Dust Hazard Analysis & Area Classification

Technical, code-compliant DHA and hazardous area classification for new and existing processing plants. Hazloc Labs delivers engineering-grade risk analysis, testing, and compliance for combustible dust hazards.

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Dust Hazard Analysis and Area Classification

Why is Dust Hazard Analysis Needed?

Regulatory Drivers

NFPA 652, 654, 61, 484, and OSHA 1910.272 require DHA for all facilities handling combustible dusts. Insurance carriers and AHJs increasingly demand documented DHA for new and existing plants.

Technical Drivers

Combustible dusts (organic, metal, plastic) present explosion and flash fire risks in process equipment, conveying, and storage. DHA quantifies these risks and identifies credible ignition sources (mechanical, static, electrical, hot surfaces).

Process Safety

DHA is a core element of process safety management (PSM) and risk-based engineering. It supports safe design, operations, and change management for new builds, expansions, and M&A due diligence.

Who Needs DHA? Where is it Required?

Dust Hazard Analysis is essential for a wide range of industries, facility types, and process areas. The following summarizes where DHA is most critical and typically required by code, insurance, or best practice.

Industries

Food & Beverage (flour, sugar, grain, spices, starch)
Pharmaceutical, Chemical, Plastics, Rubber
Wood, Paper, Pulp, Biomass
Metals (aluminum, magnesium, titanium, zinc)

Facility Types

New and existing processing plants (design or operational)
Facility expansions, upgrades, or process changes
Mergers, acquisitions, and insurance renewals
Facilities subject to OSHA, NFPA, or insurance audits

Where in the Plant?

Dust collectors, baghouses, cyclones, and filters
Silos, bins, hoppers, storage rooms
Conveyors, mixers, blenders, mills, dryers
Process rooms, transfer points, ductwork

Hazloc Labs DHA & Area Classification Services

Dust Hazard Analysis (DHA)

  • Comprehensive site survey and process review
  • Ignition source assessment (mechanical, electrical, static, hot surfaces)
  • Risk ranking and mitigation recommendations
  • Code-compliant, actionable DHA report

Combustible Dust Testing

  • Kst (deflagration index), Pmax (maximum pressure)
  • MEC (minimum explosible concentration)
  • MIT (minimum ignition temperature), MIE (minimum ignition energy)
  • ASTM/ISO/EN test methods, sample collection and lab analysis

Area Classification

  • Zone and Division classification (NEC, IEC, ATEX)
  • Hazardous area drawings and documentation
  • Equipment selection and installation guidance
  • Support for OSHA, NEC, IEC, ATEX, and insurance compliance

Incident Investigation

  • Root cause analysis of fires, explosions, and near-misses
  • Forensic engineering and expert witness services
  • Corrective action and prevention planning

Training & Competency

  • On-site and virtual training for operators, engineers, and management
  • Custom programs for NFPA, OSHA, and best practices
  • Organizational competency in process safety

Our DHA Process: Engineering Steps

1. Site Survey & Data Collection

Review of P&IDs, process flow diagrams, and MSDS
Site walkdown and interviews with operations/maintenance

2. Dust Sampling & Testing

Collection of representative dust samples
Lab analysis for Kst, Pmax, MEC, MIT, MIE

3. Hazard Identification

Identification of combustible dust sources and ignition points
Assessment of process equipment, ductwork, and building areas

4. Risk Assessment

Likelihood and consequence analysis (qualitative/quantitative)
Prioritization of hazards and risk ranking

5. Mitigation & Controls

Engineering controls (venting, suppression, isolation)
Administrative controls (housekeeping, training, SOPs)

6. Documentation & Reporting

Preparation of code-compliant DHA and area classification reports
Presentation of findings, recommendations, and compliance roadmap

Why Hazloc Labs?

Technical Expertise

  • Certified fire protection specialists, chemical engineers, and process safety professionals
  • Experience with complex, high-hazard facilities
  • Active participation in NFPA, AIChE, and industry committees

Client-Focused Delivery

  • Clear, actionable reports and engineering drawings
  • Responsive communication and project management
  • Support during audits, inspections, and insurance reviews

Frequently Asked Questions

How often is a DHA required?
NFPA 652 requires DHA to be updated every 5 years or after significant process changes.
What is included in a DHA report?
Findings, risk evaluation, mitigation recommendations, area classification, and compliance documentation.
Do I need area classification if I have a DHA?
Yes. Area classification is a separate but related requirement for electrical safety and equipment selection.
Which tests do you offer?
Kst, Pmax, MEC, MIT, MIE, and more—per ASTM/ISO/EN standards.
How quickly can Hazloc Labs deliver?
Most projects are completed within 2–4 weeks, depending on facility size and complexity.

Contact Hazloc Labs

Phone

972-383-9097

Email

hazloclabssales@gmail.com

Location

Dallas, TX, USA