Surface preparation plays a crucial role in ensuring the longevity and reliability of both old and new industrial assets. This was especially true for a newly constructed water tank in Carrollton, Missouri (USA). Designed for use in the water and wastewater industry, the tank's steel interior was covered in mill scale, which had to be removed prior to coating. 

With a total area of 6,100 square feet that needed to be prepped, the project called for a White Metal finish (SP-5) in order to have a flawless application of the new tank's protective coating. With these necessities in mind, contractor Coast to Coast Industrial, turned to Sponge-Jet technology.

Blasting tank interiors can prove to be challenging, as most tanks are considered confined spaces. Worker safety is closely monitored on these kinds of projects, making a low-dust, low-rebound abrasive essential for increasing hole watch visibility and minimizing risk of injuries. Tanks (and other confined space areas) generally receive minimal inspection outside of periodic, scheduled maintenance. With this in mind, it is of the utmost importance to prep surfaces and apply the new coatings correctly the first time as it could be years before a problem with a failed coating is recognized.

While conventional abrasive blasting methods often generate significant amounts of dust and waste, Sponge-Jet Sponge Media offers a low-dust, recyclable solution that reduces waste disposal costs up to 85%. On this project, blasting with Sponge Media generated 19 times less waste than ordinary abrasives, leading to remarkable savings in waste disposal costs.

Throughout the duration of the project, the team achieved a production rate of 2.8 square feet per minute. For Coast to Coast Industrial, using Sponge Media proved to be a game changer, properly achieving the required coating standards of a white metal blast, exceeding initial client expectations. 

Sponge-Jet Regional Manager Cliff Mohling said, "The Coast to Coast crew did a great job managing media and multiple feed units to keep things moving smoothly.  Even with multiple nozzles blasting, air handling equipment was minimal to keep good visibility in the environment. Mil scale was no match for Sponge Media's superior cutting characteristics."

Many in the industry express a desire to prioritize worker safety and environmental sustainability, yet “cost-per-pound” often dictates decision making in abrasive selection for industrial projects. Coast to Coast Industrial’s choice to use Sponge Media delivered a superior surface preparation method that ensured worker safety, reduced environmental impact, and significantly lowered waste disposal costs. This project demonstrates that with the right technology and know-how, companies can achieve the best of both worlds…budget savings, without compromising on safety or sustainability.