Primas Dry Ice Blasting July 2017 - Capability Statement - Restoring A Water & Acid Damaged Antique Teak Table, Perth, WA.
Primas Dry Ice Blasting was instructed by an antique collector to restore a table made from golden teak. The table was over 200 years old and had great personal and historical significance to the owner.
Over the last couple of decades the table had had a number of coats of timber stain applied to it. Recently the table had been exposed to the elements, had suffered significant water damage and was covered with moss and lichen. On discovering the table's poor condition the owner sent it to be repaired by professional antique furniture restorers. The restorers tried to remove the timber stain firstly by sanding the table back. Due to the many crenellations in the teak sanding did not remove much of the stain. Next the restorers tried to remove the stain using a strong acid wash, however, this process was also unsuccessful.
Primas Dry Ice Blasting analysed the golden teak surfaces and identified that according to the Janka hardness test it would withstand dry ice blasting treatment without sustaining damage. Using very mild settings and blasting techniques, Primas Dry Ice Blasting restored the table's surfaces in preparation for the application of a shellac used on antique furniture.
The timber stain and acid wash etching was efficiently and effectively removed without causing any damage to the golden teak surfaces. The stain was also removed from the many nooks and crannies in the wood's surface. To remove stain from these areas using hand tools would have been an extremely laborious and time consuming process. Careful use of dry ice blasting successfully restored the damaged table and saved a significant amount of cleaning time and expense.
Capability Statement June 2017 - Primas Restoration - Restoring Fire Damaged Internal Bricks and Mortar, Perth, WA.
Primas Restoration was instructed by an insurance builder to restore internal bricks and
mortar that had been damaged in large domestic fire. Over 100 years old, the bricks made up an original kitchen fire place which was regarded by the owners as a key feature of building's heritage appeal.
The fire started in the kitchen adjacent to the fireplace due to the failure of an appliance. As
the appliance burnt out, heavy and toxic, soot and smoke damage coated the fireplace bricks and mortar. Structurally sound and important to the home's aesthetic, the insurance builder requested that dry ice blasting be used to restore the feature fireplace bricks and mortar. The restoration process was further complicated by the fact that new cabinetry and fixtures had been installed around the kitchen and next to the bricks and mortar to be dry ice cleaned.
Primas Restoration conducted an analysis of the bricks and mortar and concluded, given their age and construction, that they were extremely brittle and fragile. Using the least aggressive settings and blasting technique possible, Primas Restoration employed dry ice blasting to remove the soot and smoke damage from the bricks and mortar. Particular care was taken around the affected areas abutting the new cabinetry and fittings.
The soot, smoke damage and odour was efficiently and effectively removed without causing any damage to the bricks, mortar, cabinets or fittings. Given the nature of the soot and smoke contamination coupled with the fragility of the bricks and mortar, cleaning by hand or abrasive blasting methods would have led to significant damage being caused. Extremely precise and careful use of dry ice blasting successfully restored the damaged surfaces and saved a significant amount of cleaning downtime.
Cost Benefit Analysis June 2017 - Primas Dry Ice Blasting - Removing Polymers from a Plastics Extruder, Perth, WA.
A packaging company in Perth was struggling with cleaning its large, intricate, multi-story plastic extruders. Production quotas and near constant operation meant that cleaning downtime was difficult to schedule and lost production represented significant opportunity costs for the business. The plant is classified as food grade and as such the ability to clean using chemicals was limited. The presence of sensitive manufacturing equipment adjacent to the machines ruled out cleaning with water or secondary media.
The company’s manufacturing process caused small amounts of overspray which led to the extruder arms, cages and rollers becoming contaminated with plastic polymer. As this contamination increases over time the company’s Production and Quality Managers record significant decreases in production and marked increases in defects and waste. The Managers also notice frustration among machine operators as the extruders become increasingly difficult to operate efficiently and effectively.
After initial discussions the company recognised the value dry ice blasting could provide but were reluctant to proceed given budgetary constraints. Primas Dry Ice Blasting provided a solution by producing a simple cost benefit analysis so the company could clearly determine whether using dry ice cleaning would be a financially prudent decision.
AN EXAMPLE FROM THE COST BENEFIT ANALYSIS
The analysis identified production downtime cost as a key metric. Here, for example, each machine produces approximately $20,000 worth of product per day. To clean each machine by hand using solvents usually took the maintenance team five days. This downtime resulted in lost production valued at $100,000. Primas Dry Ice Blasting estimated that it would take one day to clean a machine which would result in a production downtime saving of $80,000.
The cost benefit analysis clearly identified that by using Primas Dry Ice Blasting the company could significantly reduce production downtime costs and eliminate a range of risks attached to cleaning the machines by hand. After receiving instructions from the company, Primas Dry Ice Blasting cleaned one machine in a day as per its estimation. Subsequent to this, the company confirmed that the dry ice cleaning had also improved production output and decreased defects.
Operations Video May 2017 - Primas Dry Ice Blasting - Removing Primer and 3 Layers of Paint from a Steel Framed Extruder Perth, WA.
Primas Dry Ice Blasting was recently instructed to prepare a steel framed extruder for repainting. The client, based in Perth, WA, requested that a white steel finish be provided so that no further surface preparation would be needed.
The extruder was positioned in a busy manufacturing plant and was surrounded by high value and sensitive production equipment. Very concerned about the potential for damage to adjacent equipment the client asked that dry ice blasting be used. Dry ice blasting removed the primer and paint without causing any damage to the extruder or nearby equipment. Under pressure to maintain a food grade manufacturing environment, the client, by using dry ice blasting was able to avoid using chemicals, water or secondary media in the cleaning process.
As you can see from the video below the blasting process was highly efficient and significant down-time was avoided as the only clean up required was to sweep up the paint that had been removed.
Capability Statement May 2017 - Primas Dry Ice Blasting - Exposing Welds on Conveyor Brackets Perth, WA.
Primas Dry Ice Blasting was instructed by an engineering company to remove two layers of paint and one layer of primer from washers that had been stitch welded to conveyor brackets. The brackets were being supplied to a multinational mining company which was installing a conveyor at a new mine. A quality inspector for the mining company identified that the washer welds did not meet engineering specifications and requested that all the washers be seam welded as originally ordered.
Primas Dry Ice Blasting's engineering client had fabricated 200 of the conveyor brackets and then had them sand blasted and painted offsite prior to the quality inspector requesting that the welds be redone. The client, under pressure to meet a delivery deadline, wanted the welds exposed in situ so that they could be seam welded onsite, inspected and then sent offsite for sand blasting, repainting and subsequent delivery to the mining company.
Primas Dry Ice Blasting removed the paint and primer from the stitch welds holding 800 washers to 200 conveyor brackets in the client's yard. A containment tent was erected to capture and efficiently dispose of the contaminants removed by the blasting process.
The paint and primer was efficiently and effectively removed from all of the stitch welds and washers. By providing a smooth, white steel finish the client was able to seam weld all of the washers without any further surface preparation. Primas Dry Ice Blasting did not damage any of the bracket substrates and negative environmental impacts were eliminated through the use of an effective containment system. Dry ice cleaning in situ significantly reduced the amount of coordination and transportation time, risk and expense when compared to having the conveyor brackets removed and abrasive blasted off site, then returned for re-welding and then being removed again for sand blasting, painting and delivery.
Capability Statement Dec 2016 - Primas Dry Ice Blasting - Disassemble, Clean and Reassemble Coffee Roasting Plant in Perth, WA.
Primas Dry Ice Blasting was instructed by a national coffee roasting enterprise to disassemble, clean and reassemble its plant in Perth, Western Australia. A number of the plant's easily accessible components had been cleaned regularly, however, a full shutdown and deep clean had not been completed under the current management.
The plant was heavily contaminated with coffee bean waste including chaff, hard dry gum,
grease and oil. The gum-like contamination in the hopper and valve pipes was baked on due to proximity to the roasting drum. A heavy build up of chaff and gum was severely
restricting the extruder pipes leading to the afterburner and the plant's fans, motor and drive chain were heavily built up with general contamination. Primas agreed on a plan to
disassemble, clean and reassemble the plant's components with the West Australian Site
As the plant's components were disassembled and dry ice blasting progressed it was
identified that where oily and viscous coffee bean contamination was encountered dry ice
blasting did not pop the contaminant off but rather removed it and then pushed it around the substrate concerned.
Primas carefully disassembled the roasting plant and provided a deep clean of all components using dry ice blasting. Where oily and viscous contamination was encountered the components were dry ice blasted, wiped with dry cloths to remove the majority of the contamination and then dry ice blasted again. Particular care was taken to not damage sensitive surfaces, components and nearby equipment. After the cleaning was completed Primas reassembled the plant.
The roasting plant was carefully disassembled, cleaned and efficiently reassembled. The coffee bean chaff, gum, grease and oils were effectively removed from the plant's components without damaging its various substrates or electrical circuitry. The clean resulted in improved air flow through the roasting barrel which led to more even roasting, improved flavour characteristics and increased production throughput.
Capability Statement Dec 2016 - Primas Dry Ice Blasting Rust from 44 Inch Ball Valve Components in Perth, WA.
Primas Dry Ice Blasting was instructed to remove heavy rust contamination from five 44 inch ball valve housings, five valve adaptors, ten trunnion plates and eight valve elbows. The majority of the components had been used at an off shore oil rig while others had been used as part of on shore operations. The valves were disassembled as the valve balls were being replaced and the valve housings and components reconditioned and then reassembled and tested with the new valve balls.
The rust contamination on the components ranged from light surface rust to complete rusting of the mill scale layer and significant pitting of the various substrates. The client requested that the surface rust be stripped from the components and that a smooth, white steel finish be provided. Given that some of the components weighed over nine tonnes the client requested that the cleaning be completed in situ and that the painted and machined surfaces of the components were not damaged.
Primas protected the various painted and machined surfaces of the components and then
carefully removed the rust from all affected surfaces. Care was taken to not over-blast on
to sensitive surfaces.
The rust was efficiently and effectively removed from all of the components and a smooth,
white steel finish was provided. Dry ice blasting did not damage any of the substrates cleaned or harm any of the painted to machined surfaces. Dry ice blasting also significantly reduced the amount of time, expense, risk and coordination that would have been required if the components had been removed and abrasive blasted off site.
Capability Statement Nov 2016 - Primas Dry Ice Blasting Paint from Cast Iron Bearing Housings in Perth, WA.
Primas Dry Ice Blasting was instructed to remove three coats of paint from eight cast iron
bearing housings. Five of the housings were mounted to large winders and had gear boxes
assembled. Two of the gear boxed had also had a motor assembled. Three of the housings
had not been mounted to winders and could be removed from the site for cleaning.
The bearing housings were coated with the manufacturer's original red paint and an
additional two coats of grey paint had been applied. The client requested that all layers of
paint be stripped from the housings so they could be repainted to the end user's
specifications. The client requested that the five mounted housings be cleaned in situ without damaging the assembled components or housings and the unmounted housings be cleaned at the Primas workshop.
Primas wrapped up the assembled gearboxes and motors and then carefully removed the
paint from the bearing housings. Care was taken to not over-blast on to the winders.
The paint was efficiently and effectively removed from each of the bearing housings without damaging any of the various components or substrates. Dry ice blasting did not damage or introduce secondary media to the winders, gearboxes or motors that the housings were mounted to. Dry ice blasting slashed the amount of time that would have been required if the housings had been removed and abrasive blasted.
Technical Brief Nov 2016 - Primas Dry Ice Blasting - Is dry ice really a non-abrasive blasting media?
A study published by Clemson University (Molen, Joosten, Beentjes and Megens, 2011, p. 96) found dry ice pellets to be 1.5-2.0 on the Mohs hardness scale.
The Mohs scale is used to characterise mineral hardness through the ability of a harder material to scratch softer material and the softer material not being able to scratch the harder material.
Using Mohs methodology it can be argued that dry ice particles are non-abrasive to all substrates that are harder than dry ice or above 2.0 on the Mohs scale.
The following table places dry ice on the Mohs scale and identifies it as being the softest or least abrasive blasting media.
Notwithstanding the relative softness or non-abrasiveness of dry ice compared to other blasting media it is important to understand that dry ice blasted at a surface using a high pressure stream can cause damage to surfaces and equipment if strict professional practices are not observed.
Primas Dry Ice Blasting continues to refine and augment its technical understanding of specific contaminates, substrates and environmental conditions and how best to safely and effectively dry ice clean when encountering ever changing combinations of these factors.
Molen, R., Joosten, I., Beentjes, T., and Megen, L. 2011 “Dry Ice Blasting for the Conservation Cleaning of Metals.” In Metal 2010: proceedings of the interim meeting of the ICOM-CC Metal Working Group, Charleston, 11 October 2010, pp.96-103. Clemson: Clemson University.
Capability Statement Oct 2016 - Primas Dry Ice Blasting Fire Damaged Heritage Joists and Boards in Perth, WA.
Primas Dry Ice Blasting was instructed by an insurance builder to restore wooden floor joists and boards that had been damaged in a fire. The joists were situated between the basement and ground floor of a three story heritage listed building in King Street, Perth..
The Jarrah floor joists and boards were installed when the building was constructed in the
early twentieth century. The fire, which started in the rear lane, caused charring and smoke
damage to the basement ceiling and ground floor. As the majority of the joists and boards
appeared structurally sound, the insurance builder requested that dry ice cleaning be used to restore these components by removing the charring, soot, smoke damage and odour. The fire had disrupted a busy enterprise which was very keen to begin trading again.
Primas Dry Ice Blasting quickly coordinated with the business owner to complete the fire
restoration work outside of working hours in order to minimise interruption to the business.
The wooden joists and boards were restored using a powerful stream of dry ice.
The charring, soot, smoke damage and odour was efficiently and effectively removed without damaging the Jarrah components. Dry ice blasting slashed the amount of restoration downtime and business interruption and allowed the heritage assets to be saved.