Abrasive Blasting Cabinets, Dust Collectors, Vacuums & HVLP Paint Spray Systems
HOW TO INSTALL CORRECT METAL PIPING IN YOUR SHOP
When we first moved into our Canfield, Ohio plant, we installed all of our air lines with metal piping, being sure that the pipe size was correct for our needs, and correctly designed so that moisture in the air lines could be easily removed with water separators and drain valves. This is a necessity when operating any type of abrasive blasting equipment, plasma burning equipment or simple air tools. To see a very detailed piping diagram and other information on airline accessories, parts and fittings, please see:
One of our customers (Mr. EZ of Ringgold, Georgia) used the above piping diagram and airline accessories to install a neat airline piping system in his shop. Shown below are three pictures of his shop. Take a careful look of how the piping was installed with "risers" to keep the moisture within the metal pipes until it can be removed with our water separators and drain valves. EZ even has a neon "Open Sign" to welcome visitors.
Center picture shows the best way to install such piping. The main air line from your compressor runs horizontially across the walls of your shop. At each airline hookup station, the pipe drops down towards the floor with a drain valve to blow water out of the piping as shown. You can place a bucket under this pipe to catch the water when valve is opened. Just above this drain valve is a short length of pipe stubbing out horizontially and then an elbow facing up and another elbow facing to left. This section of piping is called the "riser" and is very important, as we are using gravity to keep the moisture within the piping below this area, so that most moisture can be removed when opening the drain valve (suggest daily).
Air is then directed into a moisture separator and then to an airline regulator, whch is used to regulate the air pressure from your main line to whatever pressure is to be used for your particular application. For most abrasive blasting in a Skat Blast Cabinet, we recommend 80 to 85 psi, as higher pressures will pulverize the abrasive on impact, eventually turning the abrasive into a powder form, which will not blast effectively, and will also create much dust within the cabinet, resulting in poor visibility. Looking at the above setup, see that EZ installed two moisture separators. Not a bad idea, although we would recommend that the second separator be a Coalescing Filter, which is the best choice for a final airline filter.
*Note: There are exceptions to the above suggestion as to pressure. If using "First Choice" or other lower cost abrasives and are blasting very rusty objects such as wheels or some heavy steel automotive components, you may want to increase your pressure above the recommended 85 psi. It will cut faster, but the abrasive will break down quickly, resulting in the necessity of changing your abrasive more frequently. Blasting with worn out abrasive is never satisfactory, as results and visibility will be poor.
Abrasives should be change on a regular basis and we offer many choices for various projects that you might need. See other section of this web site by clicking "Abrasives" at Home Page.
WARNING: Do not use Silica Sand for abrasive blasting, even within a closed cabinet. Sand is a severe health hazard, as operator is always exposed to dust when loading and unloading cabinet. Also sand breaks down quickly on impact & turns to dust quickly, so visibility is poor.
WARNING: Do not install any airline piping with PVC or plastic piping. Even though it may be rated at high pressure, it is unsafe and is banned in many states. Reason: should the PVC piping get damaged on impact for any reason, it will shatter and "explode", sending pieces of plastic in the form of shrapnel in all directions, with a strong possibility of personal injury. As an example, if you bump the PVC piping with a cart or any object, it will break. This is even more likely in colder climate areas. We have also heard reports of PVC piping systems failing after a few years, due to a deterioration of the inside surface of the piping from the oils that are commonly within air lines that come from your air compressor. There is a new type of plastic piping now being sold by TP Tools that has metal reinforcement built into the inside of the plastic to minimize danger of breakge under impact. Call TP Tools for more information on this new product.
Please feel free to call us for more information on this subject, or for help with designing a proper airline piping system in your shop. We offer a Free Tech Line for our customer either before or after the sale and we answer our phones live! Best time to call is from 10 AM to 6 PM weekdays Eastern Time. Toll Free: 800-321-9260
"BUILD YOUR OWN CABINET KITS" are available.
These are described in TP Tools Catalog in detail at www.tptools.com
See below for a really professionally built cabinet that was made by one of our customers (Ken D, Westminster, MD). Using Skat Blast Plans and components and ordinary plywood and some metal legs, Ken was able to build a cabinet that will serve him well for many years. The nice thing about using Skat Blast componets is that they are always available at TP Tools in Canfield, Ohio for immediate UPS shipment. This means no down time.
Side view of Ken's Cabinet. Notice that he used two door latches, which is always a good idea to keep the dust created in blasting where it belongs. Floodlight was installed in the upper left hand corner - out of the way, but aiming at the work area in front of the gloves. Switch and duplex receptacle is on top left of cabinet and turns on the floodlight, and a vacuum can be plugged into the outlet. Ken opted for a foot pedal operation and added a very useful accessory - a blow gun inside the cabinet to blow dust of the surface of small parts. This is evidenced by the two air hoses entering the cabinet on right front (one to power gun and one to the blow gun).
Other then the legs, the entire cabinet was made of plywood. The lens, lens trim and glove and glove flanges were purchased from TP Tools at moderate cost. Joints were neatly aligned and sanded to where they cannot be seen and the cabinet was painted with light gray enamel, close to the standard color used by Skat Blast. If you look closely, you can see the inner lens protector, which is attached to the inside of the tempered glass lens. This protector is made of durable Mylar and can be changed as it gets scratched from blasting. These are sold in convenient packages of three and are always in stock at TP Tools in Canfield, Ohio
Front View, showing Power Gun and Blow Gun. Metal framework attaches to the wooden cabinet with either wood screws or bolts and nuts. Notice electrical outlet with switch at top left, which can be used to turn on the vacuum and light. A very professional job and with Skat Blast plans and components, you can make this very same cabinet, using regular carpenter shop tools. Not shown in this picture is a trap door at bottom of funnel, which is used for dumping used abrasive. This is available at TP Tools and is spring-loaded to keep it closed. Always remember to change abrasive on a regular basis, as blasting with worn out abrasive is one of the main reasons for poor visibility inside a cabinet, as well as not being cost effective, due to slow results. Most any abrasive can be used in this cabinet. See other section of this web site for a description and pictures of available abrasives that are in stock.
Side View - If we didn't know better, we would think this was one of our Skat Blast Cabinets! It is identical in appearance to our cabinets, including Gloves, Lens, Floodlight and Work Area Sscreen. As you blast, rust and paint are instantly removed and drop to the bottom of the funnel, along with abrasive. When foot pedal control is pressed, air passes through the power gun at about 80 PSI and pulls the abrasive from the bottom of the funnel and injects it into the air stream. This powerful blast removes paint, rust and scale quickly and efficiently. For small parts, we recommend the use of a hand-held "Bolt Basket" that holds the parts so that they do not become lost. This is not shown in this picture and if Ken doesn't have one of these, you can be sure that we will send one to him quickly. As you blast, the abrasive mix can be used over and over again until it turns to dust. At that time it should be replaced.
Congratulations Ken on building one of the nicest cabinets that we have seen, although there are undoubtedly many other similar cabinets, as we have sold thousands of "Build Your Own Kits". These kits are available in several types:
a) Trigger Operated Kit includes Trigger Gun, Pickup Tube, Siphon Hose and Air Inlet Hose, along with a clearly illustrated set of Instructions and Plans. Extra Nozzles are included.
b) A Foot Pedal Operated Kit includes all of the above, except that a Foot Pedal Control is included, and gun does not have trigger. This type of setup eliminates operator fatigue when pulling trigger for extended periods of time. Extra Nozzles are included and long-wearing Ceramic or Tungsten Carbide Nozzles are available at extra cost.
c) Trim Kits are available in several sizes and include Gloves, Glove Flanges and Gaskets, Tempered Glass Lens, Inner and Outer Lens Protector, Lens Frame with Gaskets and Screws. A Floodlight Assembly is included which includes a Duplex Outlet and Power Cord.
d) Cabinet Plans are included with all of the above kits, but are available separately at moderate cost and can be shipped via 1st class mail to U.S. and Canada.
See our Free Catalog for more details, or see www.tptools.com and in the block at upper left-hand side of Home Page, enter Build Cabinets.
Skat Blast - Made in U.S.A in Canfield, Ohio.
Call for Free TP Tools Catalog (Sent 1st Class Mail USA & Canada only)
Toll Free 1-800-321-9260 or 330-533-3384 or www.tptools.com
* Note: Click on links on left side of this page to visit other sections of this site.
Quality Control - At Skat Blast, Inc. the following controls have been implemented so that you can be assured of a high-quality, dependable product that will give years of dependable service.
Each step of the manufacturing process is carried out by experienced employees who have years of experience in building abrasive blasting cabinets and each production and manufacturing employee is responsible for his or her Quality Control. Control Sheets are completed and signed by each, certifying that company procedures and methods are followed. Employee suggestions are always carefully considered, as we want to build the best possible product at the lowest possible price.
Records Retention: Separate notebooks are maintained in our offices for each production and manufacturing employee and these records are retained for reference if needed at any time.
Samples: At most job stations are actual samples of the finished product, which can be easily viewed by department employees. These samples are mounted on the wall.
The Ohio EPA requires documentation for our 2 paint spray booths. Each painter is required to complete and maintain a daily log sheet, showing the number of gallons of paint and thinners used in his or her work area. Log books are inspected on a regular basis by Company Officers.
Each Employee is responsible for his or her Quality Control, and an inspection of his or her methods is made on a weekly basis by a Company Officer (daily for new-hires).
Independent Contractors are required to complete a very detailed form explaining Company regulations, and in particular, our No Smoking Rules (we are a Non-Smoking facility). Such forms are kept on file in our offices for reference at any time.
Parts Wanted: Plant Employees are responsible for completing a "Parts Wanted" form, to be sure that parts are available for production. While our computer system normally tracks components for manufacturing, the employee has the ultimate responsibility for keeping his or her parts in supply, so that production is not delayed or disrupted.
Safety First Program: Skat Blast has developed, published and distributed a very detailed and comprehensive Safety First and Hazard Communication Program Manual, including mandatory rules for safety at our workplace. Employees sign a receipt acknowledging that they have received this and other manuals at the time of distribution. Safety Meetings are held monthly for plant employees. Attendance is mandatory and such attendance is recorded and kept on file.
Inspection Procedures: Incoming goods are inspected upon receipt and once approved, are labeled and placed in suitable bin locations for use in manufacturing. In most cases, components are tested for breakage, using pre-approved methods of destruction. We want to know how our components will hold up under abuse.
Manufacturing Inspection is done at each step of the process by a Company Officer or Supervisor. At certain steps, an inspector is paged by the crew leader of the department, and an inspection is made, prior to further processing. Other inspections are made randomly to be sure that employees are following Company Procedures. Such procedures are normally in writing and are distributed to each employee, as well as being kept on file in a Procedure Manual.
Housekeeping: Most visitors to our plant comment about the clean environment and well-maintained premises, both inside and out. A clean place to work is a safe place to work. Lighting is more than adequate and sky lights are numerous so that we can build a quality product. Each employee is responsible for keeping his or her work area clean. You can be sure that our attention to detail will be reflected in the quality of our products.
MSDS (Material Safety Data Sheets) are kept on file in our offices and upgraded on a regular basis. To be sure that our customers have this information, a separate MSDS is enclosed with each and every carton of abrasives. For customers on record, this information can be supplied through the Internet on request.
Off-Premises Control: We have various 'Tooling" used by our vendors to manufacture components. We require that our vendors sign a "Tooling Agreement" to recognize that such tooling is our exclusive property and is available for inspection or return at any time. Asset Control Numbers have been assigned to this tooling and the Asset Control Number has been stamped into, or otherwise affixed to the tooling in a suitable manner. On rare occasion, we will visit our vendor to inspect and/or label our tooling and to determine how the tooling is cared for and stored. Our vendor is evaluated at this time for our information.
Tracking: We keep track of rejects, late deliveries, poor packaging, damages and other important factors in determining the status of our vendors. In most cases, we have alternate vendors and/or sources of supply so that a steady supply of parts and components are always available for out production, as well as for our customers.
Parts and Engineering Drawings: Each component and/or assembly has an Engineering Drawing, commonly known as a "Print". A Print is sent with every purchase order for components, to minimize errors and to pinpoint the specifications. Prints are approved by one or more Company Officer and are maintained in our computer system, as well as being retained off-premises for safe-keeping.
Literature: We publish detailed Instruction Booklets for our products, which are illustrated and written in a method that is easy to understand. In addition, most of our products are labeled with additional information, hang tags and labels. A Safety First Manual is enclosed with every product, as well as with every outgoing order.
Conclusion and Mission Statement: Skat Blast, Inc. is committed to our Quality Control in all aspects of our business, from the development of written policy for our employees, to detailed information for our vendors and suppliers. We do not make verbal agreements, and we follow up any phone call of importance with a written letter and/or email.
We feel that "the customer is always right", and we go the extra mile to further that goal. We do not believe in "Voice Mail" or "Automated Phone Answering", preferring instead to handle things in a more personal way. We address all correspondence and answer all mail and emails promptly, usually the same day. We treat our vendors and employees with respect at all times, so that we can build a quality Made in USA product. We truly enjoy providing our equipment to our customers, and hope that we can make life just a little easier for them, based on what our equipment will do for them and the technical help that we always provide.
Our goal is not to become "bigger" but, instead, be "better". Honesty and integrity are of prime importance in all dealings with our customers, our suppliers and our employees,whom we want to thank for our success.