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MANAGING ALUMINIUM DUST RISK FOR STRONGER INSURANCE TERMS
Why Dust Explosion Risk Is a Major Underwriting Focus
Aluminium dust is a combustible particulate. When fine dust becomes suspended in air and meets an ignition source, the result can be a rapid fire or explosion. This is why insurers treat aluminium dust hazards as a priority risk for aluminium manufacturing, machining, polishing, grinding, sanding, cutting and recycling operations.
The risk is not limited to the point of generation. Dust can migrate and accumulate on beams, ledges, equipment housings and inside ductwork. A small ignition event can disturb deposits and create secondary explosions. Strong insurance outcomes depend on demonstrable controls: effective extraction, safe dust handling, housekeeping standards, suitable equipment selection, and documented procedures.
Dust Explosion & Combustible Metal Risk Insurance (Aluminium)
This page explains how insurers assess combustible metal risk and what “good” looks like when presenting an aluminium dust exposure to underwriters. It is also a practical checklist of the information we will ask for to obtain terms.
Insure24 arranges aluminium manufacturing insurance for extrusion, casting, machining and finishing businesses across the UK. Where aluminium dust is present, we help position the risk correctly, highlighting controls and addressing the common underwriting concerns that lead to exclusions or inflated premiums.
- Grinding, sanding, fettling and finishing dust hazards
- Extraction, ducting, dust collectors and maintenance controls
- Housekeeping, cleaning methods and dust accumulation risk
- Ignition sources: hot works, static, friction, electrical faults
- ATEX/DSEAR assessments and hazardous area management
- Insurer expectations for separation and explosion protection
Key Drivers of Combustible Metal Risk
Underwriters typically assess the “likelihood of dust becoming airborne” and the “likelihood of ignition”, then focus on the consequences: fire spread, confinement, secondary explosions, and business interruption impact. The factors below tend to drive pricing and terms.
- Dust type and particle size (fine dust generally higher risk)
- Generation rate (hours per day/week, number of workstations)
- Whether dust is mixed with other materials or contaminants
- Extraction adequacy (capture at source, airflow, make-up air)
- Collector type, location (inside vs outside), and explosion protection
- Ductwork layout, cleaning access, and inspection regimes
- Housekeeping standards and prohibited cleaning methods
- Ignition controls (hot work permits, spark detection, static control)
- Segregation from other operations and fire compartmentation
Extraction, Filtration & Dust Collection: What Insurers Look For
Dust control is the cornerstone of combustible metal risk management. Insurers want evidence that dust is captured at source, transported safely through ducting, and collected into a system that is maintained and designed with explosive dust in mind. If your extraction is undersized, poorly maintained, or poorly located, the underwriting outcome will usually reflect that.
Capture at source
The best outcomes come from engineered capture at the point of generation (rather than relying on general ventilation). Underwriters often want to see design documentation, airflow rates, and confirmation that hoods, shrouds and guards are used correctly in real operations (not just “on paper”).
Ducting and dust migration
Ductwork can become a hidden risk if dust deposits build up internally or if there are dead legs where material collects. Insurers may ask about ducting layout, access points for inspection/cleaning, and whether the system is checked and cleaned on a documented schedule.
Dust collectors
Collector type and location matter. Many insurers prefer dust collectors sited outside or in separated enclosures, with appropriate explosion relief/venting or other protections (depending on design). Where collectors are inside, insurers may require additional safeguards or impose exclusions/conditions. We help present your system properly so insurers can make an informed decision.
Waste handling and storage
How you store and dispose of collected dust and swarf also matters. Underwriters often want to know: how frequently waste is removed, whether bins are lidded, whether dust is kept away from ignition sources, and whether wet collection is used where appropriate. If you recycle swarf/dust, the collection and transport arrangements should be clear.
Housekeeping & Cleaning Standards
Dust accumulation is one of the most common reasons insurers restrict cover. If dust can accumulate on elevated surfaces, within voids, or around production lines, a small ignition event can become a major loss. Insurers will ask about your cleaning method, frequency, supervision and how you prevent “hidden” dust build-up.
Many insurers favour cleaning approaches that minimise re-suspension of dust (and avoid using compressed air for blowing down dust deposits). For strong terms, it helps to demonstrate: written cleaning schedules, allocated responsibility, and evidence that high-level cleaning is addressed (not only floors).
- Documented housekeeping plan and cleaning frequency
- Safe cleaning methods (that do not disperse dust into air)
- High-level cleaning controls for beams/ledges/ducting areas
- Immediate clean-up of spills and dust-producing activities
- Waste bin management and regular removal
“Dust risk was the sticking point for our renewal. Insure24 helped us evidence extraction maintenance, cleaning schedules and separation of our collector system — and the insurer removed restrictive terms.”
Production Director, Aluminium Machining CompanyPROTECT YOUR BUSINESS
- Cover structured around combustible dust risk (subject to insurer appetite)
- Support explaining controls to underwriters and surveyors
- Advice on common exclusions and how to avoid them
- Option to add business interruption and machinery breakdown
- Claims support and practical incident guidance
FREQUENTLY ASKED QUESTIONS
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Can aluminium dust really explode?
Yes. Fine aluminium dust can be combustible. If it becomes airborne and meets an ignition source in a confined space,
it can result in a rapid fire or explosion. This is why insurers focus heavily on extraction, housekeeping and ignition control.
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What information do insurers want to see?
Typically: your process description, dust generation activities, extraction/collector specification, maintenance and inspection records,
housekeeping schedules, any DSEAR/ATEX assessments, separation/segregation details, and claims/incident history.
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Are dust collectors better located outside?
Often, yes. Many insurers prefer collectors to be outside or in separated enclosures to reduce the impact of an incident.
However, the right approach depends on your system design and controls. We’ll help you present the risk appropriately.
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Does business interruption cover apply after a dust explosion?
Business interruption can be added to protect your gross profit or revenue following insured damage (for example, fire),
subject to an indemnity period and policy terms.
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Will insurers exclude combustible dust losses?
Some insurers may impose exclusions or conditions where controls are unclear or where the exposure is high.
Strong risk presentation, documented controls and appropriate systems can help avoid restrictive terms.
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Can you cover aluminium recycling and swarf processing risks?
Yes. Recycling, swarf and fines processing can introduce additional combustible dust and contamination risks.
We can approach specialist markets and structure cover around your exact process.