Respirable Crystalline Silica Control Safe Operating Procedure

Product Overview

Summary: This Respirable Crystalline Silica Control SOP sets out a clear, practical framework for managing silica dust exposure in Australian workplaces. It helps businesses systematically identify high-risk tasks, implement effective controls, and demonstrate compliance with WHS laws and silica-specific regulations.

Respirable crystalline silica (RCS) is a major health hazard in many Australian industries, particularly construction, stonemasonry, civil works, mining, tunnelling, and manufacturing. Uncontrolled exposure can lead to silicosis, lung cancer and other serious respiratory diseases, creating significant legal, financial and reputational risk for businesses. This SOP provides a structured, evidence-based approach to controlling silica dust, aligned with current Australian WHS legislation and regulator expectations.

The document guides you through the full lifecycle of silica risk management: from identifying RCS-generating tasks, selecting appropriate engineering controls (such as water suppression and on-tool extraction), and specifying suitable respiratory protection, through to air monitoring, health surveillance and record keeping. It defines clear responsibilities for supervisors and workers, standardises safe work methods for cutting, grinding, drilling and polishing silica-containing materials, and embeds practical housekeeping and decontamination practices to prevent dust build-up and cross-contamination. For businesses under pressure to demonstrate compliance with silica reforms and prohibition of uncontrolled engineered stone, this SOP helps turn high-level obligations into day-to-day, auditable practice.

Key Benefits

• Ensure compliance with Australian WHS legislation and silica-specific regulatory requirements across relevant states and territories.
• Reduce worker exposure to respirable crystalline silica, lowering the risk of silicosis and long-term occupational disease claims.
• Standardise high-risk tasks such as cutting, grinding, drilling and polishing so that consistent, proven controls are always applied.
• Demonstrate due diligence to regulators, clients and insurers through documented procedures, monitoring and review processes.
• Improve workforce confidence and safety culture by providing clear instructions, training prompts and defined responsibilities.

Who is this for?

• Directors and PCBUs
• WHS Managers
• Health and Safety Advisors
• Construction Project Managers
• Workshop and Factory Managers
• Site Supervisors and Leading Hands
• Stonemasonry Business Owners
• Civil and Demolition Supervisors
• Engineering and Fabrication Managers
• HSEQ Coordinators
• HR and Training Managers

Hazards Addressed

• Inhalation of respirable crystalline silica dust leading to silicosis and other lung diseases
• Chronic respiratory conditions arising from repeated low-level silica exposure
• Acute over-exposure during high-dust tasks such as dry cutting, grinding or polishing
• Secondary exposure from contaminated clothing, equipment and surfaces
• Exposure to mixed hazardous dusts where silica is present with other contaminants
• Manual handling and ergonomic risks associated with dust control equipment and vacuum systems
• Eye and skin irritation from airborne dust and slurry splashes
• Housekeeping and fire risks from dust accumulation in enclosed or semi-enclosed areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (including respirable crystalline silica and high-risk tasks)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Identification of Silica-Containing Materials and Tasks
• 6.0 Hierarchy of Control for Respirable Crystalline Silica
• 7.0 Engineering Controls (water suppression, on-tool extraction, isolation)
• 8.0 Administrative Controls (work planning, scheduling, exclusion zones, permits)
• 9.0 Personal Protective Equipment (selection, fit testing, use and maintenance)
• 10.0 Safe Work Procedures for Common Silica-Generating Activities
• 11.0 Air Monitoring, Exposure Assessment and Health Surveillance
• 12.0 Housekeeping, Decontamination and Waste Management
• 13.0 Emergency Response and Incident Management (over-exposure, equipment failure)
• 14.0 Training, Consultation and Communication with Workers
• 15.0 Inspection, Auditing and Continuous Improvement
• 16.0 Record Keeping and Documentation Control

Legislation & References

• Work Health and Safety Act 2011 (Cth and harmonised state/territory equivalents)
• Work Health and Safety Regulations 2011 – Hazardous chemicals and airborne contaminants provisions
• Safe Work Australia – Workplace Exposure Standards for Airborne Contaminants (respirable crystalline silica)
• Safe Work Australia – Managing the Risks of Respirable Crystalline Silica from Engineered Stone in the Workplace: Code of Practice (where adopted)
• Relevant state and territory silica dust Codes of Practice (e.g. NSW, QLD, WA, VIC guidance on managing RCS)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 1269 series: Occupational noise management (where combined cutting/grinding hazards are considered)
• AS/NZS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use