Dust.
It seems harmless enough, right? The kind of thing you ignore on a bookshelf at home until someone writes “Clean me” in it with their finger. (Let’s be honest — most of us have been guilty of that.) A bit of a nuisance, maybe, but definitely not something you’d associate with explosions.
But in industrial settings, dust — especially fine, dry, combustible dust — is a whole different beast. It doesn’t just settle quietly in the corners. Under the right conditions, it can become a serious ignition risk, capable of triggering powerful and dangerous explosions.
If you’re designing systems for industrial sites, or managing the day-to-day operations of a busy workshop, dust deserves your full attention — not just a half-hearted flick with a feather duster. Because workplace safety, unlike the housework you’ve been meaning to get to, can’t be put off until the weekend.
Understanding the Risk: Combustible Dust 101
Let’s start with the basics. A dust explosion can occur when five things come together:
- Combustible dust
- Oxygen
- An ignition source
- Confinement of the dust cloud
- Dispersion of the dust in the air
This set of five conditions is known as the “dust explosion pentagon.” It might not have the star power of the Avengers, but when all five elements align, the outcome can be far more explosive — and not in a good way.
Industries like woodworking, welding, grinding, metal polishing, and food processing are all high-risk environments when it comes to combustible dust. Unfortunately, many of these hazards go unnoticed until it’s too late.
Regulations like AS/NZS 4745 and international standards (e.g. ATEX & IECEx) exist for a reason. They’re there to guide both the design and ongoing management of safe systems. And ignoring them? Let’s just say that’s one compliance issue you don’t want to explain to WorkSafe.
Designing for Safety: What Engineers and Consultants Need to Plan For
If you’re involved in the design or specification phase of an extraction system, you’re in a powerful position — literally. You have the opportunity to build in safety from the ground up. That includes incorporating measures to prevent, isolate, and suppress potential explosions before they become headline material.
Here’s where smart design and clever components come in:
VST Explosion Suppressors and Isolators
These are engineered to detect and suppress ignition within milliseconds — shutting things down before a spark becomes a catastrophe. Isolation valves also prevent flames from travelling back through ductwork and into other parts of the system. Bonus: VST components are modular and compact, making them easy to integrate in both new builds and retrofit projects.
Acting as the first line of defence, spark arrestors help prevent ignition sources (from welding, grinding or other hot processes) from reaching dust collectors. Nordfab’s modular ducting makes installation simple, and adjustments down the track even simpler.
Nederman CARZ Explosion Isolation Valves
Another valuable design option is the Nederman CARZ explosion isolation valve — a mechanical device that reacts instantly to pressure waves caused by an explosion. Once triggered, it closes off the duct to prevent the flame front from travelling back into other parts of the system. It’s ideal for use in woodworking environments or where fine, dry dust is common, and it’s effective in both new builds and retrofit scenarios. The CARZ valve is easy to service and doesn’t require external energy to operate, making it a smart and reliable addition to any safety-focused system.
When you design systems with these components in place, you’re not just protecting equipment — you’re protecting people and minimising downtime. That’s the kind of design that earns repeat clients and trouble-free audits.
Staying Safe on the Ground: What Workshop Managers Can Do
So, you’ve got a great system in place. Tick. But safety isn’t a set-and-forget deal.
Workshop managers play a key role in ensuring that dust safety systems are used correctly and maintained well. Some of the most common risks we see on-site?
- Blocked ducts
- Bypassed filters
- Dirty filters
- Missing spark arrestors
- Systems running long past their last inspection
Sound familiar?
Good news: staying safe doesn’t have to be complicated. Regular checks, clear signage, and making sure your team knows what’s what goes a long way. And if you’re working in a process like welding or metal polishing, having a Nordfab spark arrestor in place is a no-brainer.
Need a refresher on how your suppression or isolation system works? You’re not the only one — these systems can be complex, and it’s important to know exactly what you’re working with. We’re always happy to walk you through the details and make sure everything’s doing what it’s supposed to.
Retrofit Ready: When It’s Time for an Upgrade
Maybe your current system was installed back when flip phones were still a thing. Or maybe it works okay, but you’re not sure it’s compliant with today’s standards. The good news is, modern safety components like VST isolators and Nordfab spark arrestors are designed to retrofit into existing systems with minimal disruption.
At AtSource, we can assess your current setup and recommend practical upgrades that fit your workflow, your budget, and your compliance needs.
We recently supported a secondary school wood workshop in upgrading their outdated dust extraction system. The project involved installing a Nederman CARZ explosion isolation valve to help protect against flame propagation in the ducting. The system is now safer, fully compliant, and continues to run with minimal disruption to the school’s daily activities — a win for both safety and practicality.
Design Smart. Operate Safely. Sleep Well.
Dust safety isn’t just a design issue. It’s not just an operations issue either. It’s a whole-of-system approach — and it’s easier to get right when you’ve got the right people and the right products in the mix.
Whether you’re sketching out a new layout or managing a decades-old system, AtSource can help. We supply and install industry-trusted components like VST Engineering explosion protection, Nederman CARZ Explosion Isolation Valves and Nordfab spark arrestors, and we offer expert advice to make sure your system’s as safe as it is efficient.
Got questions? Ready for an audit? Want to know if your current setup is up to scratch? Get in touch — we’re here to help you breathe a little easier.