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    Abrasive Blasting Case Studies GMA ToughBlast Global Americas Sustainability

    Efficiency in Waste Management Enhances US Shipyard Operations

    Overview

    Project

    A shipyard in New York harbor recently transitioned to GMA ToughBlast™ garnet for its blasting operations, leading to notable improvements in waste management and operational efficiency.

    Location

    New York, U.S.

    Surface Area

    10,219m² (110,000ft²)

    Task

    Improve operational efficiency and reduce costs by addressing key issues associated with slag abrasives, including high dust levels and excessive abrasive consumption.

    Challenge

    High dust emissions, high consumption leading to frequent downtime for refilling, and costly disposal processes.

    Challenge 

    Previously reliant on slag abrasives, the shipyard faced challenges that significantly impacted both costs and productivity. Key issues included high levels of dust, substantial waste disposal requirements, and the need to frequently schedule abrasive deliveries to meet production demands.

    Solution

    The shift to GMA ToughBlast™ garnet for cleaning two steel ocean barges with a combined surface area of 10,219m² (110,000 ft²) proved transformative. The shipyard saw a remarkable reduction in abrasive consumption—just 250 tonnes of garnet were needed, compared to the 825 tonnes of copper slag typically required for a project of this scale. This reduction not only cut down on the amount of abrasive used but also minimized the volume of waste generated, leading to significant savings in disposal costs.

    Additionally, the lower consumption rate extended the time between refills of the blasting pots, eliminating the need for frequent interruptions during the night shift. Workers were able to continue blasting operations uninterrupted, with refills conveniently scheduled for the day crew. 
    This process efficiency was further enhanced by the use of bulk bags for refilling, replacing the need for multiple daily deliveries of slag by 25-tonne bulk tankers. The switch to bulk bags allowed for more flexible delivery schedules and reduced logistical strain, all while maintaining continuous production.

    Power through thick industrial coatings.

    GMA ToughBlast™

    Total consumption savings

    Using GMA ToughBlast™ , the shipyard experienced substantial savings of up to 70% in abrasive consumption. The total garnet consumption was only 250 tonnes compared to 825 tonnes of copper slag typically required for a project of this size. 

    70%

    Savings

    Using GMA ToughBlastTM

    GMA’s Garnet Recovery Program

    The shipyard took full advantage of GMA’s used garnet recovery program.
    Delivery vehicles were reloaded with spent garnet, which was then returned to GMA’s Fairless Hills processing plant. This closed-loop system eliminated disposal costs, which typically ran up to USD $150 per ton plus freight for slag. By reducing waste to zero, the shipyard significantly improved its waste management practices and overall environmental footprint.

    Low Dust Blasting With GMA Garnet™

    A More Sustainable Choice 

    Using GMA Garnet™ abrasives resulted in significantly lower dust emissions, thanks to the material’s natural toughness and high specific gravity, which ensures rapid settling. This reduction in dust not only improved operator visibility and safety on-site but also allowed blasting operations to be conducted during the day, unrestricted by the high dust levels previously caused by slag abrasives.

    With GMA Garnet™, the shipyard not only achieved greater efficiency in blasting operations but also implemented a more sustainable waste management strategy, aligning with modern environmental standards and reducing overall operational costs. 

    The cost effective and sustainable option for used blast abrasive media disposal.

    Garnet Returns Program

    Topics

    Abrasive Blasting Case Studies GMA ToughBlast Global Americas Sustainability