The danger of aluminum dust: an underestimated risk in industrial environments

What is aluminum dust?

When grinding, milling, drilling or polishing aluminum, particulate matter is released. These tiny particles are highly flammable and spread easily through the air. During processing, the protective oxide layer on the metal disappears, causing the dust particles to react more quickly with oxygen. This increases the risk of explosion. A well-functioning dust extraction system prevents these concentrations from being reached at all.

Risks of aluminum dust

Aluminum dust poses significant risks, which can be divided into three main categories:

• health: The fine particles penetrate deep into the lungs and can lead to chronic conditions such as bronchitis or aluminosis — a form of dust lung. Skin and mucous membranes are also irritated.
• Explosion and fire hazard: Just about 30-60 g/m³ of air, aluminum dust forms an explosive mixture. Sparks, hot surfaces or electrostatic discharge can already be sufficient for an explosion, especially in confined spaces.
• Environment: Precipitated aluminum dust pollutes soil and water. In the long run, these harms plants and animals in the environment.

These risks highlight the need for stringent security measures. In addition to appropriate personal protective equipment, dust extraction systems are particularly crucial — they ensure aluminum-free air and thus create a clean and safe working environment.

Legal obligations and explosion protection

The explosion limits for aluminum dust are around 30—60 g/m³ of air. That means: even small sources of ignition can cause an explosion. Because the fine particles spread easily in the air, such an explosion can cause a devastating chain reaction and trigger further detonations.

Due to the significant risk of explosion, companies where aluminum dust is released are obliged to carry out a risk analysis in accordance with the Arob Act. In doing so, all possible sources of danger are identified and the associated risks are evaluated. This assessment includes the dust concentration in the air, the particle size of the dust, the presence of ignition sources, the spatial conditions, as well as the tools and work processes used in explosive zones.

Based on this risk analysis, companies must take appropriate security measures. This includes, in particular, the installation of ATEX-certified extraction and filter systems, regular cleaning to prevent dust accumulation and the training of employees. It is also mandatory to draw up an explosion protection document. It describes all required safety measures and states that they are actually complied with. An important part of this is the zoning of risk areas. This provides insight into the overall risk level and is usually classified as follows:

• Zone 20: continuous presence of an explosive atmosphere
• Zone 21: occasional presence of an explosive atmosphere
• Zone 22: an explosive atmosphere rarely and only for a short time

After the initial risk analysis, regular reassessments are mandatory. Only with an up-to-date and thorough analysis, combined with appropriate protective measures, can the risks of working with aluminum dust be effectively minimized.

Safe handling of aluminum dust

Since aluminium dust is both flammable and harmful to health, safe disposal is imperative. The collected dust must be stored dry in lockable, explosion-proof and clearly marked containers — far from sources of ignition and other reactive substances. Transport must take place in accordance with the ADR regulations for hazardous substances, and only certified specialist companies are allowed to carry out the disposal. Important: All steps require comprehensive documentation and staff must be well trained. Ideally, the aluminum dust will eventually be recycled to save resources.

Smart workplace design

It's not just industrial vacuum cleaners that reduce the amount of aluminum dust — a sophisticated design of the workspaces also contributes to this. For example, smooth work surfaces are easy to clean, while it is better to avoid hard-to-reach corners and edges, as particulate matter quickly accumulates there. It is also effective to place extraction systems close to the workplaces. In this way, the dust is extracted directly at the source and prevents spread.

To be well prepared for emergencies, all work areas must have at least two exits. There must also be emergency showers outside the work zones. Powder fire extinguishers are mandatory; the use of carbonic acid or halons as extinguishing agents is both ineffective and prohibited. In short: a smartly designed workspace significantly increases safety.

Inhaled aluminum dust — the effects

Aluminosis: a serious lung disorder

Inhaling aluminum dust for a long time can lead to aluminosis. Aluminosis is a specific form of dust lung that occurs when aluminum particles accumulate in the alveoli over a longer period of time. This buildup causes inflammatory reactions that damage lung tissue and ultimately lead to scarring, also known as fibrosis.

What makes aluminosis extra insidious is that the symptoms are often vague and unspecific at first. Common complaints include:

• Shortness of breath, especially during physical exercise
• Dry cough
• Chest pain or pressure

At a more advanced stage, lung function is significantly reduced. The condition is usually diagnosed via lung x-rays and lung function tests, which show the damage. Unfortunately, there is no cure for aluminosis. The treatment therefore focuses on alleviating the symptoms and limiting further exposure to aluminum dust as much as possible. Preventive measures, such as effective ventilation and personal protective equipment, are therefore essential.

Personal protective equipment

Good personal protective equipment significantly reduces the health risk for employees. A respirator with a P2 or P3 filter is particularly important. These filters effectively stop even the finest aluminum particles so that they cannot reach the respiratory tract.

Safety glasses protect the eyes from dust contact, while protective gloves prevent skin irritation. In addition, antistatic workwear helps to minimize the risk of sparking due to electrostatic charging. In this way, the right equipment directly contributes to a safe and healthy working environment.

Minimizing dust deposition with extraction systems

Extraction systems play a crucial role in limiting dust accumulation in the workplace. They filter harmful aluminum dust particles directly from the air — right where they are created. This continuous filtering not only keeps the work environment clean and safe, but also ensures that companies remain within the legal limits for harmful substances.

In addition, extraction systems significantly extend the life of machines because there is less wear and tear due to dust particles. In this way, they not only contribute to the health of employees and the quality of the end product, but also to lower maintenance costs and higher operational reliability. An investment in extraction technology is therefore an investment in safety and efficiency.

An effective aluminum dust extraction system must comply with:

• ATEX certification: Suitable for explosive environments.
• High extraction capacity: Air velocity of at least 20 m/s at the extraction point.
• Multistage filter system: Includes HEPA filters and automatic cleaning.
• Explosion protection: Pressure relief, spark arresters and explosion-proof dust containers.
• Antistatic and grounded components: Prevents electrostatic charging.
• Durable material: Preferably stainless steel for corrosion resistance.
• Convenience: Automatic monitoring, energy-efficient control and maintenance-friendly construction.
• Noise level: Quiet to use (below 80 dB) for a pleasant working environment.

Kiekens: your partner in safe aluminum dust extraction

Aluminum dust is a serious safety hazard. At Kiekens, we understand this challenge. With our high-quality, ATEX-certified extraction systems, we optimally protect your employees, machines and work environment. Thanks to our years of experience and customized solutions, we offer safety, efficiency and sustainability. Contact us for free advice!