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Unit 10: Sandblasting & Surface Treatment

Microcredential ID: U10-SBST-001 Title: Sandblasting & Surface Treatment Operator Version: 1.0 Duration: 7–9 hours (3 modules Γ— 2.5–3 hours each) Prerequisite: General lab safety orientation (OSHA 10-hour equivalent) Certification Level: Intermediate (equipment + hazard management)

Unit Overview

Abrasive blasting is a high-energy surface treatment process that uses pressurized air and granular media (sand, glass beads, aluminum oxide, etc.) to clean, finish, or decorate material surfaces. This unit develops competency in selecting appropriate media, operating sandblasting cabinets, managing respiratory hazards (particularly silica exposure), and achieving decorative and functional surface finishes.

Learners will understand the physics of abrasive blasting, hazard recognition (particularly silicosis risk), proper respiratory protection, and technique for achieving uniform, professional finishes while maintaining occupational health and safety standards.

Industry Context: Abrasive blasting is critical in metal fabrication, automotive restoration, signage production, jewelry making, and industrial maintenance. The global sandblasting equipment market is valued at $4.2B (2024), with critical emphasis on occupational safety due to silica-related health hazards.

Alignment to Standards

OSHA Standards:

  • 29 CFR 1910.134 β€” Respiratory Protection Program (required for all silica blasting)
  • 29 CFR 1910.1025 β€” Lead Exposure (if blasting lead-painted surfaces)
  • 29 CFR 1910.97 β€” Non-Ionizing Radiation (eye protection for grinding/finishing work)
  • 29 CFR 1910.95 β€” Occupational Noise Exposure (sandblasting cabinets: 85–110 dB, requires hearing protection)

ANSI Standards:

  • ANSI/ASSE A10.49 β€” Control of Siliceous (Silica) Dust in Construction
  • ANSI/ASSE Z1.10 β€” Criteria for Safety Practices with the Selection, Care, and Use of Respirators

Industry Standards:

  • AWS A3.0 β€” AWS Specification and Code for Safety in Welding, Cutting, and Allied Processes (includes abrasive media standards)
  • NFPA 484 β€” Combustible Metals (relevant for reactive media)

Learning Outcomes

By the end of this unit, learners will:

Knowledge Outcomes:

  • Explain the physics of abrasive blasting and media–material interaction
  • Describe media types (silica, non-silica alternatives) and their properties, costs, and hazards
  • Articulate the silica hazard and understand why crystalline silica inhalation causes silicosis
  • Identify the components of a blasting cabinet system and how each contributes to safe operation
  • Distinguish between respirator types (P100, powered air-purifying respirators) and appropriate use cases

Skill Outcomes:

  • Select appropriate blasting media for a given material and aesthetic goal
  • Set up and operate a sandblasting cabinet safely and effectively
  • Achieve uniform surface finishes with appropriate nozzle technique and media distance
  • Perform fit testing and proper donning of respiratory protection
  • Inspect and maintain blasting equipment and dust collection systems
  • Monitor dust exposure using simple diagnostic tools

Competency Outcomes:

  • Independent Operation: Set up, execute, and troubleshoot sandblasting workflows without supervision
  • Hazard Management: Recognize silica exposure risk and implement appropriate engineering and personal controls
  • Safety Practice: Consistently follow respiratory protection and equipment protocols
  • Quality Achievement: Produce decorative finishes meeting aesthetic specifications
  • Equipment Stewardship: Maintain blasting cabinet, media, and dust collection for optimal performance

Unit Structure

Module Title Duration Focus
M1 Abrasive Blasting Fundamentals 2.5 hrs Media types, silica hazard hierarchy, cabinet anatomy, compressed air systems
M2 Cabinet Operation & Technique 2.5 hrs Media selection, nozzle control, surface prep, decorative finishing, coverage uniformity
M3 Respiratory Protection & Ventilation 2.5 hrs Silicosis prevention, respirator selection, fit testing, dust collection, exposure monitoring

Assessment Strategy

Formative Assessment:

  • Knowledge checks in each module slide deck
  • Hands-on practice with blasting technique (instructor feedback)
  • Media selection decision-making exercises

Summative Assessment:

  • Unit Quiz: 35–40 questions covering all modules (80% pass threshold)
  • Practical Capstone:
  • Demonstrate proper respirator fit and donning
  • Set up blasting cabinet with correct media and settings
  • Execute a decorative blasting project on sample substrate (glass, metal, or ceramic)
  • Achieve uniform finish with no missed areas or over-blasting
  • Complete written safety check and hazard recognition form
  • Equipment Competency Checklist: Instructor verification of safe, independent operation

Assessment Rubrics:

Blasting Technique Quality (0–4 scale): - 4 = Professional finish: uniform texture, even coverage, clean edges - 3 = Good finish: mostly uniform with minor variations - 2 = Acceptable finish: visible inconsistencies but functional - 1 = Poor finish: multiple unblasted areas or over-blasted spots - 0 = Unacceptable: major defects or safety violations

Safety Protocol Adherence (0–4 scale): - 4 = Exemplary: proactive hazard management, perfect fit/donning, continuous compliance - 3 = Competent: follows all protocols correctly with minor oversights - 2 = Acceptable: understands protocols but occasional lapses - 1 = Needs improvement: multiple protocol violations - 0 = Unsafe: systematic non-compliance or hazard creation

Instructional Resources

Digital Resources:

  • Slide decks (4–5 slides per module) with embedded instructor notes and hazard graphics
  • Video: "Silicosis: A Silent Killer" (educational documentary excerpt, 5 min)
  • Media comparison chart (silica vs. alternatives: cost, hazard, dust production, recyclability)
  • Respirator fit-testing protocol (step-by-step guide with photos)
  • Troubleshooting flowcharts (poor finish, excessive dust, media clumping)

Physical Resources:

  • Sandblasting cabinet (60–80 L, table-mounted; brands: Harbor Freight, Eastwood, Lincoln Electric)
  • Blasting media samples (crystalline silica, glass beads, aluminum oxide, steel shot, walnut shell, corn cob)
  • Air compressor (5–10 CFM minimum at 90 PSI) with moisture trap and regulator
  • Dust collection system (HEPA filter cartridge, vacuum with 5-micron capability minimum)
  • Respirators (P100 cartridge filters, powered air-purifying respirator PAPR unit)
  • Sample substrates (glass, mild steel coupons, ceramic tiles, aluminum)
  • Fit-testing hood or nozzle

Reference Materials:

  • OSHA Quick Facts: "Crystalline Silica" (1-page summary)
  • Equipment manual: "Sandblasting Cabinet Operation & Maintenance"
  • Media comparison table (dust production, cost, recyclability, hazards)
  • Noise level measurements (equipment specifications)
  • SDS sheets for all media types (printed and accessible in lab)

Accessibility Considerations

Inclusive Design:

  • High-contrast diagrams showing silica hazard progression
  • Audio-described video of proper respirator fit (essential for deaf/hard-of-hearing learners)
  • Written procedural guides (supplement to video demonstrations)
  • Odor/sensory guidance: "Sandblasting may produce mineral dust smell; if you are sensitive to odors, request breaks"

Neurodivergent Accommodations:

  • ADHD: Shorter segments, hands-on blasting practice during lectures to maintain focus
  • Dyslexia: Color-coded media types (silica = red warning icon, alternatives = green safe icon)
  • Autism: Explicit social expectations and routine predictability; quiet practice round before group sessions
  • Anxiety: Option to observe first, then practice; emphasis on "this is a learning environment"

Certification Pathway

To earn the "Sandblasting & Surface Treatment Operator" micro-credential:

  • [x] Complete all 3 modules
  • [x] Pass unit quiz (80% minimum)
  • [x] Complete hands-on activities (100% participation)
  • [x] Pass practical capstone (80% quality on blasting finish + safe operation)
  • [x] Pass respirator fit test and demonstrate proper fit/donning
  • [x] Sign hazard acknowledgment and respiratory protection program agreement

How to Use This Unit

For Instructors:

  1. Review this unit index and all module materials
  2. Conduct a pre-unit safety briefing on silica hazards (required)
  3. Ensure respirators and fit-testing supplies are available
  4. Prepare sample substrates and media for practice
  5. Have SDS sheets for all materials visible and accessible
  6. Demonstrate proper technique before learner practice

For Learners:

  1. Understand that respiratory protection is non-negotiable in this unit
  2. Participate fully in fit testing (proper fit is your protection)
  3. Practice nozzle technique on scrap materials before the final project
  4. Ask questions about hazards or discomfortβ€”speak up immediately
  5. Complete the capstone project with focus on both safety and quality

Prerequisites & Sequencing

Hard Prerequisites: - General lab safety orientation (OSHA 10-hour equivalent) - Ability to wear and tolerate respiratory protection

Recommended Sequencing (if taking full curriculum): - Complete Unit 09 (Vinyl Cutting) or Unit 11 (3D Scanning) first for foundational lab skills - Unit 10 and Unit 12 (Glass Working) pair well for comprehensive finishing skills

Version History

Version Date Changes
1.0 March 2026 Initial release: 3 modules, full assessment suite, respiratory protection protocols

Ready to start? Begin with Module 1: Abrasive Blasting Fundamentals β†’