You have been told you need a dust hazard analysis (DHA), and the first question on your mind is fair: what is this going to cost? Most providers will not put a number on their website. We will. For most single facilities, a DHA written to NFPA 660 runs $15,000 to $20,000+.
That range is real, but your number depends on your facility. Below is what moves it, what you should expect to get for it, and how to get a fixed price before you commit to anything.
The short answer
- Small, simple facility (one building, one or two dust-producing processes, one collector): toward the low end of the range.
- Typical manufacturing plant (several process areas, multiple collectors, some conveying or storage): the middle of the range.
- Large or complex site (multiple buildings, many process lines, mixed materials, on-site visit required): $20,000 and up.
Dust testing, if your study needs it, is a separate lab cost. So is travel, when a visit is truly needed. Both should be spelled out on your quote before you sign.
What drives your price
1. How many process areas are in scope
This is the biggest factor. A DHA looks at every place your dust is made, moved, collected, or stored: mixers, mills, sanders, conveyors, silos, bins, dust collectors, and the rooms they sit in. Each one has to be evaluated on its own. Ten process areas take more time than three.
2. How many buildings
Each building is its own compartment to evaluate for dust accumulation and deflagration risk. A second building with its own dust sources adds real scope.
3. Whether your dust has been tested
If you have test data for your material (Kst, Pmax, MEC, MIE), the analysis can use it directly. If you do not, the DHA can treat your dust as combustible, or your quote may recommend testing for specific materials. Testing is a lab fee on top of the DHA, and it adds time to your schedule.
4. How complete your documents are
A current layout, photos of your process, Safety Data Sheets, and equipment information let a qualified person work efficiently. Gaps mean more back-and-forth, and sometimes a site visit to fill them.
5. Remote, hybrid, or on-site
Most facilities can be studied remotely, using your documents and a live video walkthrough with your team. That keeps travel off your quote. Large or complex sites, or ones where your insurer or authority having jurisdiction (AHJ) wants a visit, may need someone on-site.
6. Whether you need a new DHA or an update
If you already have a DHA and your process has not changed much, an update can be lighter work than starting from scratch. If your old DHA is thin or your process has changed a lot, it is often closer to a new study.
What should be included in the price
Before you compare quotes, make sure you are comparing the same thing. A complete DHA quote should include:
- Review of your documents and a walkthrough of your facility (remote or on-site)
- Identification of your combustible dust hazards, process area by process area
- Evaluation of your existing safeguards against the NFPA 660 requirements that apply
- Written recommendations your team can prioritize
- A draft for your review, at least one revision round, and a final report
- A clear schedule and a fixed price
If a quote is far below the range, ask what is missing. Template reports that swap in your company name are cheap for a reason, and they may not hold up when an insurer or inspector reads them closely.
What is usually not included
- Dust testing. Lab fees are separate and depend on how many samples and which tests.
- Design or installation of fixes. A DHA identifies hazards and recommends safeguards. Designing and installing them is separate work.
- A professional engineer’s seal. NFPA 660 does not require one. If your AHJ or insurer asks for a sealed report, your PE reviews and seals it, and any revisions they request are typically billed hourly.
How to get a fixed number
The fastest path to a real price is a short intake. You tell us what you make, what dust you handle, how many areas and buildings are involved, and what documents you already have. From that, we can quote a fixed price, typically within two business days, with the scope, format, and schedule written out.
Most studies finish in 4 to 6 weeks from your deposit and complete documents. Any facility that books a DHA with us also gets free setup of our compliance software once it launches, with your equipment and findings loaded so you can track your recommendations after the report is done.
Get your fixed DHA price
Fill out a 15-minute intake and get a fixed quote, typically within two business days. Available in all 50 states.
Questions facilities ask about DHA cost
How much does a dust hazard analysis cost?
Most single-facility DHAs run $15,000 to $20,000+. Your price depends on how many process areas and buildings are in scope, whether your dust has been tested, how complete your documents are, and whether the study is remote or on-site.
Is dust testing included in the DHA price?
Usually not. Lab testing is a separate cost. If you already have test data, send it with your intake. If you do not, your quote should say whether testing is needed.
Is a DHA update cheaper than a new DHA?
Often, yes, if your existing DHA is solid and your process has not changed much. If your old report is thin or your process has changed a lot, the work gets closer to a new study.
Why do DHA quotes vary so much?
Scope. Some quotes cover every process area with written recommendations and a review round. Others are template reports. Compare what is included, not just the number.
Does a remote DHA cost less?
Usually, because travel comes off your quote. Most facilities can be studied remotely using documents, photos, and a live video walkthrough.