Evaluation of Needle Gun and Abrasive Blasting Technologies in Bridge Paint Removal Practices

This paper reviews the results of a U.S. Environmental Protection Agency (EPA) study that assessed needle gun technology as an alternative to conventional abrasive blasting technology to remove lead-based paint from steel bridges in western New York State. The study analyzed the operational and logistical aspects as they relate to worker health and safety, environmental protection, hazardous waste generation, and costs as compared to those arising from conventional abrasive blasting. In this 1992 EPA study, the costs and the product quality aspects favored conventional abrasive blasting over the needle gun technology for removing lead paint. However, abrasive blasting exposed workers to airborne lead levels that exceeded Permissible Exposure Limits (PELs) as established by the Occupational Safety and Health Administration (OSHA), as well as emitting high levels of lead-contaminated dusts and debris into the environment. It was estimated that more than 500 lbs of lead-contaminated spent abrasives and paint waste were released into the environment during paint removal operations. The needle gun system reduced (up to 97.5%) the generation of hazardous waste and the airborne concentrations (up to 99%) of respirable dusts and lead-containing particulates generated during paint removal operations. However, labor costs for the needle gun were three times higher than those for abrasive blasting primarily because of slower production rates that necessitated more operating personnel. The higher labor costs of the needle gun are partially offset by the increased costs associated with the expendable abrasive blast media and hazardous waste disposal. In the EPA study, the productivity of the needle gun system was 12.2 ft²/hr vs. 147.5 ft²/hr for abrasive blasting. A post blast was needed for the needle gun system to meet surface preparation specifications. When factoring in the costs of full containment structures to meet OSHA's 1993 Lead Exposure in Construction regulation, the needle gun system has the potential to be economically competitive with conventional abrasive blasting.