The aim of this paper is to present a risk analysis method that can be applied to factories where combustible dust is handled, in the form of raw materials, products or by-products, and therefore at risk to explosion. The work was carried out on site: a consistent number of companies that deal with the surface finishing of objects in aluminium through grinding were examined. The aluminium. powder produced as a by-product is generally captured by suction plants and then subjected to dry or wet type abatement. In order to provide a rational approach to the risk assessment and frequency estimation, each company was divided into the so-called fields of study; and four risk assessment topics were identified for each field. A brief review of the methods that are available for the consequence magnitude estimation, regarding both the pressure wave and the launching of missiles, is also provided. (C) 2004 Elsevier Ltd. All rights reserved.