Aluminum (Al) is considered the most widely distributed element in nature especially in the earth's crust. Workers in the secondary Al industries are occupationally exposed to intense environmental Al dust. This study was carried out to assess the levels of indoor respirable Al dust in addition to the changes in some hematological and biochemical parameters of the exposed workers. An animal experiment was performed to investigate the histopathological changes on the trachea and lungs of rats exposed to Al dust to assess the risk of Al exposure among the workers. The results of this study showed that the highest respirable dust concentration was detected in the finishing department (6459.33 µg/m³) that exceeded the permissible exposure limit. While, the lowest concentrations 2182.29 and 1220.88 µg/m³ were found in casting and rolling departments, respectively. A significant decrease in RBC's count, Hb, HCT, MCV, MCHC and platelets number with significant increase in WBC's, lymphocyte counts, serum urea and creatinine level were observed in exposed workers when compared to the control group. Furthermore, rats exposed to inhalation of dust induced some histopathological changes in their trachea and lung tissues. The degree of these changes was proportional to the duration of Al dust exposure. Thus, strict enforcement of appropriate, effective preventive and control measures must be required.