Rank: Forum user 
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We have a process that irregularly needs to involve the hand grinding the ends off of small (diameter 3mm) solid beryllium copper plugs for electronic devices. This creates minute traces of the solid, which could in theory be removed using a solder fume extractor. Duration of task is once a month for 10/15 minutes. One supervisor says absolutely not acceptable since beryllium compounds are carcinogenic. Other supervisor / staff happy to continue to do this activity. Thoughts? Suggestions? please Edited by user 15 October 2025 10:40:48(UTC)
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Rank: Super forum user
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ah the wild west... What Hazards I think you are facing... - Beryllium Copper (BeCu): Typically 0.5–3% beryllium in copper.
- Hazard: The beryllium in dust or fume form is a Category 1 carcinogen (IARC) and can cause chronic beryllium disease (CBD), a serious lung disease.
- Route of exposure: Inhalation of dust or fumes. Handling solid, intact pieces is low risk, but grinding produces fine particles, which are respirable.
Even very small quantities, if inhaled, can pose risk. There is no completely “safe” exposure threshold for beryllium dust in occupational settings—hence extreme caution is warranted. - A solder fume extractor may reduce some dust, but typical units are not rated for carcinogenic metal dust. HEPA filtration or dedicated metal dust containment is better.
- 10–15 min/month seems trivial, but beryllium’s toxicity is so high that even single-event exposure is considered hazardous, particularly if particles are respirable.
What I think you should do now... - Stop hand grinding immediately until a proper COSHH assessment is done.
- Explore pre-machined plugs or mechanical methods that avoid dust.
- If grinding cannot be avoided:
- Move operation into a fully ventilated enclosure with HEPA filtration.
- Use PPE with P100 respirator, gloves, eye protection.
- Limit exposure to trained personnel only.
- Document the risk assessment and supervisory approval.
Remember: the supervisor who is “happy to continue” is underestimating risk; even a few minutes of exposure to beryllium dust can be hazardous. Get hold of a copy of INDG 311 by the HSE to highlight awareness : https://www.hse.gov.uk/pubns/indg311.htm
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 1 user thanked stevedm for this useful post.
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