FactSheet
Hazard Alert: Combustible Dust Explosions
Combustible dusts are fine particles that present an explosion hazard when
suspended in air in certain conditions. A dust explosion can be catastrophic
and cause employee deaths, injuries, and destruction of entire buildings. In
many combustible dust incidents, employers and employees were unaware that
a hazard even existed. It is important to determine if your company has this
hazard, and if you do, you must take action now to prevent tragic consequences.
How Dust Explosions Occur
In addition to the familiar fire triangle of
oxygen, heat, and fuel (the dust), dispersion
of dust particles in sufficient quantity and
concentration can cause rapid combustion
known as a deflagration. If the event is confined
by an enclosure such as a building, room,
vessel, or process equipment, the resulting
pressure rise may cause an explosion. These
five factors (oxygen, heat, fuel, dispersion, and
confinement) are known as the “Dust Explosion
Pentagon”. If one element of the pentagon is
missing, an explosion cannot occur.
Catastrophic Secondary Explosions
An initial (primary) explosion in processing A pharmaceutical plant after a dust explosion.
equipment or in an area where fugitive dust has
accumulated may dislodge more accumulated Industries at Risk
dust into the air, or damage a containment Combustible dust explosion hazards exist in
system (such as a duct, vessel, or collector). a variety of industries, including: agriculture,
As a result, if ignited, the additional dust chemicals, food (e.g., candy, sugar, spice,
dispersed into the air may cause one or more starch, flour, feed), grain, fertilizer, tobacco,
secondary explosions. These can be far more plastics, wood, forest, paper, pulp, rubber,
destructive than a primary explosion due to furniture, textiles, pesticides, pharmaceuticals,
the increased quantity and concentration of tire and rubber manufacturing, dyes, coal, metal
dispersed combustible dust. Many deaths in processing (e.g., aluminum, chromium, iron,
past incidents, as well as other damage, have magnesium, and zinc), recycling operations,
been caused by secondary explosions. fossil fuel power generation (coal), and 3D
welding (a form of 3D printing).
Initial Explosion Secondary Explosion
Prevention of Dust Explosions
To identify factors that may contribute to a
explosion, OSHA recommends a thorough
hazard assessment of:
• All materials handled;
• All operations conducted, including by-products;
• All spaces (including hidden ones); and
• All potential ignition sources.
Dust Control Recommendations • Spark/ember detection for suppression activation;
• Implement a hazardous dust inspection, testing, • Develop an emergency action plan; and
housekeeping, and control program; • Maintain emergency exit routes.
• Use proper dust collection systems and filters;
Applicable OSHA Requirements Include:
• Minimize the escape of dust from process
equipment or ventilation systems; • §1910.22 Housekeeping
• Use surfaces that minimize dust accumulation and • §1910.307 Hazardous Locations
facilitate cleaning; • §1910.1200 Hazard Communication
• Provide access to all hidden areas to permit • §1910.269 Electric Power Generation, Transmission
inspection; and Distribution (coal handling)
• Inspect for dust residues in open and hidden areas • §1910.272 Grain Handling Facilities
at regular intervals; • General Duty Clause, Section 5(a)(1) of the
• If ignition sources are present, use cleaning Occupational Safety and Health Act (Employers
methods that do not generate dust clouds; must keep workplaces free from recognized hazards
• Use only vacuum cleaners approved for dust likely to cause death or serious physical harm).
collection; and
Resources
• Locate relief valves away from dust deposits.
Readily available from www.osha.gov are:
Ignition Control Recommendations • Combustible Dust National Emphasis Program
• Use appropriate electrical equipment and wiring • Safety and Health Information Bulletin (SHIB) (07-
methods; 31-2005) Combustible Dust in Industry: Preventing
• Control static electricity, including bonding of and Mitigating the Effects of Fires and Explosions
equipment to ground;
See the SHIB or www.osha.gov for other applicable
• Control smoking, open flames, and sparks;
standards.
• Control mechanical sparks and friction;
• Use separator devices to remove foreign materials The primary National Fire Protection Association
capable of igniting combustibles from process (NFPA) consensus standards related to this hazard are:
materials; • NFPA 654, Standard for the Prevention of Fire
• Separate heated surfaces from dusts; and Dust Explosions from the Manufacturing,
• Separate heating systems from dusts; Processing, and Handling of Combustible
• Select and use industrial trucks properly; Particulate Solids
• Use cartridge-activated tools properly; and • NFPA 61, Standard for the Prevention of Fires
• Use an equipment preventive maintenance program. and Dust Explosions in Agricultural and Food
Injury and Damage Control Methods Processing Facilities
• NFPA 484, Standard for Combustible Metals
• Separation of the hazard (isolate with distance);
• NFPA 664, Standard for the Prevention of Fires and
• Segregation of the hazard (isolate with a barrier);
Explosions in Wood Processing and Woodworking
• Deflagration isolation/venting;
Facilities
• Pressure relief venting for equipment;
• NFPA 655, Standard for the Prevention of Sulfur
• Direct vents away from work areas;
Fires and Explosions
• Specialized fire suppression systems;
• See www.nfpa.org to view NFPA standards.
• Explosion protection systems;
This is one in a series of informational fact sheets highlighting OSHA programs, policies or
standards. It does not impose any new compliance requirements. For a comprehensive list of
compliance requirements of OSHA standards or regulations, refer to Title 29 of the Code of Federal
Regulations. This information will be made available to sensory-impaired individuals upon request.
The voice phone is (202) 693-1999; teletypewriter (TTY) number: (877) 889-5627.
DSG 12/2014
