The Connecticut (CONN-OSHA) On-Site Consultation Program was asked by a repeat client, a company that manufactures power distribution and lighting systems, to help address a combustible dust hazard in its deburring room. The employees in this department ground and deburr parts made from aluminum and other metal alloys. The company knew about the consultation program because CONN-OSHA had previously helped it abate several Federal OSHA citations at a different facility.

During the consultation visit, the consultant observed that dust collection methods were not being used to contain the combustible metal dust created by the deburring/grinding operations. Metal dust had accumulated throughout the room, obscuring the color of surfaces. Dust accumulations of greater than 1/32 inch were detected on multiple surfaces throughout the room including overhead lighting fixtures, ductwork, shelves, equipment, and flooring.

Aluminum is a combustible dust. The consultant had the dust from these surfaces analyzed and confirmed that the dust was explosive. In addition to inadequate housekeeping and the absence of effective dust controls, the consultant noted that the employer had not provided employees with an appropriate fire extinguisher and an approved vacuum cleaning device. Lastly, the employees had not been trained in the hazards of combustible dust and the measures they could take to protect themselves.

During the consultation visit, the consultant provided the employer with multiple resources from OSHA's Combustible Dust webpage and the consultant helped the employer correct the combustible dust hazard.

The employer implemented multiple controls which protected their 200 employees from the serious harm of a dust explosion incident:

• To minimize the escape of aluminum dust generated by the deburring/grinding operations, the employer installed a downdraft table to be used exclusively for aluminum parts. In addition, the employer installed a wet dust collector which was specifically designed for the collection of aluminum, titanium, or other highly combustible metal dusts, and which complied with National Fire Protection Association (NFPA) Standard 484 for containment of combustible metals.
• The employer hung a Class D portable fire extinguisher in the deburring room. This type of fire extinguisher can be used on combustible metals. A sign was posted above the extinguisher and a team of employees were trained in the safe use of the fire extinguisher.
• The employer purchased an explosion proof vacuum approved for Class II, Division 1 locations (locations where combustible and explosive dusts are in the air under normal operation conditions and in quantities sufficient to produce explosive or ignitable mixtures).
• The employer eliminated the use of compressed air for cleaning.
• The entire deburring room was thoroughly cleaned. Machines/equipment that were no longer used were removed from the room. As the room was decluttered, this allowed for more thorough cleaning. Furthermore, the employer developed rigorous housekeeping procedures in which employees were trained.
• The employer developed a training program on combustible dust and provided employees with training.

As a result of its work with CONN-OSHA's On-Site Consultation Program, the company has a greater appreciation of combustible dust hazards and appropriate control measures. Going forward, the company has indicated that it would like CONN-OSHA's assistance addressing other occupational hazards at its facility.

The OSHA On-Site Consultation Program offers no-cost and confidential occupational safety and health services to small and medium-sized businesses in all 50 states, the District of Columbia, and several U.S. territories, with priority given to high-hazard worksites. Consultants from state agencies or universities work with employers to identify workplace hazards and how to fix them, provide advice for compliance with OSHA standards, train and educate workers, and assist in establishing and improving safety and health programs. On-Site Consultation services are separate from OSHA enforcement efforts. To locate the OSHA On-Site Consultation program nearest you, call 1-800-321-OSHA (6742) or visit www.osha.gov/consultation.