Hazards Analysis, Code Compliance & Procedure Development

Services to identify process safety hazards and facilitate compliance with established standards and codes.

Combustible Dust Testing

Laboratory testing to quantify dust explosion and reactivity hazards

Flammable Gas & Vapor Testing

Laboratory testing to quantify explosion hazards for vapor and gas mixtures

Chemical Reactivity Testing

Laboratory testing to quantify reactive chemical hazards, including the possibility of material incompatibility, instability, and runaway chemical reactions

DIERS Methodology

Design emergency pressure relief systems to mitigate the consequences of unwanted chemical reactivity and account for two-phase flow using the right tools and methods

Deflagrations (Dust/Vapor/Gas)

Properly size pressure relief vents to protect your processes from dust, vapor, and gas explosions

Effluent Handling

Pressure relief sizing is just the first step and it is critical to safety handle the effluent discharge from an overpressure event

Thermal Stability

Safe storage or processing requires an understanding of the possible hazards associated with sensitivity to variations in temperature


Classification of hazardous materials subject to shipping and storage regulations

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents


Model transport of airborne virus aerosols to guide safe operations and ventilation upgrades


Model transport of contamination for source term and leak path factor analysis

Fire Analysis

Model transport of heat and smoke for fire analysis

Flammable or Toxic Gas

transport of flammable or toxic gas during a process upset

OSS consulting, adiabatic & reaction calorimetry and consulting

Onsite safety studies can help identify explosibility and chemical reaction hazards so that appropriate testing, simulations, or calculations are identified to support safe scale up

Mechanical, Piping, and Electrical

Engineering and testing to support safe plant operations and develop solutions to problems in heat transfer, fluid flow, electric power systems

Battery Safety

Testing to support safe design of batteries and electrical power backup facilities particularly to satisfy UL9540a ed.4

Hydrogen Safety

Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen

Spent Fuel

Safety analysis for packaging, transport, and storage of spent nuclear fuel

Decommissioning, Decontamination and Remediation (DD&R)

Safety analysis to underpin decommissioning process at facilities which have produced or used radioactive nuclear materials

Laboratory Testing & Software Capabilities

Bespoke testing and modeling services to validate analysis of DD&R processes

Nuclear Overview

Our Nuclear Services Group is recognized for comprehensive evaluations to help commercial nuclear power plants operate efficiently and stay compliant.

Severe Accident Analysis and Risk Assessment

Expert analysis of possible risk and consequences from nuclear plant accidents

Thermal Hydraulics

Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions

Environmental Qualification (EQ) and Equipment Survivability (ES)

Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions

Laboratory Testing & Software Capabilities

Testing and modeling services to support resolution of emergent safety issues at a power plant

Adiabatic Safety Calorimeters (ARSST and VSP2)

Low thermal inertial adiabatic calorimeters specially designed to provide directly scalable data that are critical to safe process design

Other Lab Equipment and Parts for the DSC/ARC/ARSST/VSP2 Calorimeters

Products and equipment for the process safety or process development laboratory


Software for emergency relief system design to ensure safe processing of reactive chemicals, including consideration of two-phase flow and runaway chemical reactions


Facility modeling software mechanistically tracks transport of heat, gasses, vapors, and aerosols for safety analysis of multi-room facilities


Our highly experienced team keeps you up-to-date on the latest process safety developments.

Process Safety Newsletter

Stay informed with our quarterly Process Safety Newsletters sharing topical articles and practical advice.


With over 40 years of industry expertise, we have a wealth of process safety knowledge to share.

Recent Posts

Hazard Prevention: Putting Metal Dust to the Test

Posted by Sara Peters on 02.25.19

By Sara Peters, Customer Outreach & Digital Media Specialist, Fauske & Associates, LLC

We regularly hear about the dangers of dust in manufacturing environments dealing with organic or chemically based particulates. However, the fines produced during metal fabrication work can also create an incredibly dangerous and energetic dust, as we were unfortunately reminded with the January 2019 dust collector fire at the Nickkei MC Aluminum America, Inc. location in Columbus Indiana.

Dr. Ashok Ghose Dastidar, Vice President, Dust & Flammability Testing and Consulting Services at Fauske & Associates, LLC, frequently uses the comparison of aluminum dust to TNT (which we already know is a powerful explosive) to emphasize its potential volatility, stating that one gram of aluminum dust has about the same explosive energy as 0.7 grams of TNT. That is a lot of power in a seemingly insignificant amount of dust.

Of course, with any type of dust, it is important to perform a hazardous materials test to characterize the hazard risk of the material in question by determining if an explosion hazard exists and, if so, how energetic it may be as the probability of risk based on how the material responds to heat, spark, impact and frictional forces. There are a lot of testing methods available to determine the deflagration hazards of dust samples per ASTM International, OSHA (Occupational Health & Safety Administration, NFPA (National Fire Protection Agency), ISO/IEC (International Organization for Standardization/International Electrotechnical Commission) and UN (United Nations). Given this, the challenge can be ascertaining which tests are best for a certain material.

To help in this area, NFPA published multiple standards with applicability dependent on the types of dust that comprise the mixture. Odds are that if you have a dust containing metallic material, typically, NFPA 484: Standard For Combustible Metals (2019) or NFPA 654: Standard for The Prevention Of Fire and Dust Explosions From The Manufacturing, Processing, and Handling of Combustible Particulate Solids (2017) or are the two standards to go for guidance.

Determining exactly which standard is pertinent can be tricky, however. For this reason, our dust team has prepared the following pictogram to help you determine which set of tests and which NFPA standard is most appropriate for your unique case. Take a look and if you are still unsure, do not hesitate to contact a qualified combustible dust testing expert for assistance.


hazardous materials test combustible metal dust


If you are interested in learning more about combustible dust check out our case study on an explosion accident that occurred during the cleaning procedure of a pan coater. 

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Topics: Combustible Dust, NFPA 652


Is My Dust Combustible?

A Flowchart To Help You Decide
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