Surface Preparation

Our Specialised Surface Preparation Methods:

We utilise a comprehensive suite of methods to achieve the ideal surface profile and cleanliness:

1. Abrasive Blast Cleaning (Shot Blasting)

Abrasive blast cleaning, often referred to as shot blasting or grit blasting, is one of the most effective and widely used methods for achieving a thoroughly clean and profiled surface. This process involves propelling abrasive media at high velocity onto the substrate, removing rust, old coatings, mill scale, and other contaminants, while simultaneously creating a surface profile that enhances mechanical adhesion for new coatings.

• How it Works: A compressed air stream or centrifugal force is used to accelerate abrasive particles (such as steel grit, shot, or garnet) onto the surface. The impact removes impurities and etches the substrate.
• Applications: Ideal for steel structures, tanks, pipelines, and heavily contaminated concrete where a high degree of cleanliness and a specific anchor profile are required. It’s particularly effective for preparing surfaces for heavy-duty industrial coatings.

2. Ultra-High Pressure Water Jetting (UHP Water Jetting)

Ultra-High Pressure (UHP) Water Jetting is an environmentally friendly and highly effective method that uses water pressurised from 10,000 psi (700 bar) up to 40,000 psi (2750 bar) to remove contaminants and existing coatings. This method can remove old coatings, rust, and other deposits without damaging the substrate.

• How it Works: Focused streams of extremely high-pressure water break the bond between contaminants/coatings and the substrate, effectively cleaning and preparing the surface.
• Applications: Commonly used for removing old coatings, rust, and scale from metal surfaces, cleaning concrete, and preparing surfaces in environments where dust and abrasive media are problematic or prohibited. It minimises airborne dust and avoids chemical use.

3. Dry Ice Blasting

Dry ice blasting is a non-abrasive, non-conductive, and environmentally conscious cleaning method that uses solid carbon dioxide pellets. When the pellets impact the surface, they sublimate (turn directly into gas), creating a micro-explosion that lifts contaminants without damaging the substrate.

• How it Works: Compressed air accelerates dry ice pellets towards the surface. Upon impact, the pellets rapidly expand into gas, removing contaminants through a combination of kinetic energy and thermal shock.
• Applications: Perfect for delicate surfaces, intricate machinery, electrical components, and areas where secondary waste (like abrasive media) must be minimised. It leaves no residue, making it ideal for food processing plants, historical restoration, and sensitive industrial equipment.

4. Track Blasting

Track blasting is a highly efficient and contained method of surface preparation primarily used on horizontal surfaces, such as concrete floors and steel plates. A self-contained unit moves across the surface, recycling the abrasive media and capturing debris.

• How it Works: A blast wheel within the machine propels abrasive media onto the surface. A vacuum recovery system immediately collects the spent abrasive and removed contaminants, providing a dust-free operation.
• Applications: Excellent for preparing concrete floors for resin coatings, removing paint lines, cleaning bridge decks, and preparing large flat steel surfaces. It provides a consistent profile and minimises environmental impact due to its contained nature.

5. High Pressure Jetting (Water Jetting)

While UHP water jetting is for extreme pressures, standard High Pressure (HP) Jetting (typically 5,000-10,000 psi) is also a valuable tool for surface cleaning and preparation. It’s effective for general cleaning, removal of loose paint, dirt, grime, and some weaker coatings.

• How it Works: Pressurised water is used to wash away surface contaminants.
• Applications: General surface cleaning, removal of loose debris, washing down large areas, and preparing surfaces that do not require an aggressive profile.

6. Surface Cleaning

Beyond mechanical methods, comprehensive surface cleaning is a fundamental step in all preparation processes. This includes degreasing, washing, and neutralising surfaces to remove oils, greases, salts, and other invisible contaminants that can compromise coating adhesion.

• How it Works: Utilising specialised detergents, solvents, and neutralising agents, followed by thorough rinsing and drying, to ensure a chemically clean surface.
• Applications: Essential for virtually all coating projects, particularly before abrasive blasting or direct coating application.

7. Vacuum Removal Systems

Integral to many of our surface preparation processes, particularly dry abrasive blasting and track blasting, are advanced vacuum removal systems. These systems ensure that hazardous dust and debris are safely and efficiently extracted from the work area.

• How it Works: High-powered vacuums with HEPA filtration capture airborne particles and collected debris, maintaining a clean and safe working environment.
• Applications: Used in conjunction with dry preparation methods to minimise environmental impact, protect worker health, and ensure a dust-free surface ready for coating. This is particularly important for projects like benzene fuel storage tank clean and gas free surface preparation, where contaminant removal is critical.

Why UCL Excels in Surface Preparation

Choosing Ultimate Coatings Limited for your surface preparation needs means partnering with a team that understands the critical role it plays in your project’s success.