BlueSky at Work: Excellence in Rocketry
In this case study, BlueSky dust collectors are used at a SpaceX project in Texas during thermal spray coating processes. BlueSky machines filter dangerous particulates out of the air, supporting productivity and ensuring safety on site.
Brownsville, Texas is home to SpaceX’s 480 foot tall launch tower, an integral support structure for the Starship rocket program. To protect the tower from corrosion and thermal shock, a zinc-alloy arc spray was applied to mission-critical structures. This practice is standard in industry, extending the life of essential components and infrastructure.
On site, the thermal spray process was carried out in large, specially constructed spray booths. Surface preparation required grit blasting, and together with fine metallic particulates, produced large volumes of airborne dust. This by-product of metallizing processes quickly fills spray booths, limiting visibility and increasing the risk of inadvertent inhalation. As a prerequisite to mitigate unsafe working conditions, large capacity dust collectors were mandated to manage airborne hazards.
The particulates produced during metalization processes are typically extremely fine, often submicron, and are easily inhaled by workers when PPE is compromised. If inhaled, metallic fume and dust exposure increases the risk of respiratory issues, metal fume fever, pneumoconiosis, and other health risks. Airborne particulates are regulated by the EPA, OSHA, and local agencies, protecting personnel and the environment from high volume dust. All BlueSky technology meets and exceeds regulatory requirements so operators and workers can rest easy while they complete essential processes.
In March of 2021, BlueSky was contracted to capture airborne grit/zinc alloy dust during the metalization phase of the SpaceX launch tower. This project was stringently monitored, with BlueSky dust collectors being uniquely suited to the application. On site, our dust collectors resolved visibility issues in spray booths and protected personnel from accidental dust exposure.
While dust collectors generally meet regulatory requirements, BlueSky dust collectors are set apart from competitors by superior functional performance and ease of operation. In this application for zinc alloy spraying and surface preparation, small particulates cake onto dust collector filters tenaciously, severely diminishing the filter life and air capacity of the machine. BlueSky’s proprietary Pulse&Shake™ system and unique filter configuration, included in every BlueSky unit, deals with all thermal spray dust types, maximizing filter life without compromising flow rate. This novel technology makes our machines uniquely optimal for high volume fine dust.
The mobile configurable machine design of BlueSky dust collectors was essential, allowing the machine to be optimized quickly and easily for different phases of the project. The modular design of the machines deployment made it cost effective to maintain ideal ventilation airflow throughout the duration of thermal spray coating. These features set BlueSky apart from the rest, prioritizing cost effective and flexible configuration without compromising on performance.
When it's time to rent or purchase a dust collector for your project, don't compromise on safety and efficacy. SpaceX contractors trusted BlueSky to keep their site safe, and you can too. It’s not rocket science, breathe easy with BlueSky.
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Find out what codes regulate your site at the link below, and learn more about how dust collection protects personnel and the environment.
BlueSky Turn-Key Services
BlueSky offers more than just state-of-the-art dust collectors, we also provide white-glove services to maintain our dust collectors and replace filter decks on-site at your rocketry project. With a BlueSky Air Cleaner, you can say goodbye to in-house filter replacement and the expenses, hazards, personnel, and downtime that come with that process.
A BlueSky service contract saves you money on maintenance and ensure zero dust exposure to your staff and job site. Set up regular maintenance visits, or simply give us a call to replace your Smartbox®. Our highly trained technicians will personally replace your filters on site in a few minutes, not the hours or days it takes to service other machines. Your used Smartbox® will be replaced with a new one, and your site will be up and running before you can say ‘That was fast!’ Your used Smartbox® will be handled in a BlueSky facility, and the dust will never see fresh air again. With BlueSky’s dust collector servicing, maintaining your machine is a dust-free breeze.
Don't let the dust settle. Contact us now for a free quote or to discuss which BlueSky system is best for your project.
About Us
For inquires to rent or lease a BlueSky air-cleaning system, please submit the contact form or call using the numbers below, and we will respond shortly to begin configuring the ideal machine for your project site.
A BlueSky air-cleaning system can handle hazardous and non-hazardous dust types. It can also be configured as a dry-scrubbing system to capture or neutralize gaseous contaminants. A single BlueSky machine can induce 2,500 - 60,000 SCFM. Each machine is mobile, or can be placed on a fixed stand based on the project need.
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