Bust the Dust with Hazardous Dust Control Solutions from Clayton

How Can Dust Be a Hazard in Aerospace?

However tiny the risk may seem, dust can cause major damage – not only if ingested by an aircraft or inhaled by a human, but also if ignited.

Dust as Foreign Object Damage (FOD) to Aircraft

Every year foreign object damage costs the aviation industry US$13 billion through direct costs like fixing damaged parts, to indirect costs such as delays, unscheduled maintenance, increased fuel costs, and aircraft changes.

At its worst, FOD can cause expensive and significant damage to aircraft, along with injuries to workers, pilots, and passengers, and even death.

Examples of external FOD hazards include bird strikes, hail, ice, sandstorms, ash clouds, or objects left on the runway, while examples of internal FOD hazards include items that could get jammed in control cables, and short-out electrical connections.

One example of FOD that is often not considered risky is fine particulate matter (PM2.5). These dust particles can be 30 times smaller than the width of a human hair, they can be harmful to aircraft, and also the catalyst for numerous deadly health conditions in humans.

Dust as a Health Risk for Aircraft Mechanics

PM2.5 commonly encountered by aircraft mechanics include hexavalent chromium (Cr VI), lead, cadmium, aluminium dust, carbon fibre, ceramic dust, and fibreglass, which are all found within the coating of an aircraft which is commonly sanded back and repainted.

Researchers from the National Aeronautics and Space Administration (NASA) found, that breathing in PM2.5 particles likely contributed to the early death of 2.89 million people globally.

Of these premature deaths, 1.19 million died from heart disease, 1.01 million died from a stroke, 287,000 died from chronic obstructive pulmonary disease (COPD), while a further 23,000 passed away from lower respiratory infections, and 166,000 died from lung cancer.

Dust Causing Combustible Dust Explosions in Hangars

Along with FOD and health risks, dust can also be explosive. According to the US Occupational Safety and Health Administration (OSHA), combustible dusts can fuel a flash fire or explosion when dispersed in a dust cloud.

In a study conducted between 2006 and 2017, the US Chemical Safety and Hazard Investigation Board (CSB) identified 111 combustible dust incidents that resulted in 6 fatalities and 337 injuries.

To minimise the risk of further incidents involving combustible dust, OSHA advises workers in industries that handle combustible solids, like the aviation industry, to capture dust before it escapes into a work area by using properly designed, installed, approved, and maintained dust collection systems.

Once the dust is captured, OSHA advises that any combustible dust be contained within equipment, systems, or rooms built to safely handle combustible dust.

After containing the combustible dust, OSHA encourages workers to clean their work areas, overhead surfaces, and concealed spaces frequently and thoroughly to remove any combustible dust not captured or contained.

Keeping your Hangar Dustless with Clayton – Dustless Made Simple

Since 1984, the Industrial and Aerospace Source Capture Specialists, known as Clayton, have become an industry leader in hazardous dust control solutions. Starting with an initial vacuum designed to remove asbestos, the company has cultivated a legacy of innovation and is consistently improving its product line to best meet the needs of workers in the automotive, aerospace, and industrial sectors.

Clayton is best known for its ability to design solutions to solve specific dust control problems for customers within the aerospace industry – from designing dustless sanders for trouble areas of the F-22 Raptor, to custom piped systems designed to help commercial airlines move planes through their paint hangars.

Understanding the importance of knowing their customers’ needs, Clayton puts the tools and equipment into the hands of workers to ensure they are satisfied with the dust removers.

DustMaster System Configurations – A DustMaster System for any Occasion

Clayton says each configuration of the DustMaster System builds on one another, and interlock to form a single standalone unit. The DustMaster ULPA Vacuum is available as a standalone unit and is the heart of the DustMaster System.

The Consolidated Hose Reel and Toolkit (CTK) add-on provides storage for vacuum hoses, compressed air lines, sanders, tools, and abrasives. It is available with or without casters and can ride atop the vacuum.

Clayton’s Cyclonic pre-separator is an add-on unit that captures 99% of debris before it gets to the primary filter bag. This means fewer filter changes and less loss of suction.

The all-in-one configuration for the DustMaster System sees the suction, tool storage, and cyclonic pre-separation all included in a single package.

DustMaster Electric and Pneumatic ULPA Vacuums – A Powerful and Mobile Solution

Available in both electric and pneumatic, the DustMaster Series ULPA Vacuums are Clayton’s most powerful solution for portable dustless sanding, dust extraction, and general cleanup – and the heart of the DustMaster system.

It is designed for the removal of coatings containing hexavalent chromium (Cr VI), lead, cadmium, other heavy metals, carbon fibre, ceramic dust, fibreglass, and mould.

Clayton notes the DustMaster units are portable, and include features for the most demanding applications, while all components are extra-heavy duty to ensure long life and extreme durability in military and industrial environments.

The DustMaster employs three stages of filtration, with a filter bag, a pre-filter that is 95% efficient at 0.3 microns and an ULPA filter that is 99.9995% efficient at 0.12 microns. Clayton says the ULPA filter will last several years with proper maintenance and use.

The DustMaster also features the patented Safe-Filter-Change, which allows workers to change disposable filters in complete safety, by leaving the vacuum running while changing the filter bag. The downdraft into the pre-filter or ULPA filter contains any dust trying to escape and prevents worker exposure.

Other features include a dual vacuum motor, Auto On/Off feature, adjustable shut-off delay, filter gauge panel and a built-in manifold for air tools.

The DustMaster is available with a range of bags and filters, along with a nylon cover to help keep the DustMaster looking like new. Contact us for more information.

Hornet Ultra-Portable Pneumatic HEPA Vacuum – For Dustless Sanding and Composites Fabrication

The Clayton Hornet Ultra-Portable Pneumatic HEPA Vacuum is incredibly efficient and powerful enough to use with sanders, grinders, and cutting tools. The unit is small enough to carry out to the flightline but packs more than enough power for corrosion control, surface preparation, or general cleanup.

The Hornet has been designed for the removal of coatings containing hexavalent chromium (Cr VI), lead, cadmium, other heavy metals, aluminium dust, carbon fibre, ceramic dust, fibreglass, and mould. These units are extremely portable, and lightweight, and feature extra-heavy-duty components that ensure long life and extreme durability in industrial and military environments.

Clayton says the Hornet also incorporates Safe Filter Change, which means technicians can open the filter compartment and change the primary vacuum filter without protective gear or exposing other workers to hazardous dust.

Fitting into a package with a diameter of only six inches, the Hornet is so portable that it can be used for deployment or mobile maintenance operations. Workshops with central vacuum systems or larger mobile vacuums will find new freedom to perform spot repairs in the hangar or on the flightline, without exposing workers or the environment to hazardous dust.

Features of the Hornet include ATEX certification for use in combustible dust atmospheres, a cooling wand, an ergonomic backpack harness, and a wall bracket to mount the Hornet.

The Hornet can be purchased in 4 packages ranging from the ACE-1000 configuration which comes with random orbital sanders and abrasives, along with backup pads and protector pads for each, to the 500-400 package which is just the Hornet Vacuum. Contact us for more information.

The Scorpion Handheld HEPA Vacuum – An Industry First

The Scorpion HEPA Vacuum is a pneumatic vacuum so light and small it can be carried by hand or worn over the shoulder. The device’s powerful air motor easily picks up dust and debris and helps maintainers control FOD while also protecting them from exposure to heavy metals such as cadmium, hexavalent chromium, lead, and more.

The Scorpion can be used for cleanup after manufacturing and maintenance, or it can be paired with a shrouded tool to control dust and debris while sanding, grinding, cutting, or drilling.

Clayton says the Scorpion features a tough Lexan canister which showcases the cyclonic action of the vacuum. Users will get hours of enjoyment watching rivets, dust, and metal shavings spinning around the belly of the Scorpion.

The HEPA cartridge filter provides the right level of protection, exhausting clean air back into the workplace. For vacuum sanding or shrouded tools, the Scorpion features pass through compressed air, so you’ll only need a single air line to power the vacuum and tool.

Packages available with the Scorpion include a Cleanup Kit, a Vacuum Sanding Kit, and a Military Combo Kit that features everything you need for vacuum sanding and cleanup. Contact us for more information.

The WartHog G2 HEPA Vacuums – HEPA Vacuums for Industrial and Aerospace Applications

Clayton’s WartHog G2 HEPA Vacuums are designed to conduct a broad range of jobs across a wide variety of industries. Options include cleanup and dustless sanding models for general and toxic dust commonly encountered in the industrial and aerospace sectors.

All WartHog G2 models feature absolute HEPA filtration, feature the choice of electric or pneumatic power, and can be configured with a poly or steel tank.

Manual On/Off models are designed for general cleanup and housekeeping for 1-2 users and are considered best for collecting dry dust and debris where absolute HEPA filtration is required.

Pneumatic Auto On/Off Dustless Sanding models are designed for dustless sanding with pneumatic sanders and are best suited to collecting dry dust and debris from sanding operations where absolute HEPA filtration is required.

Cleanup and toxic dustless sanding models with Manual On/Off are designed for toxic cleanup and housekeeping. They are best suited to collecting dry dust and debris where absolute HEPA filtration is required. These vacuums also include a Differential Pressure Gauge for filter monitoring, a grounding/bonding jack, and Safe-Filter-Change port for on-the-spot bag changes. Contact us for more information.

The WartHog HEPA Cleanup Vacuums – An Ideal Solution for Dust Extraction and General Cleanup

Clayton’s WartHog HEPA cleanup vacuums provide the airflow, filtration, and durability expected from an industrial vacuum. They are designed to remove coatings containing hexavalent chromium (Cr VI), lead, cadmium, other heavy metals, carbon fibre, ceramic dust, fibreglass, mould, and asbestos.

These units feature extra-heavy-duty components that ensure long life and extreme durability for industrial and military environments. Components are modular and field serviceable for easy replacement after years of service.

The WartHog is available with either electric or pneumatic power and can be had with either a steel or poly tank.

Clayton also offers WartHog HEPA Aero vacuums which are an ideal solution for dustless sanding, dust extraction, and general cleanup. These vacuums provide the airflow, filtration, and durability expected from an industrial vacuum. They are designed to remove coatings containing hexavalent chromium, lead, cadmium, other heavy metals, carbon fibre, ceramic dust, fibreglass, mould, and asbestos.

The WartHog HEPA Aero vacuum features extra-heavy-duty components that ensure long life and extreme durability for industrial and military environments. Components are modular and field serviceable for easy replacement after years of service.

Aerospace features include a grounding jack to eliminate static buildup and a Safe-Filter-Change port for containing hazardous dust while changing filters.

Clayton also offers the WartHog HEPA Wet/Dry Vac, which is an ideal solution for dust extraction and general cleanup. These vacuums provide the airflow, filtration, and durability expected from an industrial vacuum. They are designed to remove coatings containing hexavalent chromium, lead, cadmium, other heavy metals, carbon fibre, ceramic dust, fibreglass, mould, and asbestos.

Clayton says WartHog HEPA Wet/Dry vacuums feature extra-heavy-duty components that ensure long life and extreme durability for industrial and military environments. Components are modular and field serviceable for easy replacement after years of service. These devices also include water level automatic shut-off for picking up bulk liquids or wet debris without a HEPA filter. Contact us for more information.

The Barracuda Immersion Vac/Separator – Containing Sparks and Combustible Dust

Clayton’s Barracuda Two User Immersion Vac/Separator has been designed specifically to capture live sparks, embers, and combustible dust like aluminium and titanium. The device’s powerful vacuum motor draws air and collected particles into the immersion tank and forces it through a roiling water bath, instantly quenching sparks, and thoroughly wetting dust out of the airstream.

Meanwhile, three stages of additional filtration ensure that the air exhausted from the system is dust and moisture-free.

When it is time to empty the tank, all the user needs to do is pull the valve lever to dump the water and debris out through a filter sock and into any floor drain. Once the tank is empty, the system can be connected to a normal garden hose and a series of spray heads inside the unit will flush the tank.

This ensures no sediment builds up on the internal components. The large window on the side of the Barracuda makes it simple to confirm the water level in the tank and allows spectators to view the carnage as dust and debris get consumed by the Barracuda.

Other features of the Barracuda include an all-stainless-steel construction that will never rust, along with a drain filter to easily collect and dispose of sludge, a low-level water shut-off, and an automatic on/off pneumatic tool sync.

The Barracuda can be fitted with a range of accessories including cleanup hoses, air/vac work hoses, compressed air lines, a conductive heavy-duty clean-up toolkit, and an aircraft grounding cable. Contact us for more information.

The Stingray HazLoc HEPA Vacuum – Designed for Potentially Explosive Dust Atmospheres

The Stingray HazLoc HEPA Vacuums are designed for use in potentially explosive dust atmospheres and the removal of hexavalent chromium, paints containing lead or chromates, aluminium dust, carbon fibre, ceramic dust, fibreglass, and mould.

The vacuum features extra-heavy-duty components that ensure long life and extreme durability for industrial and military environments. Clayton says the Stingray incorporates Safe Filter Change for the containment of hazardous dust while changing filters.

Other features of the Stingray include ATEX certification for use in explosive dust atmospheres, all-stainless-steel non-sparking construction, an adjustable machined aluminium air-powered venturi, a grounding jack and cable, and is available in either a 5 or 15-gallon capacity.

Accessories available for the Stingray include filters, filter bags, prefilters, an aircraft grounding wire and plug, and a compressed air hose. The device is also compatible with Clayton’s range of cleanup vac and air/vac work hoses. Contact us for more information.

Tent and Vent Overspray Filtration System – Paint Anywhere, Any Shift

The Clayton Tent and Vent is designed to allow aircraft painting on the hangar floor without exposing workers to overspray and VOCs. The TV-1400 enables a better paint application with less rework as it removes and filters overspray paint particulate which can often dry in the air and contaminate the fresh paint job.

Systems designed to remove airborne paint particulates, especially those containing chromates, must adhere to NESHAP 98 Test Method 319 for aerospace painting and de-painting operations. The TV-1400 meets all standards for the safe evacuation and filtration of chromated primers and other coatings.

After the work area is masked with a poly tent, the TV-1400 is connected to compressed air. It maintains the tented area under negative pressure, rapidly turning over the air within, while three wet particulate filters collect overspray, and a 24-inch charcoal filter absorbs VOCs returning clean odour-free exhaust air into the hangar.

The TV-1400 exhaust can be connected to optional flex ducting to route the clean air to the outside. The Tent and Vent System can be purchased with or without consumables, and a consumables replenishment kit is also available.

Accessories available for the Tent and Vent System include a range of filters and a duct extension kit with an available storage and transport cart. Contact us for more information.

AeroLite Composite Housing Palm Sanders – Durable and Smooth Sanding Solutions

Clayton’s range of AeroLite Composite Housing Palm Sanders features three sizes of vibration-absorbing comfort grips that improve feel and reduce hand fatigue. The range of palm sanders also features a curved alloy steel throttle level that provides unparalleled durability with perfect ergonomics.

Designed to reduce internal friction for a higher power transfer ratio, simplified maintenance, and longer tool life, the AeroLite range has a full floating rotor. This polymer rotor provides faster acceleration and lower overall tool weight.

A tip valve provides precise teasing for perfect sander control, whole a bearing protection system allows one-way filtered airflow to pass into the spindle bearing chamber, resulting in a cooler running, dust-free bearing with an extended life.

On the underside of the AeroLite, a speed control switch combines on-the-fly speed adjustment while helping to prevent inadvertent switching. A single-piece motor shaft and pad balancer features heat-treated steel and precision machined construction for smooth and durable operation.

Central vac sanders require a portable or central vacuum for dust extraction, which comes standard with a 1-inch threaded vacuum port so it can be attached to any Clayton vacuum system.

Random orbital or dual action sanders simultaneously spin the sanding disk and move in an ellipse. This unique random sanding action eliminates swirl marks in your work. These are available in three sizes and three orbits.

Orbital or jitter sanders move from front to back and side to side simultaneously and are typically used for fine-finish sanding or getting into square corners. These sanders are available in 7 sizes, all with a 1/8-inch orbit.

Henchman Supplies all the Clayton Products You Need for Dustless Sanding

Henchman Tools is an international single-source supplier of premium hand and power tools, specialised tooling solutions, and custom-designed toolkits renowned for their superb quality finish and design.

As an official distributor of Clayton products in Australia, we can import and supply their range of vacuums, sanders, pads, hoses, air lines, and filters for any aviation and aerospace company, both locally and internationally. Contact us for more information.