Product Overview

Summary: This Dust Extraction Systems Safe Operating Procedure sets out clear, practical steps for selecting, operating, maintaining and monitoring dust extraction equipment in Australian workplaces. It helps organisations control airborne contaminants at the source, protecting workers from respiratory illness, improving air quality and supporting compliance with WHS and respirable crystalline silica requirements.

Dust extraction systems are a critical control for managing airborne contaminants generated by cutting, grinding, sanding, drilling, polishing and material handling activities across construction, manufacturing, woodworking, mining, metal fabrication and similar industries. Poorly designed, operated or maintained systems can leave workers exposed to respirable crystalline silica, hardwood dust, welding fumes and other hazardous airborne particles, leading to serious long-term health issues and potential non-compliance with Australian WHS laws. This Safe Operating Procedure provides a structured, step-by-step approach to ensure dust extraction systems are used effectively as part of a hierarchy of controls, rather than as an afterthought.

The SOP covers the full lifecycle of dust extraction system use – from pre-start inspection and system configuration, through safe operation and housekeeping, to routine maintenance, filter changes and performance monitoring. It defines roles and responsibilities, specifies minimum PPE requirements, and sets out clear controls for common risks such as blocked ducting, inadequate capture velocity, incorrect hood positioning and unsafe manual cleaning practices. By implementing this procedure, businesses can demonstrate due diligence, improve air quality, support health surveillance programs and reduce the risk of enforcement action, workers’ compensation claims and costly downtime.

Developed for the Australian regulatory environment, this document aligns with relevant WHS legislation, exposure standards and codes of practice, and can be easily integrated into existing safety management systems, SWMS, risk assessments and toolbox talks. It provides a ready-to-use, professionally structured template that can be customised to specific plant, processes and site conditions, ensuring a consistent and defensible approach to dust control across all operations.

Key Benefits

• Ensure effective control of airborne dust and fumes through consistent, best-practice operation of extraction systems.
• Reduce worker exposure to respirable crystalline silica, hardwood dust and other hazardous contaminants, supporting better long-term health outcomes.
• Demonstrate compliance with Australian WHS legislation, exposure standards and relevant codes of practice for airborne contaminants.
• Standardise pre-start checks, operation and maintenance of dust extraction systems across multiple sites and teams.
• Minimise equipment failures, unplanned downtime and costly clean-ups caused by poorly maintained or misused extraction systems.

Who is this for?

• WHS Managers
• Health and Safety Representatives (HSRs)
• Workshop Supervisors
• Production Managers
• Site Supervisors
• Maintenance Managers
• Plant Operators
• Fabrication and Joinery Supervisors
• Construction Project Managers
• Facilities Managers

Hazards Addressed

• Inhalation of respirable crystalline silica (RCS) and other hazardous dusts
• Exposure to hardwood dust and associated carcinogenic risk
• Respiratory irritation and occupational asthma from fine particulate matter
• Combustible dust explosion and fire risks in certain materials and environments
• Noise exposure from poorly controlled extraction equipment
• Manual handling injuries during filter replacement, duct cleaning and waste removal
• Eye and skin irritation from airborne particles
• Slip, trip and fall hazards from dust accumulation on floors and work surfaces
• Electrical hazards associated with dust extraction equipment and control panels
• Ergonomic strain from awkward access to extraction hoods, ducting and collection units

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Legislation and Standards
• 3.0 Definitions and System Overview
• 4.0 Roles and Responsibilities
• 5.0 Hazard Identification and Risk Assessment for Dust-Generating Tasks
• 6.0 Selection and Configuration of Dust Extraction Systems
• 7.0 Required PPE and Supporting Control Measures
• 8.0 Pre-Start Inspections and System Readiness Checks
• 9.0 Safe Operating Procedure for Dust Extraction Systems
• 10.0 Housekeeping, Waste Handling and Disposal of Collected Dust
• 11.0 Maintenance, Filter Replacement and Duct Cleaning Requirements
• 12.0 Performance Monitoring, Airflow Verification and Record Keeping
• 13.0 Emergency Procedures (System Failure, Fire, Spills and Exceedances)
• 14.0 Training, Competency and Supervision
• 15.0 Review, Audit and Continuous Improvement
• 16.0 Document Control and Revision History

Legislation & References

• Model Work Health and Safety Act and Regulations (as implemented in each state and territory)
• Safe Work Australia – Workplace Exposure Standards for Airborne Contaminants
• Safe Work Australia – Code of Practice: Managing the Risks of Airborne Contaminants at the Workplace
• Safe Work Australia – Code of Practice: Managing the Risks of Respirable Crystalline Silica from Engineered Stone in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• AS 1668.2: The use of ventilation and airconditioning in buildings – Mechanical ventilation in buildings
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 3000: Electrical installations (Wiring Rules)