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Surface Preparation Solutions For Defense & Heavy Manufacturing

Heavy equipment manufacturing facilities often struggle with struggle with breakdowns, lost downtime, bottlenecks, and labor shortages. For 50 years, BlastOne has been providing effective corrosion control solutions that help manufacturers improve productivity and profitability. With over 50 years of experience, we specialize in high-quality, efficient blasting and coating systems tailored to meet the unique needs of defense manufacturing and heavy equipment companies. Whether you’re facing tight deadlines, quality challenges, or cost pressures, BlastOne is your trusted partner for achieving consistent, reliable results. 

Blast & Paint Solutions

Are you looking to remove a bottleneck in your production facility? Blasting and painting heavy equipment that is built from ¾” thick steel and weighs a 3-4 ton isn’t something that every company is geared up to support. However it is these very facilities in USA that today are looking to invest in new facilities and technology. They are seeking to transform their coating operations from a facility that is dusty, dirty and dangerous, into a cutting-edge, robotic center of excellence. BlastOne has been in the game of building blast and paint facilities for over 50 years. If you are looking for a solution that is highly productive, and built to meet the needs of your rugged, behemoth sized equipment, look no further. 

Blast and Paint Facility Design

BlastOne supplies blast and paint facilities that cut costs and improve both production rates and safety records. Large, enclosed halls can be designed and engineered to incorporate robotics and provide ventilation and visibility for both painting and grit blasting. The abrasive recovery and recycling systems work efficiently, while humidity-controlled air helps prevent oxidation and flash rusting of the steel between the blasting and coating processes. The configuration of the rooms can be designed around the equipment that you are building or repairing. Ventilation systems are designed to meet the industry standards, to ensure compliance and operator safety. Normally, because of the size of the rooms, a separate structure is required for the booth and building structure. 

BLAST AND PAINT HALL APPLICATION

BlastOne provides a diverse selection of high-performance products designed to meet the unique challenges of the defense & heavy equipment industry:

robotics with cabin

Robotic Blast Room with Cabin

novae robotics

Robotic Blast Room

novae robotics control room

Robotic Control Room

novae cascading airwash system

Abrasive Recycling

novae oscillating conveyor

Oscillating Conveyor

novae abrasive tower

Abrasive Storage Tower & Blasting Equipment

blast booth with material handling

Blast Room with Material Handling

heil air distribution

Air Distribution

novae dust collection

Dust Collection


STRATEGIC FACILITY PLANNING & CAPACITY STUDIES

Designing a blast and paint facility for defense and heavy equipment manufacturing is a long-term investment that requires careful planning. BlastOne uses a proven Design | Bid | Build approach to deliver high-performance, cost-effective facilities tailored to each client’s needs. From concept to completion, BlastOne streamlines processes, reduces risks, and prepares operations for future growth. With more than 45 years of expertise, BlastOne also provides ongoing maintenance, training, and consumable support—ensuring each facility operates reliably throughout its life cycle. View Our Project Journey

BlastOne’s team of experienced production planners carefully reviews your current schedules and future workload to ensure your facility is right-sized and aligned with long-term growth. Capacity Studies provide a systematic approach to improving the efficiency of blasting and painting operations—analyzing workflows, identifying bottlenecks, and delivering practical solutions to enhance productivity while lowering costs. By investing in a strategically designed blast and paint facility, defense and heavy equipment manufacturers can accelerate production, reduce expenses, and achieve consistent, high-quality coatings.

Key Components of Capacity Studies:

      • Workflow Assessment | A thorough evaluation of current processes to identify inefficiencies.

      • Bottleneck Identification | Detection of areas that impede productivity.

      • Implementation of Solutions | Application of targeted improvements tailored to specific operational needs.

    • Sustained Efficiency | Development of strategies to ensure long-term operational gains.

EVERY JOURNEY STARTS WITH A PHONE CALL
Connect with a professional today.

Robotic Solutions

The use of robotics in sandblasting is an emerging trend within the defense and heavy equipment industry. Robotic blasting systems improve productivity, reduce costs, and enhance safety in ways that traditional methods cannot. These systems are easy to operate, highly customizable, and can switch to manual blasting when needed. Many facilities can integrate robotic blasting systems to enhance productivity and consistency in surface preparation. This is especially beneficial for companies that regularly produce similar structural components, such as tanks, beams, or other heavy equipment. 

For future growth, you can design a “robot-ready” blast room. This allows for scalability, enabling you to automate abrasive blasting processes as your product lines expand with the simple installation of a robotic system. 

Robotic 3

ROBOTIC BLAST FACILITIES

BlastMan robots, designed specifically for blasting environments, can achieve production rates of up to 2,000 square feet per hour, ensuring efficient and uniform surface treatment. These advanced robotic systems are built to withstand the harsh conditions of blast chambers, offering reliable and precise operation. Trusted for over 30 years in the USA and globally for blasting railcars and foundry blocks, BlastMan robots provide a proven track record. Automating the blasting process can reduce manual labor, improve safety, and ensure high-quality standards across all treated surfaces. 

FOR INFORMATION ON SELECTING
ABRASIVE BLASTING ROBOTS –
Refer to our comprehensive Buying Guide.

Abrasive Recovery Systems

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Abrasive media is one of the biggest recurring costs for any abrasive blasting facility. A single blaster can blast up to 6 tons of steel grit in a single day… however if a blasting facility is designed correctly, you are able to recycle your steel grit between 50-100x, which lowers the cost dramatically.  

BlastOne offers an many different abrasive recycling options, which operates seamlessly in the background, ensuring no interference with daily operations and requiring minimal maintenance.

Performance3 Analytics

OPTIMIZING SURFACE PREPARATION: THE PERFORMANCE3 ADVANTAGE

PEATS – How to optimize your current repair process.

For 50 years BlastOne has been obsessed with helping our clients achieve Superior Performance. While other companies focus on selling products, BlastOne owes its success to understanding which products, practices, and procedures deliver the greatest productivity and profitability to the project at hand.  Our mission is to make jobsites Faster, Safer, Cleaner – in service to both the industrial work crews as well as to the assets they’re protecting.

Our winning formula focuses on providing Superior Equipment, Superior Abrasives, and Superior Know-How to maximize safety and productivity on each and every jobsite. The outcome of this focus resulted in developing the industry’s most systematized strategy for delivering Superior Performance and profitability. We call this strategy PERFORMANCE 3… and our clients experience average productivity lifts of 30% along with 10% cost reductions when implementing our recommended tactics.

    • Process (P) | We decide what is the process and/or method of surface preparation for the project at hand, taking into account any unique challenges.

    • Equipment (E) | Determine which equipment combination will give you the safest and greatest performance.

    • Abrasive (A) | Different jobs may require different abrasives. Working from the specification and application backwards, we select the right abrasive to most efficiently achieve the results required.

    • Technology (T) | IntelliBlast providing real-time results from the field to ensure operations requirements and expectations are being met, and exceptions are being managed.

  • Sustain (S) | Follow through on the improvements made through real-time monitoring, onsite support, on-the-tools training and regular reporting.

NEED HELP SELECTING THE RIGHT EQUIPMENT FOR YOUR PROJECT?
Check out our Blasting and Spray Equipment Buying Guides for detailed recommendations tailored to your needs.

Case Studies

Steffes Corporation Image

ROBOTIC BLAST SYSTEM FOR ABRAMS TANKS

An automated 8-axis robotic blast booth delivered a fourfold increase in productivity, cutting blasting cycle times from 12 man-hours to under three hours and reducing manual touch-ups from 12 hours to just 20–30 minutes. The solution optimized efficiency, recovered 100% of steel grit, and lowered labor costs while meeting rising production demand.

— General Dynamics Land Systems 

MATERIAL HANDLING SOLUTION FOR 80 TON BEHEMOTHS

A government defense contractor needed a blast and paint facility capable of handling large military vehicles efficiently. BlastOne designed and installed a custom blast room and paint booth system with full abrasive recovery and dust collection. The solution improved turnaround time, reduced labor requirements, and ensured compliance with strict military coating standards—all while maximizing safety and productivity for high-demand defense projects.

— Government Defense Contractor

BUILD IN-HOUSE BLAST AND PAINT CAPABILITY

Granite State Manufacturing partnered with BlastOne to modernize its blasting operations. By installing a high-efficiency blast booth with full abrasive recovery and dust collection, the company improved productivity, reduced manual cleanup, and maintained consistent surface preparation quality. The solution also enhanced worker safety and streamlined workflow to support increasing project demands.

Granite State Manufacturing

Real Solutions. Real Impact.

See the Results!

Facts & Industry Challenges

    • Why do we blast and paint these large pieces of equipment 

      Defense and heavy equipment are typically made from steel, and steel rusts when it is open to the elements meaning that our equipment will breakdown and eventually rust to nothing, unless we intervene. Steel products need an impenetrable durable barrier to protect the steel from corrosion, we call it paint. These assets are large investments, and if they become prematurely corroded, impact profitability and reduce productivity. Abrasive blasting will ensure that the surface is ready for quality coating (paint) application, by creating a clean surface with an anchor profile, which strengthens the coating adhesion and lengthens the lifespan of the coating. 

    • Lack or regular maintenance leading to breakdowns and High refurb costs 

      Blast media is aggressive, and its supposed to be… however this means that our facilities are constantly trying to wear themselves out and need the help of a good maintenance program to keep them operating in top condition. Regular daily, weekly and quarterly maintenance can extend a blast booths life from 15 years to 45 years, and if you have found someone on your crew that understands this equipment and can do the regular maintenance, He will become your greatest asset. But like all things, we can all do with training, so enroll your maintenance team in BlastShield Academy, they will learn the fine-art of maintaining a blast system, and how to keep a facility operating productively. 

    • Production bottlenecks from growing demand and labor shortages 

      Industry is returning to America and combining this with the current tight labor market is causing labor shortages in fabrication facilities which results in production bottlenecks and the struggle to lift production rates. This is pushing the demand for robotic solutions to a new level. 

Defense & Heavy Manufacturing Resources

25 Important Considerations when Building a Blast Facility

If you are purchasing a turnkey blast room for building it yourself, there are 25 subjects you need to be well versed in. BlastOne has compiled a detailed report containing an in-depth guide on all the critical components of a blast room: design considerations, abrasive education, and production techniques.

Download

BlastOne Facilities & Equipment Catalog

Looking to improve your blasting, painting, or finishing operations? The BlastOne Facilities Catalog details custom-built blast and paint rooms, dust collection systems, abrasive recovery, robotics, and material handling solutions—engineered for safety, efficiency, and reliable performance in demanding industrial environments.

Download

Knowledge & Learning

Videos from the Experts

How to | Primed Insights | Safety Tips

3 Reasons Why Blasters and Painters Should Have a UV Light

Watch Video

Chloride Field Testing Demonstration

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Fairhaven Shipyard Testimonial

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