Doddema, CEO of the Monti Group, for MontiPower explained to the press the motivation to join the alliance.

For surface preparation at heights and at difficult to access objects cordless means double freedom. Freedom to contractors to use batteries of other CAS members and freedom without the hassle of loose cables or hozes. MontiPower offers 5,5Amp and 8Amp/18V batteries to power their new Bristle Blaster Cordless and the new wearless Vinyl Zapper Ultimate based on the new MontiPower patented adaptor system.

You can read the whole statement of CAS here.