Blasting Media & Methods Compared
The abrasive matters as much as the operator. Here's what each media and method is used for, and its trade-offs.
Get QuotesMedia at a glance
| Media | Aggressiveness | Typical uses | Material cost / lb* |
|---|---|---|---|
| Silica sand | High, angular | Historically general-purpose; now widely avoided because of silicosis risk | $1.50–$1.80 |
| Coal slag / copper slag | High | Heavy rust, mill scale, and coatings on steel | $0.20–$1.00 |
| Aluminum oxide | High, reusable | Etching hard surfaces; cabinet work | $2.00–$3.00 |
| Steel grit / shot | Very high, reusable | Structural steel profiling in recovery systems | $2.00–$2.50 |
| Glass bead | Mild, peening | Satin finish on parts, light cleaning without heavy profile | $0.50–$2.50 |
| Walnut shell | Soft | Wood, aluminum, delicate parts | $1.00–$1.30 |
| Corn cob | Very soft | Wood (including logs), brick, light cleaning | $0.80–$1.00 |
| Baking soda | Non-etching | Paint stripping and degreasing without profiling metal | $1.50–$2.50 |
| Plastic media | Mild | Paint removal on delicate metal and composites | $3.00–$6.00 |
*Material cost per pound, from HomeGuide, “How Much Does Sandblasting Cost?” (updated June 2024). You pay for labor, equipment, and cleanup too, so see the cost guide. Crushed recycled glass is also widely used as an alternative to silica sand. HomeGuide doesn't price it, so it isn't in the table.
Sand (silica)
Silica sand cuts fast and is cheap, but breathing respirable crystalline silica can cause silicosis, lung cancer, and other disease. NIOSH has recommended since 1974 that silica sand be banned as a blasting abrasive. OSHA lists it alongside other abrasives with lung hazards. Many professional blasters use substitutes, though OSHA notes that some substitutes, such as coal slag and garnet, may also carry lung hazards. Ask what's in the media and request the safety data sheet.
Soda blasting
Sodium bicarbonate is soft and doesn't profile metal. That makes it popular for stripping paint from car bodies, boats, and parts where you don't want to warp thin panels or change the surface. Because it doesn't etch, a primer may need a profile added afterward. Residue should be thoroughly washed off before painting. Soda is water-soluble and alkaline, so protect plants and drains.
Glass bead
Spherical glass beads peen rather than cut, leaving a clean satin finish on aluminum, stainless, and machined parts. Glass bead is often used in cabinets for wheels, engine parts, and hardware. It's slow on heavy rust or thick coatings.
Walnut shell
Crushed walnut shell is soft enough to clean delicate surfaces, including wood, aluminum, and engine components, with little damage. It's commonly used in parts cleaning and on some log and wood surfaces.
Dry ice blasting
Dry ice blasting fires CO2 pellets that turn to gas on impact. There's no spent media to clean up, just whatever was removed. It's used on electrical equipment, molds, food and manufacturing equipment, and fire and smoke cleanup. HomeGuide prices it at $3.50–$5.00/sq ft, the highest of the methods it lists. CO2 can build up in enclosed spaces, so ventilation matters.
Dustless / wet blasting
Wet systems, including vapor-abrasive and "dustless" brand equipment, mix water into the abrasive stream. This sharply cuts airborne dust, so these systems are popular for mobile work near homes and traffic. HomeGuide lists dustless (vacuum) blasting at $2.00–$3.00/sq ft and wet sandblasting at $1.30–$3.50/sq ft. Bare steel can flash-rust after wet blasting, so operators often use rust inhibitors. Wet methods reduce dust, but they don't remove the obligations that apply to lead paint.
Sources: HomeGuide, “How Much Does Sandblasting Cost?” (updated June 2024); OSHA, “Protecting Workers from the Hazards of Abrasive Blasting Materials” (OSHA 3697); NIOSH, “Prevention of Silicosis Deaths”.
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