Cleaning Dust at Height in Factories and Warehouses

Why dust at height is a problem for factories and warehouses

Across a varying range of industries, from bakeries to foundries, manufacturing facilities generate large amounts of dust. While dust at ground level is often cleaned regularly, whether it be floors or machinery, dust at high level can settle across all surfaces and receive much less frequent attention. “Out of sight, out of mind.” Common areas where dust can settle include lighting fixtures, pipework, cable trays, purlins, racking, machinery, or steelwork.

High level areas are understandably cleaned less frequently than ground level due to access requirements and production constraints. However, this increases the importance of scheduling annual high level cleans to remove any dust buildup that’s accumulated over the year.

In this blog, we explore the hazards of high level dust in factories and warehouses, and the importance of high quality safety provision during industrial cleaning projects to mitigate exposure risks.

The dangers of dust in industrial environments

There are various risks from dust in industrial environments, and the seriousness of risk largely depends on the size and type of dust in question. Different hazards include:

Health risks to workers

Fine dust particles can be roughly grouped into two categories:

• Inhalable dust includes larger particles that, when inhaled, can become trapped in the mouth, nose, and throat. While they still pose a risk, these particles are largely blocked by the nose, hair, or cilia cells and are prevented from reaching the lungs.
• Respirable dust are extremely fine dust particles that can be invisible to the naked eye, yet remain airborne for long periods and can be inhaled deep into to the lungs, causing significant long lasting damage.

This study from the US National Institute of Health also cites a link between consistent air pollution and dementia. Furthermore, the UK Health & Safety Executive notes that a number of dusts included their 2023 report contained asthmagens and/or carcinogens.

Fire and explosion risks

Fine particles in industrial settings such as flour and wood shavings can be extremely combustible, and can trigger a large fire or explosion if ignited. Large amounts of dust on high level surfaces can also contribute to the fire load of a facility – the total amount of material in a space that can burn.

ATEX zones are classified as areas with a high risk of explosion due to the presence of combustible dust, flammable gases or other ignition sources. These areas will require specialist ATEX specific equipment, with features such as anti-static capabilities and HEPA filters for hazardous fine material.

Operational and business risks

Buildups of dust on high level surfaces across a factory or warehouse can cause significant compliance issues, potentially leading to failed audits like BRC for food safety. Dust control should form part of a site’s HACCP procedures, being addressed on an appropriately regular basis to avoid the need for reactive measures. Staying on top of high-level cleaning can avoid unplanned shutdowns to accommodate for emergency cleans, as well as avoid the risk of failed inspections.

How cleaning dust at height can present additional hazards

The previously mentioned 2023 HSE Report Industrial Cleaning: Exposure to Dust Hazardous to Health explains how industrial cleaning, when done incorrectly, can present further risks to health.

Disturbing dust using methods such as dry sweeping or compressed air (which the HSE strongly advises not to use), can cause significantly higher concentrations of dust to remain airborne. These methods just move dust around rather than removing it at the source.

The HSE also reported a significant number of cases where industrial cleaners were not wearing their PPE and RPE properly, significantly increasing their exposure to hazardous dust.

Common mistakes when cleaning dust at high level include:

• Using compressed air – agitates dust to become airborne
• Dry sweeping – agitates dust to become airborne
• Using an insufficient industrial vacuum system below an M class – aka meeting “Medium Risk” requirements for dust extraction as set out by HSE
• Not wearing PPE and RPE – or wearing it incorrectly
• Lack of extraction/containment at the source

Partner with specialist industrial cleaning professionals

Cleaning dust at high level in factories and warehouses is specialist work that requires professional training and a history of Health & Safety commitment. Our team here at Kingfisher have completed hundreds of high level cleaning projects over the years, prioritising safety, zero product contamination and logistical provision for our clients to work around production wherever possible. It is essential to partner with industrial cleaners who can be trusted to use the correct specialised equipment, wear their PPE properly to prevent exposure hazards, and complete a high quality job to remove all dust from high level areas. That’s Kingfisher!

To discuss any high level industrial cleaning requirements, get in touch with our team today: