Shot-blast-room-9

The Challenge
During the initial site visits, the DISA engineering team conducted a thorough assessment of VMI’s existing facility. Three primary areas of concern were immediately identified:
First, the previous facility emitted substantial operational noise into the wider environment, exceeding acceptable levels for sustained worker exposure. This not only posed potential health risks to operators but also created a nuisance for surrounding areas. Second, the facility generated vast amounts of particulate matter that was not being efficiently extracted. Poor ventilation reduced visibility inside the blast area, increased the frequency of maintenance interruptions, and introduced potential health hazards from airborne dust. Third, floor space within the facility was extremely limited, meaning that any new installation had to fit within exacting dimensional constraints without compromising on functionality or accessibility.
Additionally, the abrasive materials previously used by VMI — glass bead and garnet — were found to be suboptimal for their specific processing requirements. These abrasives generated excessive dust, had limited durability, and contributed to the visibility and maintenance problems experienced in the old facility.
The Solution
DISA engineered a fully bespoke sandblasting room tailored to VMI’s specific operational requirements, addressing each of the identified challenges through a combination of innovative design features and carefully selected components.
Noise Attenuation
In accordance with HSE (Health and Safety Executive) guidelines, ambient noise levels must be maintained within regulated parameters to ensure worker protection and sustained productivity. DISA utilised sound-dampening composite panels in the construction of the blast room’s enclosure walls and ceiling to attenuate noise levels effectively. These composite panels feature a dual-layer construction: an outer skin that acts as a robust sound barrier, preventing noise transmission to the external environment, and an inner sound absorption material that captures and dissipates sound energy within the enclosure. This approach significantly reduced the operational noise emitted from the blast room, bringing it well within HSE compliance thresholds.
Dust Extraction and Ventilation Design
Poor blast room ventilation can cause major inefficiencies in production. When particulate matter cannot be extracted efficiently, it reduces visibility for the operator, increases the likelihood of rework and maintenance, and introduces potential health risks. DISA’s blast rooms are designed to operate virtually dust-free, a guarantee achieved through rigorously tested dust extraction systems.
The ventilation design works with gravity rather than against it. Fresh air is drawn through inlets positioned on the blast room’s ceiling, while dirty air is vented through outlets on the enclosure’s rear wall near the floor. This novel top-down ventilation technique holds particulates in atmospheric suspension, with air moving naturally from high to low, preventing dust from settling on the workpiece or the floor. This downward airflow pattern ensures that visibility remains clear throughout the blasting operation.
Coupled with this ventilation strategy is a powerful pulse-jet cartridge dust arrestor unit. This high-efficiency filtration system captures fine particulate matter from the extracted air stream, achieving near-complete dustless operation. The pulse-jet cleaning mechanism automatically cleans the filter cartridges at preset intervals, maintaining consistent extraction performance and extending filter life.
Abrasive Selection and Optimisation
The choice of abrasive has a direct impact on the amount of dust generated during blasting operations. In their previous facility, VMI used glass bead and garnet abrasives. While these materials have their applications in certain circumstances, they were not optimal for VMI’s specific processing requirements.
The DISA technical team conducted a series of on-site trials, testing various abrasive options to identify the most suitable alternative. Through systematic evaluation of dust generation, cleaning efficiency, durability, and lifetime cost, a final optimal abrasive was identified. This selected abrasive generated significantly less dust than the previous materials, exhibited greater durability with longer service life, delivered a faster cleaning action that reduced processing time, and offered reduced lifetime costs through lower consumption and less frequent replacement.
Floor Space Management
On-site, floor space was at a premium. The blast room dimensions were constrained to approximately 4.5 metres in both width and length, with a height of 2.5 metres. To maximise the usable space within these tight dimensions, DISA opted to install a blast-resistant roller door instead of a conventional hinged door.
This roller door solution minimises the floor encroachment typically associated with hinged doors, which require significant swing clearance for opening and closing. The vertical rolling mechanism ensures that the door occupies minimal space when open, providing better overall access to the facility and allowing VMI to make the most of their limited floor area. The blast-resistant construction of the door also ensures that it can withstand the impact of stray abrasive without degradation.
Abrasive Recovery
Due to VMI’s production requirements and the constrained dimensions of the blast room, DISA settled on a double Vaculift recovery unit for the abrasive recovery system. The Vaculift operates through a semi-manual process: settled abrasive is swept by forklift into the recovery point, where it is pneumatically conveyed into a catch box. From there, the material undergoes a separation process — lighter dust is transported to the dust collector for filtration, while heavier contaminants are captured and directed to the air wash unit.
At the air wash stage, viable abrasive is separated from debris and contaminants, allowing it to be recycled and reused in subsequent blasting operations. This recovery process not only reduces abrasive consumption and operating costs but also ensures that the abrasive used in each cycle meets the required quality standards for consistent surface treatment.
The Result
Following the installation and commissioning of the new DISA sandblasting room, VMI experienced immediate and significant improvements across multiple operational metrics. The bespoke surface treatment solution delivered increased turnaround times and improved overall production efficiency, addressing each of the challenges that had previously constrained the company’s operations.
The noise attenuation measures brought operational noise levels into full compliance with HSE guidelines, creating a safer and more comfortable working environment. The gravity-based ventilation system, combined with the pulse-jet dust arrestor, maintained clear visibility throughout blasting operations, reducing rework and maintenance interruptions. The optimised abrasive generated markedly less dust while delivering a superior surface finish, and the compact footprint achieved through the roller door design allowed VMI to maximise their limited floor space.
Customer Feedback
“The sample testing before the order was a positive experience. We previously used garnet and glass bead, which caused visibility and production issues. However, with this new abrasive, we can see a marked decrease in dust generation and an overall better finish.”
“Additionally, this new blast room has been a game changer for our operator. It had been difficult to treat our product previously as we were blasting outside, and seasonal changes were challenging to work in. However, the blast room has improved his experience significantly. Blasting in a controlled environment with great visibility has improved overall production turnaround times.”
The successful delivery of this project further reinforces DISA’s reputation as a provider of bespoke, high-performance surface treatment solutions. By addressing the specific challenges of noise, dust, space, and abrasive performance, DISA delivered a solution that not only met but exceeded VMI’s expectations, transforming their surface treatment operations from a production bottleneck into a competitive advantage.