Managing respirable crystalline silica starts with one practical rule: identify any task that can release silica dust, assess it before work begins, and use controls that stop dust being generated or capture it at the source. Do not rely on a paper mask or visible dust alone. Respirable crystalline silica (RCS) is invisible under normal lighting and can remain airborne for a long time. Exposure can cause silicosis, lung cancer and other serious diseases.
Information current at 6 August 2026. Requirements vary between Australian jurisdictions, so check the current material from your WHS or OHS regulator. The national Model Code is useful general orientation, but it is not automatically the law in every state or territory.
Where silica dust comes from
Crystalline silica occurs in many common construction materials, including concrete, bricks, blocks, mortar, tiles, fibre-cement products, stone, asphalt, sand and clay. Dust can be released during cutting, grinding, drilling, chasing, crushing, scabbling, polishing, demolition and dry clean-up.
The main hazard is the dust that reaches a worker’s breathing zone. It may also drift into nearby trades or occupied areas. Visible clouds are an obvious warning, but the absence of visible dust does not prove the air is safe. Also control related noise, vibration, electrical and flying-particle risks.
What should be sorted before work starts
Before processing a material that may contain crystalline silica:
- confirm the material and, where available, check its safety data sheet, technical data or supplier information
- define the task, tool, location, duration and people who may be exposed
- consult the workers doing the job and coordinate controls with the builder, principal contractor and other affected trades
- select equipment and controls for the actual material and task
- assess whether the processing is high risk under the requirements applying in your jurisdiction
- plan how dust, slurry, filters and waste will be contained and removed
- arrange required training, supervision, fit testing, checks and monitoring.
Under the current Model Code framework, processing a crystalline silica substance should not begin until the high-risk assessment has been completed, and all processing must be controlled. If the risk level cannot be determined, the Model Code says to treat the processing as high risk until a later assessment establishes otherwise.
What good silica controls look like
Good control starts high in the hierarchy. Consider eliminating the task, using a lower-silica material or using a method that avoids cutting. Where processing remains necessary, isolate the work and use engineering controls suited to the job.
Typical measures include integrated water suppression, on-tool dust extraction or local exhaust ventilation positioned close to the source. Maintain compatible equipment so airflow and water delivery remain effective. Restrict access, keep others out of the dust path and use wet methods or a suitable industrial vacuum for clean-up. Dry sweeping and compressed-air cleaning can put settled dust back into the breathing zone.
Respiratory protective equipment may still be needed as part of the control combination. It should suit the exposure and task, be fit-tested where required, worn correctly and supported by training. Site teams should verify controls through pre-start checks, supervision and, where required, air and health monitoring.
Documents, silica plans and SWMS
The documentation should match the work rather than repeat generic statements. It commonly records the material and task, the risk assessment, chosen controls, equipment set-up, clean-up, RPE, training, checks, responsibilities and review triggers.
Under the Model Code framework, high-risk processing requires a silica risk control plan before processing starts. The plan must be accessible and understandable to workers and followed in practice. Where high-risk crystalline silica processing forms part of construction work, a SWMS may be used instead of a separate silica risk control plan if it contains all required silica-plan information. A SWMS is also commonly required where the work meets the applicable definition of high risk construction work. Confirm the position for the project and jurisdiction before starting.
Warning signs that controls need attention
Stop and review the job if you see:
- dust escaping the tool shroud or spreading beyond the work area
- weak extraction, blocked hoses, dry water feeds or damaged seals
- slurry drying out and becoming airborne again
- workers lifting RPE to communicate or wearing it with a poor seal
- uncontrolled dry sweeping, compressed-air cleaning or dusty clothing
- changed materials, tools, locations, work rates or nearby trades not covered by the assessment
- missing consultation, training, inspection or monitoring records.
Controls should be reviewed when they are not effective, before significant workplace changes, when new hazards are identified or when workers raise concerns. Do not wait for an incident or an abnormal monitoring result.
How Blue Safe can help
Blue Safe provides compliant WHS documents tailored to the client’s activities, applicable Australian WHS/OHS requirements, jurisdiction and industry. Blue Safe guarantees the document compliance of the WHS documents it provides, including eligible customer documents after Blue Safe has reviewed and upgraded them.
We can prepare or upgrade silica-related risk documents and SWMS so the task, controls, responsibilities and records are clear for the people using them. Customers actively put the compliant documents into practice through controls, consultation, training, actions, records and evidence.