In this Peak Times Moments, we visit an area with a mixture of cities, towns, villages and open countryside: Wales. Amidst this captivating backdrop, our latest field trial came to life, offering a profound analysis of a project that sought to explore the intriguing comparison of Bristle Blaster® VS Grit Blasting.
This field trial, led by Kevin Jones, formerly the Senior Technical Manager at Wales & West Utilities, ventured into real-life scenarios, gathering data and uncovering valuable insights. With a focus on practical applications, this comprehensive analysis offers a fresh perspective for professionals seeking innovative solutions.
Wales & West Utilities, a leading utility company headquartered in Newport, Wales, operates in both Wales and the south-west of England, bearing the vital responsibility of delivering gas to over 7.5 million people across its extensive service area. With a strong emphasis on safety and reliability, the company ensures that its customers receive an uninterrupted gas supply and round-the-clock emergency services for any gas-related incidents.
The Bristle Blaster® field trial results, have yielded noteworthy outcomes. This innovative surface preparation technique has demonstrated its effectiveness, showcasing distinct advantages over traditional methods like grit blasting.
Coating Removal Guide: Surface Preparation for Coatings & Sealants
Every specific coating depending on it’s adhesion mechanism has it’s specific needs for surface profile. We like it uniform by density, regularity, and angularity. Via Keyence 3D analytical optic scans, the surface can be checked by hundreds of parameters. In this book we concentrate on Rpc, Rz and Ra values.
Bristle Blasting is a mechanical surface preparation technique designed to remove corrosion, rust, mill scale and other contaminants from metal surfaces. Unlike traditional methods that rely on abrasive materials such as sand or grit, Bristle Blasting uses a unique approach using rapidly rotating, flexible wire brushes.
BRISTLE BLASTING
When it comes to surface preparation for painting or coating applications, traditional methods such as sandblasting and chemical cleaning have long been the norm. However, in recent years, the revolutionary technique of the Bristle Blaster® has gained popularity for its effectiveness and environmentally friendly features. In this article, we will take a closer look at what Bristle Blasting is, how it works, and why it has become a game-changer in the world of surface preparation.
HOW DOES BRISTLE BLASTING WORK
The process involves the use of the Bristle Blaster® equipped with rotating brush tips. The brush tips of the Bristle Blaster® are designed to strike the affected surface with kinetic energy, which is equivalent to standard processes that use grit-blasting media. When in contact with the surface to be treated, the brushes mechanically remove rust, scale and other unwanted materials from the substrate.
BENEFITS OF BRISTLE BLASTING:
Environmentally friendly: Bristle Blasting generates minimal waste, making it an environmentally friendly option compared to traditional methods that often produce harmful dust and debris.
Improved Surface Profile: Because of the flexibility of the brushes, the Bristle Blaster® is able to adapt to irregular surfaces, providing a consistent and improved surface profile for better adhesion of coatings.
Cost Effective: Bristle Blasting is cost effective due to reduced downtime and less waste disposal, ultimately saving both time and money.
Minimal Surface Damage: Unlike abrasive blasting methods that can sometimes damage the substrate, Bristle Blasting is gentler on the surface, extending the life of the material.
Versatility: Bristle Blasting can be applied to a wide range of materials, including steel, aluminum and concrete, making it a versatile option for various industries.
APPLICATIONS OF BRISTLE BLASTING:
Bristle Blasting finds applications in industries such as marine, oil and gas, construction and manufacturing, where surface preparation is critical for coatings, painting or welding processes. It is particularly valuable for removing corrosion from ship hulls, oil platform components, bridges and storage tanks.
ADVANCED SURFACE PREPARATION
In summary, Bristle Blasting is an advanced surface preparation technique that offers numerous advantages over traditional methods. Its environmentally friendly nature, cost-effectiveness and versatility make it a valuable tool in industries where surface quality and longevity are paramount. As technology continues to evolve, Bristle Blasting is likely to become even more important as a solution for achieving optimal surface preparation results.
If you are considering surface preparation for your next project, exploring Bristle Blasting as an option could lead to significant efficiency and performance benefits.
BRISTLE BLASTER®
The patented Bristle Blaster® is the world’s first hand-operated brush belt system that compares to sandblasting in quality of surface roughness, and in results. The Bristle Blasting process is a new innovation that both removes corrosion, and generates an anchor profile using specially designed rotating brushes. The Bristle Blaster® consists of wire brush tips bent forward and dynamically matched to power tools operating at approximately 2,500 rpm.
Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
Surface preparation equipment is essential for achieving high-quality results in various industries. From removing rust and old paint to creating a smooth surface for coatings, these equipment play a crucial role in ensuring durability and longevity of the final product. Whether you are working on automotive, construction, or industrial projects, having the right surface preparation equipment is vital.
With advanced technology and innovative features, the Montipower surface preparation tools make the preparation process faster, more efficient, and safer. Invest in reliable surface preparation equipment to enhance productivity, save time, and deliver exceptional results that meet the highest industry standards.
MontiPower’s Bristle Blaster® and MBX® are revolutionary tools in the field of surface preparation. For example, it is the only hand-held power tool in the world that can “sandblast”. The patented technology removes corrosion and coatings quickly and thoroughly, but that’s not all. The Bristle Blaster® and MBX® also createsurface preparation grades comparable to Sa2½ (SSPC-SP 10/NACE No. 2) to Sa3 (SSPC-SP 5/NACE No. 1) and roughness levels as high as 120 µm Rz.
SURFACE PREPARATION WITHOUT BLASTING
MontiPower®’s various power tools are a phenomenal breakthrough when it comes to “blasting without abrasive“. Partly because of this, the power tools are seen as the perfect alternative to sandblasting. Despite the fact that sandblasting has been practiced for many years, several disadvantages to this method of surface preparation have come to light over the years. For example, sandblasting is not easy to perform yourself, making it a relatively expensive and time-consuming job to outsource to a professional. In addition, sandblasting is very persistent. Not only for the surface to be prepared – which can damage it – but also for the health of people, animals and the environment. Thedangers of sandblasting have even led to a ban on sandblasting in many countries, so other blasting media are now mostly used. With the arrival of MontiPower’s surface preparation tools, sandblasting will soon be a thing of the past. The patented properties of the Bristle Blaster® and the MBX® have formed the basis for new product series for surface preparation.
SURFACE PREPARATION WITH THE BRISTLE BLASTER®
When it comes to surface preparation for painting or coating applications, traditional methods such as sandblasting and chemical cleaning have long been the norm. However, in recent years, the revolutionary technique of the Bristle Blaster® has gained popularity for its effectiveness and environmentally friendly features. In this article, we will take a closer look at what Bristle Blasting is, how it works, and why it has become a game-changer in the world of surface preparation.
Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
Soda blasting is a mild form of abrasive blasting using sodium bicarbonate particles and compressed air, which has a gentler effect than sandblasting.
Soda blasting involves the use of compressed air to blast particles of sodium bicarbonate with a much lower intensity than traditional abrasive blasting techniques, such as sandblasting. Soda blasting is a more gentle form of abrasive blasting. It is used to clean, strip and finish surfaces in which it causes less damage and doesn’t create hazardous substances or dust.
WHAT IS SODA BLASTING?
Soda blasting is a type of abrasive blasting which uses sodium bicarbonate (baking soda) as its abrasive media. This method is often used to remove paint or other surface coatings from different surfaces. Additionally, it is a non-chemical, non-abrasive, non-toxic, and non-destructive way to clean and restore surfaces to a like-new finish. Soda blasting has been used on a variety of surfaces from antiques to industrial parts. In addition, this method is much more eco-friendly than traditional sandblasting as it does not cause the environment damage that sandblasting can.
HOW DOES SODA BLASTING WORK?
Soda blasting works by shooting pressurized sodium bicarbonate particles particles, also known as baking soda, through a high-pressure nozzle onto a surface. The soda strips away dirt without damaging underneath, due to its low impact. It is a useful technique that can clean many surfaces, especially delicate ones without causing harm.
ADVANTAGES OF SODA BLASTING
The advantage of soda blasting is that it causes much less damage in comparison to other forms of abrasive blasting. It is also much cleaner and environmentally friendly.
DISADVANTAGES OF SODA BLASTING
There are some disadvantages with this soda blasting, the potential for hazardous dust exposure, the risk of intensifying surface contamination, and the potential for costly overspray. Soda blasting is not recommended for surfaces made of electrical equipment, wood, soft metals or plastic since it could damage these materials.
COMMON TOOLS FOR SODA BLASTING
There are several tools used when soda blasting, an air compressor, an air cooler and moisture separator, a blast pot, hose and nozzle.
WHAT MEDIA IS USED FOR SODA BLASTING?
The media used for soda blasting is sodium bicarbonate particles, the three commercial grades are the Natrium 150, Natrium 260 and Natrium 300, with the number representing the approximate median particle size in microns.
IS SODA BLASTING SAFE?
Soda blasting is a safe and eco-friendly method for removing paint and rust from surfaces. The baking soda used is generally perfectly safe, so there’s no risk of exposing the environment—or yourself—to any harmful substances. In comparison to sandblasting, soda blasting is way more safe for the environment. It is also non toxic and non abrasive.
ALTERNATIVE TOOLS TO SODA 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.
Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
Dry ice blasting, or CO2 blasting is a technique of cleaning where solid CO2 is accelerated in a pressurized air flow and focused on a surface to clean it.
This technique is a very clean alternative compared to other blast cleaning methods. It can be used to clean surfaces. It is used to get rid of dirt, oil, paint, or strip pollutants from a surface. Dry ice blasting doesn’t cause contaminants to build up in the waste and dramatically lowers the secondary waste that needs to be thrown away.
WHAT IS DRY ICE BLASTING
Dry ice blasting is a process which utilizes solid carbon dioxide (CO2) pellets, known as dry ice, blasted at high speeds to clean surfaces. This method is sometimes referred to as dry ice cleaning, cryogenic blasting, or CO2 cleaning. When the pellets hit the surface the dry ice sublimates (or goes from a solid state into gas) and loosens dirt, oil, grease, and other contaminants.
This process can be used to clean a variety of surfaces, from nonporous surfaces such as metals, chrome, machinery, and conveyor belts to porous surfaces such as carpets and upholstery. Dry ice blasting is a dry and non-abrasive process that is safe and effective for a variety of industrial and commercial applications.
HOW DOES DRY ICE BLASTING BLASTING WORK?
As mentioned before, dry Ice Blasting is a clean blasting technique that is used across many industries. Dry Ice blasting is a cleaning and surface preparation method that works on the principle of accelerated particles making contact with a surface and sublimating, or evaporating, on contact.
To perform Dry Ice blasting, solid CO2 particles are propelled using compressed air onto any surface, where the particles sublimate on contact, taking any unwanted debris from the surface. The method is highly effective and safe for the environment because the particles leave no chemical residue and typically present no secondary waste disposal problems. For these reasons, Dry Ice blasting is one of the most successful blasting techniques out there, and is suitable for a variety of industrial and commercial applications.
ADVANTAGES OF DRY ICE BLASTING
The main advantage of dry ice blasting is that it is a non-abrasive form of cleaning. This means that it will not damage the surface to be cleaned, while still being effective at removing dirt and grime. Additionally, dry ice blasting does not require the use of chemicals or water, so it is more energy efficient and environmentally friendly.
DISADVANTAGES OF DRY ICE BLASTING
One of the main drawbacks of dry ice blasting is its cost. This method can be more expensive than other forms of blasting since it requires specialized equipment and training. Additionally, as it is a cryogenic technology, the extreme cold temperatures produced by dry ice can damage delicate components of the item being cleaned. Dry ice is also a relatively limited resource since it only exists in places where it is mined or produced.
COMMON TOOLS FOR DRY ICE BLASTING
Dry ice blasting requires specialized equipment such as high pressure cleaners, blasting wand and safety equipment. This makes it less flexible in comparison to our Bristle Blaster® and MBX®. This means that the cost for equipment used for dry ice blasting is high so this is a huge disadvantage.
WHAT MEDIA IS USED FOR DRY ICE BLASTING?
The media used for dry ice blasting is solid carbon dioxide (CO2) pellets. They are rice grain shaped and have a diameter of 2-3 mm. It is also known as frozen CO2.
IS DRY ICE BLASTING SAFE?
Dry Ice Blasting is a safe and non-toxic solution for a variety of different industries. This form of media blasting utilizes dry ice pellets to clean and degrease a variety of surfaces. At temperatures of -109 degrees Fahrenheit, dry ice pellets lower the surface of what they clean to temperatures too cold for bacteria, mold, and other contaminants to survive. This makes dry ice blasting a safe, non-toxic, and effective alternative to traditional dry media blasting or chemical solutions. Additionally, dry ice blasting produces no waste or run off, thus allowing for a low-impact solution to many industrial cleaning needs.
ALTERNATIVE TOOLS TO DRY ICE 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.
Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
There are several types of blasting methods, in this article we will tell more about the differences and different types of blasting methods.
Bristle blasting
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.
Bead blasting
Bead blasting has become an increasingly popular method of surface treatment. It is an effective and efficient method for removing dirt and oxidation from different materials.
There are varioussurface preparation techniques available to use and choose from. Abrasive blasting is the most well-know form of surface preparation. This method is often used for removing coatings, mill scale, paint and other dirt. In most cases, abrasive blasting involves applying air and an abrasive media with great force to the surface. This results in the removal of the material from the object. There are many different types of media to blast with. A few examples of blasting techniques with different media are: sandblasting, vapor blasting, vacuum blasting, wheel blasting and bead blasting. All these options have their own advantages and disadvantages. It this article, we will focus on bead blasting.
Centrifugal blasting
Centrifugal blasting is a type of surface finishing process where a metal surface is blasted by an abrasive material that is propelled by a centrifugal force. The process sprays the abrasive material onto the surface at a high velocity. This process is commonly used to remove scale, corrosion and burrs from a metal surface. In addition, it can be used to clean, roughen or texturize a surface or as a form of shot peening. Centrifugal blasting also provides a unique way to etch and debur surfaces. Many surface preparation projects may require manual cleaning if centrifugal blasting is not used.
Dry ice blasting
Dry ice blasting, or CO2 blasting is a technique of cleaning where solid CO2 is accelerated in a pressurized air flow and focused on a surface to clean it.
This technique is a very clean alternative compared to other blast cleaning methods. It can be used to clean surfaces. It is used to get rid of dirt, oil, paint, or strip pollutants from a surface. Dry ice blasting doesn’t cause contaminants to build up in the waste and dramatically lowers the secondary waste that needs to be thrown away.
Pencil blasting
Pencil blasting is a process of using a technique similar to “burning in” with a pencil-shaped brush. This type of blasting is often used as a way to get into areas of difficult access where heavier sandblasting is not recommended or possible. By choosing the correct material, size and shape of the media used in the process, it is possible to achieve clean, smooth finishes with minimal to no warping or crack damage. It is a common choice for the repair or blasting of raw metals, masonry, wood, plastic and other materials, as it is a more gentle and precise process than heavier blasting methods.
Sandblasting
Sandblasting involves blasting a combination of sand and air under high pressure onto the surface that has to be prepared or cleaned. Due to the high force with which the sand is applied to the surface, mill scale, dirt or any coatings are easily removed. Moreover, the sand creates a structure in the surface, which makes it easy to apply a new layer. However, despite its advantages, sandblasting also has a large number of disadvantages. For example, sandblasting is very dangerous to our health. But why is sandblasting actually so dangerous? And what are the risks?
Soda blasting
Soda blasting is a mild form of abrasive blasting using sodium bicarbonate particles and compressed air, which has a gentler effect than sandblasting.
Soda blasting involves the use of compressed air to blast particles of sodium bicarbonate with a much lower intensity than traditional abrasive blasting techniques, such as sandblasting. Soda blasting is a more gentle form of abrasive blasting. It is used to clean, strip and finish surfaces in which it causes less damage and doesn’t create hazardous substances or dust.
Steel grit blasting
Steel grit blasting is a process where metal is blasted with a small amount of compressed air and steel particles. This process can be used to clean, strip, and prepare surfaces before a fresh coat of paint or finish can be applied. The steel grit blasting process is a popular choice for many projects since it is both less abrasive and cost effective. Additionally, steel grit blasting is versatile and can be used on many different surfaces. This process is often used on metals, plastics, and wood. The steel grit blasting process is a quick and effective way to change the look of a surface by removing rust, old paint and any other contaminants that may have collected on the surface over time.
Vacuum blasting
Vacuum blasting is an abrasive blasting process that uses a vacuum to capture material during the blasting process. This process is gaining popularity in many industries due to its ability to reduce air pollution, dust, and other airborne hazards. Vacuum blasting is a dry process meaning that little or no media, cleaning agents, or water are used in the blasting process. Vacuum blasting works by using large amounts of vacuum pressure to capture the blasting media as the blasting takes place. The vacuum then filters, cleans and collects the blasting media, making it possible to reuse the same media for multiple jobs. Vacuum blasting is an effective and environmentally-friendly option for surface cleaning, paint and rust removal, and most other abrasive blasting applications.
Wet blasting
Wet blasting is a process used for the surface preparation of metals, plastics, or other materials. During this process, a high-pressure abrasive slurry is delivered to the surface. This slurry is composed of a mix of an abrasive (such as aluminum oxide or silicon carbide), water, and a detergent (which helps keep the slurry suspended and separates the abrasive debris from the surface being treated). The combination of the high-pressure stream and the suspended abrasive in the slurry blasts the surface, providing a superior surface finish that can be used for various finishes or preparation for powder coating or other processes. Wet blasting is a much more efficient process than dry blasting and produces less dust and debris, making it ideal for use in sensitive environments such as aerospace or electronics.
Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
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Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
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Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
I am text block. Click edit button to change this text. Lorem ipsum dolor sit amet, consectetur adipiscing elit. Ut elit tellus, luctus nec ullamcorper mattis, pulvinar dapibus leo.
Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
Galvanized steel is a widely used material in many industries. But what is galvanized steel, how does it differ from non-galvanized steel and what are the different ways of galvanizing steel.
What is galvanized steel?
There are many advantages to using steel in general. For example, steel can be used in many situations and is known for its strength. Yet, it also has disadvantages. For example, steel can rust over time, which reduces the quality and appearance of the steel object. To counteract this, the steel can be galvanized. This involves applying a thin layer of zinc to the steel by means of a chemical process. This protective layer ensures that the steel is less likely to rust, making the material last longer. In addition, zinc coating makes the surface less likely to be scratched, which is why many people find galvanized more attractive than the non-galvanized variety.
Ways of galvanizing steel
When steel is brought into contact with molten zinc, a chemical reaction occurs, causing the zinc to adhere to the steel surface. Over the years, different ways have been developed to initiate this galvanizing process. The technique most commonly used for this is termite galvanizing. This involves immersing the steel in molten zinc at a temperature of around 460 degrees Celsius, whereby the chemical reaction mentioned earlier takes place and the protective zinc layer adheres to the steel surface.
Other common techniques for electroplating steel are:
Electrogalvanizing: this involves placing the steel in a zinc solution, after which an electric current is passed through it. This creates a relatively thin but very strong and uniform galvanizing layer.
Mechanical plating: the steel is stirred together with zinc powder and a special galvanizing agent in a drum. Because the different materials touch each other during this process, a thin layer will be formed on the steel.
Scraping: this involves passing zinc through a spray gun in which it is liquefied. The liquid zinc can then be applied to the steel with the spray gun, provided it has been cleaned properly in advance.
Diffusion galvanizing: the steel is heated to around 400 degrees Celsius together with a zinc powder. The diffusion process that is hereby set in motion between the zinc and the steel ensures that an even layer of zinc is applied to the steel.
Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
Corrosion of steel pipelines is a common process that is unfortunately difficult to counteract. To keep the condition of the pipelines intact, it is necessary to remove the corrosion in time. When the corrosion is more persistent, the choice is often made to replace the pipeline in its entirety. A demanding and also expensive job, costing billions of dollars per year worldwide.
There are various types of corrosion in pipelines. Each type has its own characteristics and ways to combat it. But what is corrosion exactly? How does corrosion occur in pipelines? And what are the different types of corrosion that we can distinguish?
What is corrosion?
Corrosion is a deterioration of metal as a result of a chemical process. This chemical reaction is caused by contact with various factors from the environment. Often corrosion is confused with rust. However, corrosion is a broader concept than corrosion. With rust, the deterioration of the surface occurs specifically through a reaction of oxygen in combination with damp. As a result, the well-known visible brown layer appears on the metal surface. With corrosion, this deterioration can be caused by a chemical reaction of several factors. There are various forms of corrosion in pipelines. But what are the most common types of corrosion in pipelines, and what characterizes these types of corrosion?
Oxygen corrosion
Oxygen corrosion is the other name for the already mentioned rust. It is the most common and also the most visible type of corrosion in pipelines. As mentioned, oxygen corrosion is caused by a chemical reaction between oxygen and water or another form of damp. From this reaction, a so-called oxide skin is formed, which we know better as the brown layer that attacks the metal surface. An important characteristic of the oxide skin of oxygen corrosion is the open structure of the layer. This ensures that oxygen and water continue to reach the surface easily, so that the steel will slowly but surely become completely corroded. For this reason, stainless steel or aluminum is used more often in various sectors; these materials have a denser oxide skin, which makes oxygen corrosion less likely to occur.
Uniform corrosion
Uniform corrosion is broadly comparable to oxygen corrosion. Uniform corrosion also results from a chemical reaction between damp and oxygen. This form is characterized by the – the name says it all – uniform distribution of the corrosion over the entire steel surface. Uniform corrosion is considered by many to be the least dangerous form of corrosion. By taking measurements or from previous experience, the speed and extent of corrosion formation can often be predicted well. As a result, the development and consequences of uniform corrosion can often be better estimated than those of other forms of corrosion in pipelines.
Acid corrosion
In the case of acid corrosion, the combination of acid and metal react together to form hydrogen gas and metal salt. To better understand this, it is good to first look at what is actually meant by acid. This has to do with the pH value of water. Normal drinking water has a pH value of between 7 and 9.5. Does the water have a pH value below 7? Then we speak of an acid. When this acid comes into contact with metal, corrosion occurs in the form of hydrogen gas and metal salt. The degree of corrosion depends on the tension of the material. Each material has its own voltage, which can cause a current to flow between several materials. If the voltage of the material has a lower voltage than hydrogen, acid corrosion occurs.
Galvanic corrosion
The voltage of metals that were briefly discussed in the case of acid corrosion also play a major role in galvanic corrosion. This type of corrosion can occur when two different metals are in close proximity to each other. If these metals come close together, in combination with water or a similar conductor, the reaction that is set in motion will result in corrosion. In this process, more corrosion will occur on the metal with a lower voltage than on the metal with a higher voltage.
Stress corrosion
Unlike, for example, oxygen corrosion, stress corrosion is very difficult to predict and only detect at a late stage. This form of corrosion occurs particularly with tension from within, for example with dents or welds. But this is not the only factor involved in stress corrosion. When the combination of chlorides, high temperatures and internal tension come together, stress corrosion will occur, and the material will crack. Whereas oxygen corrosion and uniform corrosion occur less quickly and frequently in RVS, stress corrosion occurs more frequently in RVS.
Stray current corrosion
Stray current corrosion is a form of corrosion similar to galvanic corrosion. Stray current is electric current that flows from a conductor back to the soil or surrounding environment. The difference from galvanic corrosion is in the fact that it is not the other metal, but the actual current from the conductor that causes corrosion to occur in the steel pipeline.
Pitting Corrosion
Pitting corrosion occurs in the oxide layer that may have developed in the steel pipeline. This form of corrosion occurs mainly in the areas where the oxide layer is damaged. In addition, pitting corrosion can also occur as a result of the incorporation of chloride ions or metal particles. The corrosion that occurs in the oxide layer causes small pits to form in the steel, but these are often barely detectable at first glance.
Crevice corrosion
Similar to pitting corrosion is crevice corrosion. In this case, the corrosion does not occur in damaged surface, but in cracks. When the surface comes into contact with a conductor and also makes electrical contact with the crack, crevice corrosion will occur. As with pitting corrosion, the corrosion will develop more and more strongly and the crack will become deeper and deeper.
Intergranular corrosion
Intergranular corrosion is one of the most insidious forms of corrosion. Due to the fact that this type of corrosion is molecular, it is not or hardly visible to the naked eye. On the surface of the steel pipeline, little or no corrosion occurs, but from the inside the material is increasingly corroded. This causes the metal to become increasingly brittle, which in turn causes the metal to lose its cohesion and may eventually cause major damage.
Microbial corrosion
Microbial corrosion is one of the most unknown forms of corrosion. Nevertheless, this form of corrosion is very relevant to steel pipes, as microbacterial corrosion is especially common in pipelines. This has to do with the fact that in most cases, the bacteria thrive in oxygen-free spaces. The corrosion is caused by the bacteria secreting a substance, which has a corrosive effect on the steel. Microbacterial corrosion is most comparable to acid corrosion, but in this case the corrosion is not caused by an acid but by the bacteria.
Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
Preparing metal for painting is essential to ensure the quality and durability of paint coatings. Metal surfaces are known for their long life and the minimal maintenance they require, but even the most best metal coating technologies will fail without adequate preparation. If this is not done properly, the new paint layer will not adhere well to the metal, causing it to come off and peel sooner or later. Thus, good metal preparation for paint is essential in order to achieve a perfect result.
With the tools from MontiPower, proper prepping metal for paint becomes more efficient. With our exceptional, patented technology you can prepare metal in fewer steps than with traditional techniques. Preparing metal for painting has never been easier!
Preparing metal for painting: the essential steps
Usually it is said that preparing metal for painting has to be done in at least 4 steps.
1. Clean the surface
2. Remove paint
3. Remove rust
4. Prep the surface
5. Removal of contaminations
Only after all these steps can you start applying a new coating of paint.
What to prep metal with before painting?
Prepping metal prior to painting has several phases. To start with, it is important that dirt, paint, mill scale and other coatings or vinyls are properly removed. But what is the best way to clean metal before painting? There are a number of different options available, each with its own advantages and disadvantages.
Traditionally, metal is cleaned and prepared by means of abrasive blasting prior to the application of a paint layer. Loose Abrasive Blasting is the application of a combination of air and an abrasive under high pressure in order to clean the metal and remove coatings and dirt. Different abrasives can be used for this purpose. The original and best known form of blasting is ‘sandblasting’, but over the years many other blasting techniques have been developed. These include glass or corundum blasting, as well as wet blasting.
Sandblasting and blasting with other abrasives are widely used techniques because of the effective effect they have. Because of the great force with which the abrasive is applied to the metal, dirt and coatings like are thoroughly removed from the metal. Because this is done at such a high pressure, the metal surface is also given a surface profile by the violent impact of the abrasive that can be used as a bonding layer for the new paint layer to be applied. All these advantages of blasting suggest that it is the ideal way to clean metal before painting, but nothing could be further from the truth.
Blasting, in addition to the advantages that it offers, also has its disadvantages. It can be harmful to nature, applicators and it can be costly. With our tools, the disadvantages that come with the traditional way of preparing metal for painting, are thing of the past.
Prepping metal for paint with the Bristle Blaster® and MBX®
We went in search of a more convenient and more efficient way of preparing metal surfaces. With our Bristle Blaster® and MBX® you can perform multiple types of preparation work with one tool. Clean the surface, remove loose and remove paint and rust, all with one tool. All you have to do, is install the right type of brush.
How does this work?
The Bristle Blaster® and MBX® work using a specially developed, patented technology. MontiPower’s power tools are characterized by a rotating brush with kneed bristle tips. These springwire tips are designed in such a way as to work on the metal surface with a kinetic energy, comparable to traditional sandblasting.
In addition, the power tools are equipped with a so-called ‘accelerator bar’ which the bristle tips get stuck behind for a short time during rotation. This very brief hitch in the rotation ensures that the tips penetrate the metal surface with extra-high force. This not only cleans the surface of dirt, rust and coatings easily and effectively, but also creates a microprint that serves as a profile to promote adhesion for the paint to be applied.
In short, with our tools, you simplify preparing metal for paint to 1 simple step:
1. Use MontiPower’s power tool to remove loose paint and rust, clean and prep the surface; all at the same time
Prep metal for paint with consideration for people and the environment
The Bristle Blaster® and MBX® are 100% safe for both people and the environment. Because the tools are an alternative to sandblasting, no material is used under high pressure. Also, MontiPower’s power tools are very easy to operate. This ensures that you can simply use the Bristle Blaster® and MBX® yourself if you want to start preparing metal for painting, saving you not only a lot of time, but also money.
Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
Surface preparation is defined as “the cleaning or preparing of the metal surface prior to the application of a coating.” In practice, surface preparation embraces many things, which fall under this term. For example, the removal of mill scale , rust, removal of imperfections, removal of existing coatings and or other contaminants. The creation of a profile on the metal surface also falls under the preparation of surfaces. In this way a good adhesion layer is created between the object and the coating that is applied to it.
It can be performed by using chemicals to clean and treat the surface, or by using mechanical methods to alter its texture or remove unwanted substances such as weld spatters. To prepare materials like (stainless) steel, aluminium and wood, different surface preparation techniques can be used.
The importance of surface preparation
Surface preparation is necessary for applying a (new) coating to a surface. The preparation ensures that the new layer will adhere well, which improves the durability of the coating in case the coating is depending on thorough cleanliness and a certain surface profile to long-term adhesion. To achieve this, old layers such as paint, mill scale, rust and other dirt need to be removed from the surface. Moreover, surface preparation not only removes dirt; it also creates a profile on the surface, which serves as an adhesion layer for the new coating.
The phases of surface preparation
Surface preparation has several phases. In order to achieve the best possible result, it is important – regardless of the technique used – that these phases follow each other closely and are carried out properly. In total, six steps can be distinguished:
1. Assessment of the condition
2. Coating removal
3. Removal of surface contaminants and restore imperfections
4. Removal of loose dirt
5. Apply adhesion profile to the surface
6. Dry the surface
Assessment of the condition
Before the surface preparation can be started, it is important to assess the current condition of the material. Based on this, it can then be determined what needs to be done and what technique will be used for the surface preparation. If this is not done or done carelessly, it can cause damage to the material later in the preparation process.
Coating removal
Before the surface preparation can be started, it is important to assess the current condition of the material. Based on this, it can then be determined what needs to be done and what technique will be used for the surface preparation. If this is not done or done carelessly, it can cause damage to the material later in the preparation process.
Removal of surface contaminants
Not only the old coating; other dirt that has developed on the surface must also be removed. Over time, for example, rust, mill scale and other dirt may develop on the surface. As with the removal of the old coating, it is also important to remove these contaminants such as dirt, grease, fat and salts from the surface. If this is not done properly, it can also lead to adhesion problems of the new coating.
Removal of loose dirt
Besides the fact that rust, mill scale and other adhesion problems can occur, a surface often also has to deal with loose dirt. This can include flaking or crumbling pieces of the old coating. These too must be removed during the surface preparation process in order to ensure proper adhesion of the new coating.
Apply a surface profile to the surface
Once the old coating and all types of dirt have been removed, it is time to apply a new profile on the surface. When a proper new surface profile is applied, the new coating will adhere better than on a smooth surface in case a specific coating is depending on this anchoring profile.
Dry the surface
Once the adhesion profile has been applied to the surface, it is time for the sixth and final step of surface preparation: drying. New coatings will, in most cases, adhere better to a dry surface than to a wet surface. If the coating were applied to a wet surface, small grains will form in the material as it dries. To avoid this, it is necessary to dry the surface thoroughly first. If the six steps of surface preparation are performed accurately and carefully, the chances that the new coating will adhere nicely to the surface will be greatly increased.
Surface preparation techniques
Over the years, many surface preparation techniques have been developed. In most cases, traditionally, surfaces are mostly prepared by blasting, but dry cleaning and fire blasting are also possibilities. But how do these methods actually work, and what exactly do they involve?
Blast cleaning methods
One of the most common methods for surface preparation is blasting. The surface is prepared with a combination of air and a loose abrasive. Originally this was mostly done with sand, but this has been banned in many countries. Nowadays, blasting is also done with special abrasive grains or other materials. The grains have an abrasive effect on the surface, which removes rust and other dirt from the object. Blasting is not only used for the removal of dirt; the impact of the grains in the surface also creates an adhesion layer for the new coating.
One type of blasting is spray blasting. This technique is often used on the more vulnerable surfaces, but is in principle applicable to many materials. It works as follows: water is sprayed onto the surface with a rotating sprayer. This is not done under high pressure, but with mist jets, so that the spray slides over the object. Because of this low pressure with which the water is applied to the surface, this method of surface preparation is less efficient and also does not create a profile for the new adhesive layer.
You also have flame blasting. This involves holding a gas flame along the surface, which removes dirt and especially rust residue from the surface. However, this method of surface preparation is not very effective at removing all rust and often needs to be used alongside other techniques. In addition, improper use of the flame can quickly lead to surface damage with this type of surface preparation.
Chemical cleaning
Other common ways of preparing surfaces is chemical cleaning, which involves removing oil, dirt and other materials with detergents, solvents and other cleaners. This can be done with the following techniques:
– Degreaser/Cleaner: powerful cleaning solution that has to be poured directly onto the surface you want to clean. Then,
use a brush or cloth to scrub the solution onto the surface and rinse with water.
– Steam Cleaning: highly recommended for removing substances from large areas. Before applying any coatings, it is
crucial to ensure that the surface is completely dry and free from any residue.
– Alkaline Cleaning: effective for eliminating grease, fat, acid residue, oil, and other similar substances. With this
method, it’s also essential that the surface is completely dry and free from any residue before applying any coatings.
However, the chemical method of surface preparation can be very harsh due to the use of acid, both to the material and
to the environment and human health.
Preparing surfaces with power tools
MontiPower power tools are the solution to all your surface preparation problems. The tools of MontiPower do the same job as the usual techniques for surface prep, but better, more effective and without all the additional disadvantages.
Our specially designed technology with portable, semi-automatic machines not only ensures that the surface is cleaned, but also creates the roughness or surface profile for optimal adhesion layer for the new coating. It makes MontiPower’s power tools the alternative to ‘sandblasting‘ for smaller areas or when regulations do not allow the use of loose abrasives in the open field or where loose abrasive blasting is less productive.
We offer highly effective solutions for preparing surfaces with our Bristle Blaster®. Rust, paint, mill scale; removing the various types of dirt has never been easier. Moreover, with the use of MontiPower’s surface preparation tools, you are no longer dependent on external parties; from now on, you will be preparing surfaces all by yourself. With our wide range of rotating, patented bristles, you will always find a solution for your own specific situation at MontiPower. It makes an investment in MontiPower’s power tools the perfect investment that will save you both time and money in the short term.
Disadvantages of surface preparation
Some of the methods of surface preparation, like loose abrasive blasting and/or the use of chemicals, have been performed for many years. Yet, over the years, many of the disadvantages and dangers of sandblasting and various other methods have come to light.
Disadvantages of sandblasting
As mentioned earlier, “sandblasting” is a widely used technique for preparing substrates. However, the sand – or other blasting grains – in many cases are too cumbersome for smaller coating jobs. Because some materials are more difficult to process than others, it is recommended that this is always carried out by a professional. An intensive job, which also requires the necessary preparation, which makes sandblasting a relatively expensive way of surface preparation for smaller jobs in m2 per day. But that’s not all.
Sandblasting can be very harmful to the health of people and the environment from different perspectives such as Co2 impact. This danger lies mainly in the particles used in this process. Due to the high pressure involved in the blasting process, these particles break down into small particles. When inhaled, these particles can cause various health problems. The risks involved in sandblasting have caused this method of surface preparation to be banned in many countries, like for instance silica sand.
Disadvantages of chemical cleaning
With the chemical method of surface preparation, the danger lies in the acid that is used. This usually involves hydrochloric acid; a very aggressive agent, which can cause the necessary problems if it comes into contact with humans. In addition, when working with hydrochloric acid, a vapor is created that can be very dangerous for humans, animals, and the nearby environment.
Easy prep in various sectors
Their convenience and effectiveness makes the tools and bristles of MontiiPower widely used in various markets. Consider, for example, the production and maintenance of bridges, rail tracks, train wagons, and windmills. Infrastructure is a sector in which it is important that maintenance is not only done very well, but also safely and quickly.
Where traditional methods for surface preparation can be very labour-intensive and unsafe, MontiPower’s power tools actually contribute to a significant effect on health, safety and the economy. The same applies, for example, to surface preparation in the industrial sector, where gas and oil can be handled a lot, the marine sector, where the environment plays a major role or the welding industry, where it is very important both before and after the welding process to prepare and clean the steel properly for the durability of the object. It makes MontiPower’s power tools the solution for effective surface preparation in many situations.
Frits Doddema
Author of MontiPower®
Leadership | Sales | Marketing | Development
Our CEO Frits Doddema, born in 1970, has a background in Industrial Coatings since 1998. He worked for Sigma Marine Coatings The Netherlands, Carboline Coatings for Germany/Central Europe, STOPAQ BV from the Netherlands, and SealforLife Industries before he joined MONTI - Werkzeuge GmbH in 2018. Since 2008 he works as the CEO/Partner.
He is passionate about alternating solutions which make a true difference. Nothing is impossible is his credo. To make the impossible possible, Frits and the management believe in just one idea to make it happen and to turn the company in a great firm. The innovative approach for game-changing blasting and paint solutions is hands-on keeping in mind the difficult field circumstances for operators, respecting nature and long term costs. The mission is to avoid any disagreement over quality of prep work and coating. Frits and his team push for non-hazardous long term corrosion prevention solutions to overcome any hassle out of a coating job ensuring the best possible bond. The world’s best coatings deserve the world’s best surface preparation. Like in daily life, preparation is everything. From different perspectives like Safety, Health, Ergonomics, Productivity, Recyclability, Co2 neutrality of the plant and the coating process, Substrate Compatibility, Corrosion Resistance, Frits and team are driven to come with improved unique contribution solutions to existing and new end markets.
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