Combustible Dust Housekeeping Playbook for Small Facilities

Flour settles on rafters, aluminum fines hide behind ducts, polymer powder clings to cable trays. You cannot see the hazard until a vibration or small fire lofts the dust into the air—and then the deflagration race is on. The 2024 update to OSHA's Combustible Dust National Emphasis Program is pushing inspectors back into bakeries, wood shops, metal printers, and recyclers. Housekeeping is the first item they review. Here's how to prove you own it.

Define Your Dust in Writing

Collect samples of the dustiest materials in your facility and send them to a lab for explosibility testing (Kst, Pmax, MEC). Keep the report and note which processes generate the dust. Even if you cannot afford testing, document surrogate data from suppliers or NFPA 652 tables. Without proof, OSHA assumes the material is combustible and shifts the burden to you. Knowing the dust class guides your housekeeping frequency, vacuum selection, and hot work controls.

Map Hazard Zones

Walk the facility and identify horizontal surfaces where dust can accumulate more than 1/32 inch—the thickness of a paper clip. Pay special attention to overhead beams, equipment tops, ledges, and ventilation ducts. Mark these areas on a scaled drawing or inside Worksafely SMB's facility map. This visual lets you schedule cleaning routes and communicate expectations to contractors. Include seldom-accessed spaces like attic crawlways and mezzanine roofs; explosions often start where no one looks.

Set a Cleaning Cadence You Can Defend

Base your cleaning frequency on the rate of dust accumulation and the consequences of deferring. Critical areas near ignition sources may need daily wipe-downs. Elevated beams might tolerate monthly cleaning if dust loads stay low. Assign teams, tools, and PPE for each route. Dry sweeping and compressed air are prohibited for combustible dust. Use explosion-rated vacuum systems or wet methods when feasible. Record the date, location, method, and quantity removed during every cleaning round.

Control Ignition Sources

Housekeeping is only half the equation. Identify hot surfaces, bearings, motors, and open flames that could ignite a dust cloud. Tie predictive maintenance data—like motor temperature trends or vibration alarms—into your dust plan so you can fix ignition sources before they light the fuel. Enforce hot work permits with a special checklist for dusty areas: extra cleaning, continuous fire watch, and post-work monitoring. Document any deviations and the corrective actions.

Keep Conveying and Collection Equipment Honest

Dust collectors, cyclones, and conveying systems concentrate fuel. Inspect them for air leaks, worn filters, and grounding issues. Check explosion isolation devices and make sure relief panels discharge to safe areas. Empty collection bins before they overflow, and train operators to recognize abnormal sounds or vibrations. Tie each inspection to a work order so you can show an inspector your maintenance history.

Document Deviations and Lessons Learned

Inevitable reality: someone will discover dust layers above your acceptable level. When that happens, treat it like a near miss. Record how much dust was found, why it accumulated, and what you did about it. Did production increase? Did a fan fail? Use the event to adjust the cleaning cadence or staffing. This demonstrates to OSHA that you continually evaluate effectiveness instead of repeating the same plan forever.

Train Everyone, Not Just Housekeepers

Operators, maintenance techs, contractors, and even office staff who walk the floor need to recognize dust hazards. Train them on how dust explodes, the housekeeping plan, and how to report issues. Include simple rules: keep doors closed when sanding, empty shop-vac contents in metal containers, never weld until the area is cleared. Reinforce the message in daily huddles and post visuals near dusty operations.

Close the Loop With Evidence

Store lab reports, cleaning logs, inspection photos, maintenance work orders, and training rosters together. When OSHA shows up, you can hand over the entire program instead of digging through emails. That confidence is the difference between a warning and a citation.

Next step: Schedule dust inspections and cleaning tasks inside Worksafely SMB so supervisors get reminders, photos, and sign-offs tied to each zone.