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Workplace Health & Safety Risks Processing Aluminum

Aluminum processing in the initial stage is peformed in three basic steps: first, mined bauxite is converted into aluminum oxide; second, aluminum oxide is processed into aluminum; and third, the aluminum is cast into ingots. Depending on the type of processing and specific job, a variety of health and safety risks could be involved. Two risks universal to many jobs and stages of aluminum processing are the chance of explosion from combustible dust and the inhalation of aluminum particles.

  1. Combustible Dust

    • It's called the "Dust Explosion Pentagon": dispersion, confinement, heat, fuel and oxygen. When accumulated dust meets these five factors, a deadly explosion and even secondary explosions are possible. The aluminum processing industry, as well as others that work with tiny particles--like plastics, coal and sugar, to name a few--are susceptible to dust explosions. Fortunately, with proper planning, procedures and precautions, such accidents can be prevented. OSHA standards, as well as publications from the aluminum industry, provide detailed guidelines on how to control dust and ignition sources and maintain a safe workplace when processing aluminum.

    Exposure

    • Exposure to aluminum may occur through inhalation or contact with the skin or eyes. Short-term exposure through inhalation has not been found to be hazardous to humans, though long-term exposure may result in coughing, pulmonary weakness and shortness of breath. OSHA, in the Occupational Safety and Health Guideline for Aluminum, cites a 1991 study that linked long-term aluminum particle exposure to pulmonary fibrosis. Another referenced study in this document linked high quantities of aluminum in the brain to Alzheimer's, though this was not thought to be caused from aluminum exposure. Aluminum may also irritate the eyes and skin on contact. Protective eye wear and clothing could prevent irritation.

    Related Hazards

    • When aluminum is inhaled in the workplace, it is often combined with other metal particles, chemicals or fumes. The Centers for Disease Control's profile on aluminum toxicity cites a study of aluminum workers with high rates of bladder cancer, where inhaled carcinogens from coal tar pitch were the actual cause of the cancer.

      Because aluminum processing takes place in several stages, a number of other factors could pose health or safety risks, depending on the process and exact job,. Other health and safety hazards include inhalation of other metals, chemicals or fumes used in processing; heat from furnaces; machinery accidents; high exposure to carbon monoxide.

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