Sponge-Jet, Inc Basic Equipment Exposure Course Content

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    Sponge-Jet, Inc.Basic Equipment Exposure Course

    Sponge-Jet Feed Units All Models

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    For Safe Operation ofAll Sponge-Jet Manufactured Equipment:

    Always review and understand all operational manuals and instructional videos, prior toany equipment operation.

    Inspect all hoses and couplings for wear.

    All hoses must be restrained with coupling pins and cables, (whip-checks).

    All operators, tenders and laborers, as well as local trades must be equipped with allnecessary P.P.E. including but not limited to, eye ear and respiratory protection.

    Never perform any maintenance to the unit while under pressure.

    ALL UNITS ARE EQUIPPED WITH A SINGLE EMERGENCY STOP BUTTON WHICH WILLRENDER THE UNIT INOPERABLE WHEN DEPRESSED.

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    Benefits of a Feed Unit over a common Pressure Vessel

    Sponge-Jet Feed Units are specifically designed and engineered to flow Sponge-Jet

    Media. Sponge-Jet utilizes components such as Augers, Actuators, Tree Assembliesand advanced pneumatic logic to facilitate the flow of media through the Feed Unit,allowing for consistent and reliable operation.

    Unlike a conventional abrasive blasting machine, which uses gravity as its primaryfeeding mechanism, assisted by a compressed air flow through the pressure vessel.Sponge-Jet Feed Units rely on an automated mechanical device called the Actuator

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    which assures that the media flows from the vessel, to the Auger and is then fedinto the blast hose rather than dropped into the air stream through a cone valve.

    Sponge-Jet medias change in size and density as they progress through their lifecycle, the ability to adjust and compensate for those changes are critical. The

    designed components engineered into Feed Units allow for this compensation insimple and mostly autonomous ways. We accomplish this through adjustment of theAuger Speed/Media Feed Rate. Recommended pressures are listed on each unit.

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    Why Not A Standard Blast Pot?

    Auger Actuator Air Motor

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    Control Valve Timer

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    Two component, open-cell, particle

    -Pliant, polyurethane carrier

    -Abrasive particle/cleaning agent

    Wide range of abrasives

    All these components are needed to reliably flow Sponge-Media

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    Multitude of performance characteristics

    Grit size can vary within the base color group

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    Sponge Media Grades

    Sponge-Media consists of the unification of a composite, dust and contaminantcontrolling agent, Sponge and an encapsulated cleaning or abrasive agent.

    The composite structure of the medias provides the dust control benefit as well as thecontaminant control for all grades. While there are some minor differences in cell

    structure as a result of the abrasive or cleaning agent embedded, the general compositeis the same throughout all of the grades.

    Media choice is based on several conditions that must be evaluated prior to finalselection. Too frequently, the decision of what media has been based on how fast do you

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    application, they can also be manipulated to a point where they contribute more to failure,than they contribute to success.

    Good painting practices dictate that the profile should never exceed 50% of the primercoat thickness. It is certainly mechanically sound to expect that bigger abrasive particleswill cut through a coating faster than will smaller abrasive particles. However one of the

    items to consider though is with any abrasive smaller, finer, abrasive particles produce adenser grouping and remove coatings or contamination more efficiently than do largerabrasive particles. This can easily result in a larger abrasive requiring more dwell time toproduce equal cleaning results.

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    Sponge Media Grades

    The most critical consideration when choosing the abrasive grade is the profilerequirement of the follow-on coating. Producing a profile, that exceeds the data sheetrequirements of the future coating system leads to pinpoint rusting, added paint and laborcosts and the greater potential for immediate or premature coatings failure.

    Conventional abrasives are commonly sold in varying size ranges, Fine, Standard,Course and Extra Course for example. While these ranges do produce both ends of thespeed and efficiency spectrum previously noted, they do as well provide the opportunityto produce both inadequate and excessive profile results. Often times these blended sizecombination are based on the lower or ex endable abrasives overhead cost limitations.

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    Utilizing a tight and consistent size of abrasive, results in a consistent and repeatableprofile generation. This condition is not only known to produce improved coatingperformance, but is often times a noted and documented testing procedure, required forthe acceptance of the coatings process by both the owner and the paint suppliers qualitycontrol standards.

    Being able to achieve these consistent readings is why Sponge-Jet medias are classifiedand named utilizing specific numerical designations, S-120, S-30 S-16 or R-G40. Thistight sizing also helps limit the human error factors associated with media feed ratesettings or nozzle pressures.

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    Sponge Media - Recyclability

    Sponge Medias are intended to be recyclable. While there are other recyclable

    medias on the current open market, these abrasives are all suspect to degradationin size after each collision with the substrate. This degradation in size can obviouslyproduce inconsistent profile depths, negative changes to the angular quality and

    orientation of the profile and potentially leaving fragments of the abrasive particleembedded in the substrate. Depending on the type of abrasive used, theseremaining deposits could contribute to the corrosion condition or hinder the

    successful mechanical bond of the coating to the substrate.

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    s ponge- e on s mu p e p eces o qua y an g y s ze a ras ve or c ean ngagents into each granule of Sponge media, even as multiple recycles of the mediaare attained, the degraded material that separates from the granule is removed andsegregated by the Recycler unit, leaving only the appropriately sized abrasiveresident for the remaining blasting cycles. This helps assure that the profileconsistency remains at a high level from beginning to end of media lifecycle.

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    Primary Requirements and Components

    Air volume requirements are specific to the nozzle size utilized, balanced againstthe desired blast pressure. Larger nozzle diameters require increased volumes of

    compressed air to sustain desired pressures.Current units utilize 2.0 inch piping components so as to have the lowest pressuredrop internally. Any reduction it the supply air fitting below this 2.0 inch diameter willdefeat this benefit and limit the system throughput to that size fittings capacity.

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    The smallest fitting or coupling supplied to the unit will ultimately determine thesuccess or failure of the required production regardless of the pressure the supply

    source can produce.

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    Components

    Standard supply connections areattached to a supplied Chicago 4 lugcoupling with a Primary Supply Air

    Ball Valve behind it. This isolates themachine from the customer supplied airflow.

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    This fitting is mounted to a 2.0 inch NationalPipe Thread Straight nipple. This fitting can

    easily be removed or adapted to a fitting morebroadly accepted in your geographic region. ITIS CRITICAL HOWEVER THAT THEINTERIOR DIAMETER NOT DECREASE AS ARESULT OF THIS CHANGE.

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    Components

    Moisture is removed automatically from

    compressed air source by a Secondary

    Moisture Separator.

    It utilizes a 40 micron element as its

    standard.

    It is equipped with an automatic dumpmechanism to expel accumulatedmoisture into an appropriate collection

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    device. It is not intended to fully dry or clean thesupply of air, but to simply remove

    moisture accumulated in the last lengthof supply line.

    Most compressed air sources haveindependent moisture and temperaturecontrol devices, but this cannot beassumed as always existing.

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    Components

    After moisture is removed, the full volume

    of supply air is held at the Main Air On Off

    Valve until the operator depresses theDeadman trigger on the hose.

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