Dust Hazard Analysis
At Pontentia Engineering Services Ltd., we provide Dust Hazard Analysis (DHA) services to help facilities identify and assess combustible dust risks in compliance with NFPA 660 and other applicable standards.
Our team works with you to evaluate your processes, identify potential fire and explosion hazards, and develop practical recommendations to reduce risks and improve safety. A DHA is the first step in preventing combustible dust incidents, protecting your people, your facility, and your business.
What is Dust Hazard Analysis?
A Dust Hazard Analysis (DHA) is a systematic process used to evaluate the presence and severity of combustible dust hazards within a facility. It involves a series of carefully designed tests, with each stage building on the results of the previous one to develop a comprehensive understanding of the type and level of dust-related risks. The DHA not only identifies potential explosion hazards but also includes a risk assessment to evaluate the likelihood and potential consequences of a combustible dust event.
Based on these findings, the analysis provides recommendations to reduce or eliminate explosion risks, which may include improvements to housekeeping practices, process modifications, or enhancements to existing dust collection systems. These measures are designed to safely isolate, contain, or suppress flames and pressure, protecting both the facility and its personnel in the event of a combustible dust incident.
Why do you need a Dust Hazard Analysis?
Combustible dust poses a serious risk across many industries. Conducting a Dust Hazard Analysis (DHA) is essential for identifying combustible dust hazards within your facility and serves as a foundation for developing a comprehensive safety strategy. A DHA helps shape effective plans, processes, and procedures to mitigate the risk of fires and explosions, integrating seamlessly into your overall process safety protocols.
Too often, business owners and even local fire officials view combustible dust fires and explosions as “just part of the industry.” This mindset can lead to complacency until a catastrophic event occurs. A Dust Hazard Analysis challenges this perception by providing the insight needed to prevent these incidents, proving that combustible dust explosions are not inevitable, but preventable through proactive assessment and proper safety measures.
Why is it required?
The Occupational Health and Safety Act requires a Dust Hazard Analysis [DHA] to be performed in Industries where combustible dusts are being produced as an employer's responsibility in identifying hazardous materials in a facility.
The Canadian Electrical Safety Code [Ontario Electrical Safety Code/ NFPA 70 NEC] requires electrical equipment for use in hazardous locations to be suitable for the specific explosive atmosphere that will be present, requiring a DHA to be performed to determine the type of hazardous location zone [Zone 0,1,2,20,21,22] in which the electrical equipment will be installed.
Insurance Companies insure industrial processes because these operations carry high levels of risk, including fires, explosions, equipment failures, environmental hazards, and costly downtime. By providing financial protection, insurance helps companies recover from property damage, liability claims, and business interruptions that could otherwise cause devastating losses. In many industries, insurance is required by law, by clients, or by lenders, ensuring companies meet regulatory and contractual obligations.
Insurers also play a key role in risk management, often requiring businesses to follow safety standards, such as NFPA 660 Standard for Combustible Dusts and Particulate Solids, and make improvements to reduce hazards. Ultimately, insurance supports business continuity, protects a company’s reputation, and promotes safer, more reliable industrial operations.
NFPA 660 Standard for Combustible Dusts and Particulate Solids Requirement:
NFPA 660 states that the owner/operator of a facility where combustible dust is present must conduct a DHA to:
Identify fire, flash fire, and explosion hazards related to dust.
Assess the effectiveness of existing controls.
Recommend additional safety measures to mitigate risks.
Key Points:
The DHA must cover all new and existing processes that handle, manage, or generate combustible dust.
It must be documented and kept up to date.
It should be reviewed and updated at least every five years, or whenever major changes are made to processes or equipment.
What Industries require a Dust Hazard Analysis?
NFPA standards now unified under NFPA 660 mandate a DHA for these industries to:
Identify combustible dust hazards
Assess the likelihood and severity of fire/explosion events
Provide mitigation strategies, such as engineering controls or improved housekeeping
Even when not explicitly required by local law [AHJ], insurance companies, clients, and regulators often demand a DHA as part of risk management and compliance efforts.
1. Agricultural and Food Processing
Combustible organic dust is extremely common in food and agricultural products.
Grain handling and storage (e.g., silos, elevators)
Flour and sugar milling
Cereal, baking, and snack production
Animal feed manufacturing
Coffee, tea, and powdered beverage processing
Spice and flavoring plants
Relevant standard: Formerly NFPA 61 – Agricultural and Food Processing Facilities
2. Wood and Paper Products
Wood dust is highly combustible, especially when finely ground.
Sawmills and wood product manufacturing
Furniture manufacturing
Cabinetry and millwork shops
Paper and pulp processing facilities
Biomass pellet production
Relevant standard: Formerly NFPA 664 – Wood Processing and Woodworking Facilities
3. Chemical and Pharmaceutical Manufacturing
Many powdered chemicals and pharmaceuticals are explosive in certain concentrations.
Chemical manufacturing plants
Pharmaceutical production facilities
Plastics and resins manufacturing
Paints, coatings, and pigments processing
Relevant standard: Formerly NFPA 654 – General Manufacturing Facilities
4. Metalworking and Powdered Metals
Metal dusts are among the most dangerous, as they can produce extremely high-energy explosions.
Aluminum and magnesium machining or finishing
Additive manufacturing (3D printing with metal powders)
Welding and grinding operations
Powder metallurgy and metal additive manufacturing plants
Relevant standard: Formerly NFPA 484 – Combustible Metals
5. Textiles and Fibers
Fine fibers and dust from textiles can ignite easily.
Cotton and textile mills
Carpet and fabric manufacturing
Nonwoven fabric production
6. Plastics, Rubber, and Composites:
Plastic resin manufacturing and compounding,
Recycling plants for plastics and rubber
Powder coating operations
