Combustible Dust Testing

Laboratory testing to quantify dust explosion and reactivity hazards

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Gas and Vapor

Laboratory testing to quantify explosion hazards for vapor and gas mixtures

Classification of hazardous materials subject to shipping and storage regulations
Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen
Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Thermal Stability

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

Adiabatic Calorimetry
Data demonstrate the consequences of process upsets, such as failed equipment or improper procedures, and guide mitigation strategies including Emergency Relief System (ERS) design
Reaction Calorimetry
Data yield heat and gas removal requirements to control the desired process chemistry
Battery Safety

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

Safety Data Sheets

Develop critical safety data for inclusion in SDS documents

Cable Testing
Evaluate electrical cables to demonstrate reliability and identify defects or degradation
Equipment Qualification (EQ)
Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions
Water Hammer
Analysis and testing to identify and prevent unwanted hydraulic pressure transients in process piping
Acoustic Vibration
Identify and eliminate potential sources of unwanted vibration in piping and structural systems
Gas & Air Intrusion
Analysis and testing to identify and prevent intrusion of gas or air in piping systems
ISO/IEC 17025:2017

Fauske & Associates fulfills the requirements of ISO/IEC 17025:2017 in the field of Testing

ISO 9001:2015
Fauske & Associates fulfills the requirements of ISO 9001:2015
Dust Hazards Analysis
Evaluate your process to identify combustible dust hazards and perform dust explosion testing
On-Site Risk Management
On-site safety studies can help identify explosibility and chemical reaction hazards so that appropriate testing, simulations, or calculations are identified to support safe scale up
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 safely handle the effluent discharge from an overpressure event

FATE™ & Facility Modeling

FATE (Facility Flow, Aerosol, Thermal, and Explosion) is a flexible, fast-running code developed and maintained by Fauske and Associates under an ASME NQA-1 compliant QA program.

Mechanical, Piping, and Electrical
Engineering and testing to support safe plant operations and develop solutions to problems in heat transfer, fluid, flow, and electric power systems
Hydrogen Safety
Testing and consulting on the explosion risks associated with devices and processes which use or produce hydrogen
Thermal Hydraulics
Testing and analysis to ensure that critical equipment will operate under adverse environmental conditions
Nuclear Safety
Our Nuclear Services Group is recognized for comprehensive evaluations to help commercial nuclear power plants operate efficiently and stay compliant
Radioactive Waste
Safety analysis to underpin decomissioning process at facilities which have produced or used radioactive nuclear materials
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.

Published July 6, 2021

Blast Analysis and Design Capabilities


Emergency preparedness experts recognize the importance of structural protection against accidental and intentionally malicious blast loads. Structural integrity during an explosion is a way to mitigate the potentially catastrophic consequences from an explosion, whether due to industrial accidents or other destructive events. Increased reliance on power from hydrogen, natural gas, and battery energy storage means there is more potential for explosions in more places.

The hazards testing laboratory at Fauske & Associates (FAI) is a state-of-the-art facility for developing data on the explosion potential of materials, including dust, vapor, battery off-gas, and condensed phase materials such as organic/nitrate mixtures. Since 1980 FAI has provided critical process safety testing and consulting services to the chemical industry as well as to DOE contractors, but also has experience in blast analysis, for example due to failed natural gas or hydrogen piping at chemical processing and storage facilities. FAI, as a wholly owned subsidiary of Westinghouse Electric Company, is well-positioned to provide full-scope blast analysis and design capability to address needs of our industrial clients.


Blast analysis requires a good understanding of the blast phenomenon and the dynamic response of structural elements, and there are a number of tools and techniques available as well as relevant codes and standards to consider. Areas where this expertise has been applied include:

  • Blast design for critical facilities such as nuclear power plants, industrial sites, and military bases
  • Design of blast mitigation strategies such as barriers and enclosures
  • Design and analysis of buildings to resist progressive collapse
  • Dynamic and non-linear analysis (3D ANSYS®/LS-DYNA®/ABAQUS®) of concrete, steel, and composite structures subjected to blast and impulsive effects
  • Blast fragmentation and effects on structures and components
  • Shock and vibration effects on building components and equipment




Our team integrates its expertise in structural design, analysis, and testing to develop creative solutions for tough industry challenges. We provide high-quality products in conformance with industry codes and standards, satisfying strict internal QA processes, as well as ISO 9001 requirements. Experience in the design and analysis of nuclear-grade structures and components underpins our unique qualification to solve diverse blast analysis problems.

We are proud to offer

  • Robust blast designs that are optimized for performance and economical to fabricate and construct
  • Access to experts with extensive experience in civil, structural, and blast-related design and analysis
  • Confidence that designs will satisfy all relevant code provisions
  • Assurance that perform our work to a high-level of quality
  • Confidence that final design will perform as intended under extreme blast events


We have a broad range of blast design and analysis experience. Recent projects include:

Hydrogen Explosion Evaluation (2019-2020)

Our team performed an evaluation of effects of a hydrogen gas explosion. The gas explosion was postulated to occur in a safety-related storage tank. Our experts characterized the blast pressures and assessed the effect on integrity of the storage tank.

Containment Vessel Over-pressurization Effects (2019-2020)

Evaluation of the effects of postulated rupture of a large containment vessel was performed. The evaluation focused on shockwave effects on nearby building structures and occupants. Our experts used a combination of simplified and complex analysis tools to evaluate the safety of the building.  

Large Commercial Headquarters Building (2015-2017)

Our blast experts have experience in the blast design and analysis of critical commercial building structures. One example is a large international project, which involved developing a design basis threat and evaluating primary and secondary building structural elements for blast effects and progressive collapse potential.

Critical Manufacturing Facility (2014)

Our expertise also includes the evaluation of existing critical building structures subjected to accidental explosions. An example application is evaluating the effects of flammable gas leak at an automotive manufacturing facility. Due to the critical function of the facility, a blast analysis was performed to confirm adequate design of the explosion venting.

Military Testing Facility Design (2010-2012)

Our experts have experience in blast protection design of critical military facilities. Example projects include the blast design of a military testing facility and state-of-art dynamic analysis to support blast testing of key building elements (e.g., façade/curtainwall components, anchorages, and ventilation openings).

Contact Us

FAI has a long history of providing innovative solutions for specialized customer needs to meet code, regulatory, and other unique requirements. We have the expertise to develop, plan, and perform state-of-the-art analysis and the know-how to implement practical solutions. For more information on our blast analysis services or to contact a technical expert please email us at

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