Silica Dust Management — Safe Work Method Statement
Safe Work Method Statement for managing respirable crystalline silica (RCS) exposure during construction activities including engineered stone benchtop fabrication, masonry cutting, concrete grinding, and tunnelling operations.
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Respirable crystalline silica (RCS) has emerged as one of the most significant occupational health issues in Australian construction over the past decade. Silicosis — a progressive, irreversible, and potentially fatal lung disease — has been diagnosed in young stonemasons and kitchen benchtop fabricators at alarming rates, prompting national regulatory responses. A SWMS addressing RCS exposure is mandatory on construction sites where silica-generating tasks are performed, and the Safe Work Australia Code of Practice: Engineered Stone provides specific guidance for that trade.
The WHS Regulations were amended nationally to impose strict duty requirements on PCBUs where engineered stone is processed. From 1 July 2024, the manufacture, supply, processing, and installation of engineered stone containing 1% or more crystalline silica by weight is prohibited in Australia — making this the first material to be banned under Australian WHS law. For all other silica-generating work (concrete cutting, masonry grinding, tunnelling, pottery and ceramic work), the workplace exposure standard (WES) for RCS was halved from 0.1 mg/m³ to 0.05 mg/m³ (8-hour TWA) effective July 2020 under the Workplace Exposure Standards for Airborne Contaminants.
Control of RCS requires application of the hierarchy of controls. Engineering controls take priority: wet suppression and on-tool dust extraction connected to an H-class vacuum (compliant with AS/NZS 60335.2.69) are the standard approaches for most tasks. Isolation and enclosure are required for high-generation tasks. Administrative controls include job rotation to limit exposure duration. Respiratory protection — minimum P2 half-face respirator per AS/NZS 1716 — is a last resort and supplement, not a primary control. Air monitoring by a competent person is required to verify that controls reduce exposure below the WES.
To customise this template, list each specific task generating RCS, the substrate material and its silica content, the dust control method for each task, the air monitoring schedule, and the health surveillance program for workers with ongoing exposure. Health surveillance (lung function testing and chest X-ray) is required under the model WHS Regulations for workers in high-risk occupations.
This SWMS applies in all Australian jurisdictions. The engineered stone ban and the revised WES apply nationally, including Western Australia (model WHS laws adopted 2022) and Victoria (OHS Regulations 2017 as amended).
Personal Protective Equipment
High Risk Construction Work Types
- •Work with or near hazardous chemicals (respirable crystalline silica)
Risk Assessment
1.Identifying silica-containing materials on site
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Workers unknowingly working with high-silica materials without controls | High | Review the SDS for all construction materials before use. Identify all materials with silica content above 1% — including engineered stone (up to 95% silica), natural stone, concrete, mortar, sand, brick, block, and tile. Post an inventory of silica-containing materials at the site entry. Highlight engineered stone products — these are the highest risk materials and may only be worked dry by workers with specific engineered stone training and in compliance with state-specific regulations (which may prohibit certain dry work). | Low | Site Manager / WHS Officer |
2.Cutting, grinding, and drilling silica-containing materials
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Acute and chronic silicosis from RCS inhalation during cutting and grinding | Catastrophic | Apply the hierarchy of controls strictly: (1) Eliminate dry cutting — use wet cutting methods with continuous water suppression for all concrete, masonry, and stone cutting. (2) Substitute — use pre-cut materials to eliminate on-site cutting where possible. (3) Engineering controls — use on-tool LEV (Local Exhaust Ventilation) with H-class HEPA vacuum for all grinding and drilling tasks that cannot be wet cut. (4) Administrative — rotate workers to limit individual RCS exposure below the WES of 0.05 mg/m³ TWA. (5) PPE — minimum P2 respirator; full-face PAPR for engineered stone tasks. Conduct personal air monitoring quarterly for all workers who regularly perform silica-generating tasks. | Moderate | Workers / Site Supervisor / HSE Manager |
| Adjacent workers exposed to silica dust from cutting operations | High | Establish a 6 m exclusion zone around all active cutting and grinding operations. Post 'SILICA DUST HAZARD — PPE REQUIRED' signage at the boundary. All persons entering the exclusion zone to wear minimum P2 respirators. Where exclusion zones cannot be maintained (e.g., confined spaces), supply all nearby workers with P2 respirators and rotate out of the area at 20-minute intervals. Conduct task-based air monitoring to confirm the exclusion zone boundary is adequate. | Low | Site Supervisor / Workers |
3.Cleanup and housekeeping in silica dust areas
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Resuspension of settled silica dust during cleanup causing secondary exposure | High | Never use compressed air, leaf blowers, or dry sweeping to clean up silica dust — these actions resuspend fine RCS particles back into the breathing zone. Use wet mopping or HEPA-filtered vacuum cleaners for all cleanup activities. Apply water to floors before sweeping if vacuums are not available. Workers conducting cleanup of silica dust to wear minimum P2 respirators throughout. Dispose of silica waste slurry and vacuumed material in sealed bags — do not leave pooled or dried silica dust on surfaces. | Low | Workers / Supervisor |
4.Health surveillance and air monitoring program
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Progressive silicosis undetected due to lack of health monitoring | High | Implement a mandatory health surveillance program for all workers regularly exposed to RCS: baseline chest X-ray and lung function test (spirometry) before commencing silica work; annual chest X-ray and spirometry for all workers in ongoing silica-generating roles. Use a registered medical practitioner with occupational medicine experience. Report any abnormal results to the worker immediately and refer to a specialist respiratory physician. Maintain health surveillance records for a minimum of 30 years. Provide workers with copies of their own health surveillance results. | Low | PCBU / HSE Manager / Occupational Physician |
5.Engineered stone specific controls
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Extreme RCS exposure from engineered stone dry cutting or grinding | Catastrophic | Comply with all current state and territory regulations regarding engineered stone — note that some jurisdictions have banned or severely restricted dry work on engineered stone. Where engineered stone work is permitted, it must only be performed wet with continuous water suppression, on-tool LEV, and full-face PAPR (not half-face P2). Workers must complete engineered stone specific training. All engineered stone work to be conducted in a designated, controlled area separated from other workers. Conduct real-time air monitoring during all engineered stone tasks and stop work if readings exceed 0.02 mg/m³. | Moderate | Workers / Supervisor / HSE Manager |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.