Streamlining Surface Cleaning:

Introducing New Methods for Efficient Industrial Cleaning

by Rich Gomes, Director of Sales, Jetstream of Houston LLP |Published March 2025

High-pressure waterblasting for surface cleaning is not a new concept. Hand lancing is a common option for surface preparation and industrial cleaning applications. However, operators with hand lances often miss spots or can’t clean adequately due to the high amount of precision the job requires. This can result in dirty spots or the operator going over the same area multiple times.

Waterblasting manufacturers have moved forward by leaps and bounds in recent years, bringing the industry into the 21^st century by introducing automated methods that have revolutionized industrial cleaning. Automated industrial cleaning options increase safety and offer more efficiency than more traditional handheld waterblasting tools.

 

Automated Cleaning Options

High-pressure waterblasting breaks down dirt, grime, and old paint without damaging the surface underneath. The process leaves surfaces prepped and cleaned, removing everything from rust to old coatings to product residue or even damaged concrete.

Waterblasting can be used on many types of surfaces, even those that are at a significant height. For example, sometimes traditional methods can require crews to climb scaffolding with a waterblasting gun in hand and spend hours directing up to 40,000 psi of high-pressure water at close range, trying to thoroughly clean every square inch of a surface. This method comes with drawbacks. The work is physically exhausting and dangerous, calling for regular breaks to reduce fatigue and keep operators sharp for careful operation.

While there will always be a time and place for hand lancing, new automated robotic carrier systems are revolutionizing industrial cleaning applications. Automated carriers are programmed to move in a specific pattern across metal surfaces so operators can complete a thorough cleaning without any missed areas or unnecessary overlap, ensuring an efficient, productive process. The robotic carriers attach with magnets, allowing operators to remain safely at ground level while operating

the robot through a remote control.

Some systems feature four-wheel drive, a wide range of motion—both up and down and side to side—and the ability to drive upside down, allowing use on nearly any magnetic surface. The carriers are connected through an umbilical line to a control panel where an operator directs the robot from up to 100 feet away, significantly reducing the risk of injury from high-pressure water and hoses. Fall-protection lines secure the robot for safety.

 

The Benefits of Automation

While traditional, manual methods may get the job done at the end of the day—or a few days—they sacrifice efficiency. Automated waterblasting systems don’t need regular work breaks, safety protocol reminders, or training on how to implement best practices. To put it simply, the automated systems ensure continual operation and faster project completion.

What’s the impact on the bottom line? Many contractors find that for a cost similar to—or sometimes less than—scaffolding setup, two robots cut their other costs in half. Automated carriers often require half the number of waterblasting units and half the number of nozzles. Four crews can become four operators—one for each robot and pump. Additionally, a smaller crew size and enhanced safety reduces the risk of injury and resulting workers compensation claims.

Automated waterblasting systems present clear productivity and profitability benefits. They can achieve cleaning and removal rates of up to 40 square meters (430 square feet) per hour for paint removal jobs. In the surface preparation industry, where contractors are paid per square meter, this increases profits by allowing contractors to move onto the next job faster.

To fully realize the benefits of an automated approach to cleaning, it’s important to integrate the robotic carrier into a cohesive system that will maximize the overall efficiency of the job. This includes the pump, connections, nozzles, safety gear and—for some applications—a vacuum system.

 

Hazardous Material Collection

Open waterblasting systems use a swing arm and do not include a vacuum system. This provides benefits in terms of speed and efficiency. This method is cost effective because it doesn’t require a vacuum pump and truck.

Closed waterblasting with a vacuum blast can collects all materials, including the used water along with any paint, debris or other hazardous material. This leaves behind a completely clean and dry surface, which combats rust and allows for immediate resurfacing. Closed waterblasting also allows the hazardous material to be collected and properly disposed. Some operations even treat the water to allow safe disposal on site. Closed systems also remove vapor from the air, which improves visibility especially when operating in an enclosed area such as a storage tank. If considering this option, look for a manufacturer who can offer all aspects for the closed waterblasting system—from the robot to the vacuum, to the pump.

 

Powerful Pump Technology

While the new technology of an automated system might receive all the glory and attention, the fact remains that with any waterblasting system, the pump is the heart of productivity. The efficiency of an automated system means little without a pump system that minimizes downtime and matches the robotic carrier in efficiency.

The key to finding the right pump begins with identifying the correct size for the application. When cleaning water scale, coke, ore, or lime from reactors, storage tanks, or other facilities in steel mills, an operation should look for waterblasting pumps able to push out between 10,000–20,000 psi. However, when looking for surface preparation and cleaning for paint, rust, salt, concrete, or marine growth, operators should consider a pump that can reach up to 36,000 psi. For maximum versatility, contractors also require a pump that features interchangeable fluid ends. With this technology, crews can quickly and easily convert the pump to different operating pressures to match their full range of jobs.

While maintenance is unavoidable, operations benefit from pumps that allow streamlined service, with a simple design and a minimal number of parts. Those that use splash lubrication for oil do not contain an oil pump that can fail and cause a loss in oil circulation. Additionally, pumps that feature oversized roller and journal bearings and a forged crankshaft tend to have a long lifespan and maintenance intervals as long as 500 hours. Valves tend to be the most frequent wear item on waterblasting pumps, so opting for a pump that enables valve change outs in the field in five minutes or less has a huge impact on productivity. Additionally, considerations should include easy access to internal components and no special tool requirements.

Waterblasting safety doesn’t end where the water flows. Like the carriers they power, waterblast pumps should support safety on the jobsite. Consider pumps that feature a locking rod box that protects the operator from moving parts and high-pressure water while also providing ease of service.

 

Automated Solutions

Contractors who use automated waterblasting systems experience a boost in their bottom line, especially when they work with a trusted manufacturer. Surface cleaning tasks are far from glamorous, but the right automated tools can make it a far brighter—and safer—experience.