Hi smandeir

Since you specifically mention molten aluminium rather than aluminium dust, personally I would put DSEAR back on the shelf and assess the risks from first principles.

The potentially lethal risk is molten metal + water = explosion.

The Aluminum Association keeps global stats 2021_Molten_Metal_Incident_Annual_Summary_Report_101821.pdf (aluminum.org) though these are likely to be far less than the true picture as the statistics are the result of voluntary reporting.

But except perhaps in recycling this risk is generally well controlled. Fix the leaks in the roof, preheat the materials to be melted to remove any moisture.

Such precautions might not eliminate water and other contaminants that might cause an explosion, so then you are on to keeping the workers away from the process at more critical times, putting them into molten metal protection etc.

Edited by user 24 May 2023 16:40:03(UTC)  | Reason: Mispelt Aluminum as I am in the UK!

Agree with others, limited DSEAR risk from smelting aluminium - if any fumes were flammable etc, they will be burnt off in the furnace.

The DSEAR issues are probably around the furnace fuel - if gas and any other ancillary work activities using DSEAR flammable materials.