Blast Cleaninng of Steel Ships Using Recycled Glass

Blast Cleaning of Ship Steel using Re-cycled Glass
Professor George Bruce
9 November 2005
Ship Repair & Conversion 2005
mike.evans@incremental.eu.com
Content
Background Blast Cleaning Media Legislation & Standards Project Blasting Trials Results Conclusions
9 November 2005
Background
The Importance of Blast Cleaning Control by
Shipyard Shipowner Coating Company
Critical in good Coating of Steel
9 November 2005
Project Objectives
Testing of Re-cycled Glass Materials (RGM) Blasting Capability Productivity Surface Condition Cost Comparison
9 November 2005
Blasting Media
Natural minerals - silica sand, garnet, olivine Manufactured media - steel shot, glass grit, alumina, plastic pellets or beads, solid carbon dioxide, sodium bicarbonate Mineral slag - copper slag, nickel slag, iron slag and coal slag Organic media - corn cobs, nut shells, starch grains
9 November 2005 Ship Repair & Conversion 2005 mike.evans@incremental.eu.com
Ship Blasting Media

Sand Health and Safety Hazard Grit Copper Slag, Disposal Costs Steel Shot Expensive, Closed System Garnet High Quality but Expensive UHP Water Lower capability
RGM To be tested
UK Legislation
Landfill Tax will double disposal costs EU Packaging Directive Glass Recycling Kyoto Summit Emissions Reduction Statutory Re-cycling Targets
Trying to anticipate future legislation
9 November 2005
Working Standards
Steel Surface Finish to SA 2.5 Standard Depends on initial sub-strate 50-75 microns ideal for coating
9 November 2005
Previous Results
For Epoxy coating: Glass abrasive cleaned - 11.6 m2/hr Copper Slag cleaned 9.5 m2/hr Nickel Slag cleaned 8.0 m2/hr Glass abrasive consumed 40.9 kg/m2 Copper Slag consumed 76.7 kg/m2 Nickel Slag consumed 74.3 kg/m2
Ship Repair & Conversion 2005 mike.evans@incremental.eu.com
9 November 2005
Potential Benefits of Glass

Inert Material No Heavy Metals (unlike Copper Slag) No Salts Reduced Corrosion No Free Silica
9 November 2005
Project Blasting Trials

Initial Trials
Small Samples in Controlled Conditions Establishing Baseline Comparisons
Initial Shipyard Trials

Small Samples in Shipyard Conditions Establishing Media Capability in Shipyards
Full Scale Trials

Blasting Marine Structures
Initial Controlled Trials

Tests on Steel Plates Some Pipes Beams and other Structural Sections Established the capability of RGM Similar Performance to Grit
9 November 2005
Initial Shipyard Trials

Various Steel Plates from Ships RGM Compared to UHP RGM used wet as well as dry Compared in 2nd Shipyard to Copper Slag Samples blasted, inspected and coated
Plates prior to Blasting
9 November 2005
RGM Closeup
9 November 2005
RGM Blasting of Samples
9 November 2005
Steel Samples after Blasting
9 November 2005
Full Scale Shipyard Trials

Mooring Barge
Heavily Corroded Comparison between RGM and UHP
Mooring Pontoon
Heavily Coated Comparison between RGM and Copper Slag
9 November 2005
Mooring Pontoon before Blasting
9 November 2005
Mooring Barge before Blasting
9 November 2005
Shipyard Trial Results (1)

Abrasive Size (mm) Surface cleanliness Roughness m Dust Productivity (m/h) Specific Grit Consumption (kg/m) Dry RGM 0.75-1.5 SA 2.5 2233 2 4.19 19.33 Wet RGM 0.75-1.5 SA 2.5 2207 1 1.62 115.74 Wet RGM 0.75-1.5 SA 2.5 2207 1 4.63 42.74 UHP N/A SA 2.5 Could not be measured 1 5.15 186.48 l Water
Table 1. Shipyard 1 Full Scale Trials with different media

Mooring Barge Corrosion
9 November 2005
Blasted Mooring Barge
9 November 2005
Shipyard Trial Results (2)

Abrasive Size (mm) Surface cleanliness Roughness m Dust Productivity (m/h) Specific Grit Consumption (kg/m)
9 November 2005
Dry RGM 0.75 1.5 SA 2.5 95 3 12.649 45.21
Dry RGM 0.75 1.5 SA 2.5 2415 2 12.43 46.02
Copper Slag 1.4 2.5 SA 2.5 202 3 10.89 35.11
Copper Slag 1.4 2.5 SA 2.5 2396 2 12.87 29.72
Table 2. Shipyard 2 Full scale trials with different media

Ship Repair & Conversion 2005 mike.evans@incremental.eu.com
RGM Blasting of Pontoon
9 November 2005
Pontoon after Blasting
9 November 2005
Full Scale Shipyard Trials

Comments RGM showed a steep learning curve Wet RGM was not very successful RGM gave improved appearance RGM is a Capable Process
Further Monitoring is in Progress

Conclusions
RGM Performance is Comparable to Other Media RGM is Equally Capable of Surface Preparation for Coating RGM has similar productivity to UHP Supplies of RGM at acceptable cost are essential Further work on disposal is required
Q&A
George Bruce
9 November 2005

Blast Cleaninng of Steel Ships Using Recycled Glass

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Blast Cleaninng of Steel Ships Using Recycled Glass

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Blast Cleaning of Ship Steel using Re-cycled Glass

Professor George Bruce

Ship Repair & Conversion 2005

Ship Repair & Conversion 2005

Critical in good Coating of Steel

Ship Repair & Conversion 2005

Ship Repair & Conversion 2005

Ship Blasting Media

Trying to anticipate future legislation

Ship Repair & Conversion 2005

Ship Repair & Conversion 2005

Potential Benefits of Glass

Ship Repair & Conversion 2005

Project Blasting Trials

Initial Shipyard Trials

Full Scale Trials

Initial Controlled Trials

Ship Repair & Conversion 2005

Initial Shipyard Trials

Plates prior to Blasting

Ship Repair & Conversion 2005

Ship Repair & Conversion 2005

RGM Blasting of Samples

Ship Repair & Conversion 2005

Steel Samples after Blasting

Ship Repair & Conversion 2005

Full Scale Shipyard Trials

Ship Repair & Conversion 2005

Mooring Pontoon before Blasting

Ship Repair & Conversion 2005

Mooring Barge before Blasting

Ship Repair & Conversion 2005

Shipyard Trial Results (1)

Table 1. Shipyard 1 Full Scale Trials with different media

Mooring Barge Corrosion

Ship Repair & Conversion 2005

Blasted Mooring Barge

Ship Repair & Conversion 2005

Shipyard Trial Results (2)

Dry RGM 0.75 1.5 SA 2.5 95 3 12.649 45.21

Dry RGM 0.75 1.5 SA 2.5 2415 2 12.43 46.02

Copper Slag 1.4 2.5 SA 2.5 202 3 10.89 35.11

Copper Slag 1.4 2.5 SA 2.5 2396 2 12.87 29.72

Table 2. Shipyard 2 Full scale trials with different media

RGM Blasting of Pontoon

Ship Repair & Conversion 2005

Pontoon after Blasting

Ship Repair & Conversion 2005

Full Scale Shipyard Trials

Further Monitoring is in Progress

Ship Repair & Conversion 2005

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