Metal fabrication involves cutting, grinding and polishing that generate fine metallic particles. These dusts can include compounds of aluminium, steel, copper or other metals, some of which are hazardous to inhale or can pose combustion risks when concentrated. Understanding how to manage grinding dust protects workers, extends equipment life and ensures compliance with workplace regulations.

Identifying the Risks

Metal dusts vary in hazard. Mild steel particles may primarily cause irritation, whereas stainless steel or alloy dust can contain chromium and nickel, which present carcinogenic risks. Aluminium and magnesium dusts are combustible under certain conditions. Employers must carry out a COSHH assessment to define specific hazards and set appropriate controls tailored to the metals being processed.

Local Exhaust Ventilation and Filtration

Grinding and cutting stations should be fitted with LEV systems to capture fumes and particulates at the source. Hood design must ensure the airflow captures the full plume without interfering with the operator's movement. Filters capable of handling fine metallic particulates prevent re‑emission. For operations involving combustible metals, non-sparking equipment and grounded ducting reduce ignition likelihood. Correct airflows are critical; too low and dust escapes, too high and sparks may carry further.

Safe Housekeeping Practices

Settled metallic dust can accumulate on ledges, around machines and on floors. If disturbed, it becomes airborne again, posing inhalation and potential explosion hazards. Cleaning should be done with conductive vacuum systems rather than compressed air blow‑offs. Dust collectors should be emptied regularly and located away from ignition sources. Avoid mixing metallic dust types in collection units.

Worker Protection and Monitoring

Respiratory protective equipment (RPE) provides an added safeguard where extraction cannot capture all emissions. Regular air monitoring verifies that exposures remain below occupational exposure limits. Health surveillance may be appropriate for certain materials. Training should focus on recognising hazards, using extraction systems correctly and maintaining cleanliness of personal protective equipment.

Practical Takeaways

• Match extraction design to the specific metal being processed.
• Use conductive hoses and non‑sparking equipment.
• Never clean metal dust with compressed air.
• Monitor air quality and maintain all filters regularly.
• Keep staff trained and informed of material hazards.

Managing metal grinding dust is not only about housekeeping. It supports compliance with COSHH, improves air quality and reduces fire and explosion risks. By combining engineering controls, maintenance routines and worker awareness, fabrication shops can sustain a safer and more efficient production environment.