Silica Dust Control Checklist

Quick answer: Crystalline silica dust is a Group 1 carcinogen. It causes silicosis — an irreversible, potentially fatal lung disease. Uncontrolled dry cutting of silica-containing materials is prohibited. This checklist covers the key control measures your site needs to have in place before work begins.

Last reviewed: June 2026 by the BlueSafe Technical Team. Reflects current Model WHS Regulations, including the 2023 engineered stone amendments.

Respirable crystalline silica (RCS) is released whenever silica-containing materials are cut, ground, drilled, or disturbed. Common sources on Australian worksites include concrete, fibre cement sheeting, sandstone, brick, roof tiles, and engineered stone benchtops. Because silica particles in the respirable fraction are invisible to the naked eye, exposure is easy to underestimate — and the consequences can be devastating.

SafeWork Australia and state regulators have significantly strengthened silica dust requirements in recent years. The exposure standard was halved in 2020, and the 2023 amendments to the Model WHS Regulations introduced specific duties for engineered stone work, including a ban on uncontrolled dry cutting of engineered stone, mandatory health monitoring, and licensing requirements for engineered stone businesses.

Use this checklist alongside your site's Safe Work Method Statement. For help preparing your SWMS, see our Silica Dust SWMS Guide and Hazardous Chemicals SWMS Guide.

1. Silica Risk Assessment

Before any work involving silica-containing materials commences, a documented risk assessment must be completed.

• Silica-containing materials have been identified and listed (concrete, fibre cement, sandstone, brick, engineered stone, grout, mortar, etc.).
• The tasks that will disturb silica-containing materials have been identified (cutting, drilling, grinding, chasing, demolition, dry sweeping).
• The likely exposure levels for each task have been assessed, taking into account duration, frequency, and enclosure of the work area.
• The risk assessment has been documented and is available on site.
• Workers and HSRs have been consulted in the risk assessment process.
• The risk assessment is reviewed whenever there is a change to the work, the materials, or the controls.

2. Elimination and Substitution

The hierarchy of controls requires that elimination or substitution be considered before engineering controls.

• Pre-cut or pre-formed materials have been specified where practicable to reduce on-site cutting.
• Lower-silica alternatives (e.g. manufactured products with lower crystalline silica content) have been evaluated where available.
• Work has been relocated or scheduled to reduce the number of workers in the exposure zone.
• Engineered stone: Confirm whether the proposed task involves engineered stone (>1% crystalline silica by weight). Note that a ban on engineered stone benchtops was implemented in 2024 — verify current regulatory status with your state regulator before any engineered stone work commences.

3. On-Tool Water Suppression and Dust Extraction (LEV)

Engineered controls are the primary means of reducing silica dust at the source.

• On-tool water suppression (wet cutting) is used for angle grinders, circular saws, and other cutting equipment where practicable.
• Water suppression equipment is in good working order and water flow is adequate before each shift.
• On-tool local exhaust ventilation (LEV/dust extraction) is fitted to tools where water suppression is not practicable (e.g. indoor cutting, chasing walls).
• LEV systems are inspected and maintained in accordance with the manufacturer's instructions and inspection records are kept.
• Vacuum systems used with LEV are rated H-class (high hazard) and fitted with HEPA filtration.
• Exhaust from vacuum systems is not directed back into the work area.
• LEV performance is verified at the start of each task (suction is confirmed, filters are not blocked).

4. Avoiding Dry Cutting

• Uncontrolled dry cutting of silica-containing materials is prohibited on this site.
• Workers have been instructed that dry cutting without on-tool LEV or water suppression is not permitted under any circumstances.
• Where dry cutting with LEV is the only practicable option, the work area is enclosed or segregated, and no bystanders are present.
• Dry cutting tasks have been documented in the site SWMS with the specific controls that will be applied.

5. Respiratory Protective Equipment (RPE)

RPE is the last line of defence and must be used in conjunction with engineering controls — not instead of them.

• Workers required to wear RPE have been individually fit-tested by a competent person and records are kept.
• RPE is rated at least P2 (for most silica dust tasks) or P3/PAPR (for high-risk tasks such as engineered stone work or extensive grinding).
• Single-use dust masks that are not rated P2 or above are not used or accepted on site.
• Workers are trained in the correct donning, doffing, and inspection of their RPE.
• Disposable P2 respirators are replaced at the end of each shift, or sooner if they become wet, damaged, or difficult to breathe through.
• Reusable respirators are inspected before each use and filters are replaced in accordance with the manufacturer's schedule.
• RPE is stored correctly (away from dust, heat, and chemicals) when not in use.
• Workers with facial hair that interferes with the seal of a tight-fitting respirator have been assessed and alternative RPE (e.g. PAPR with hood) has been provided if required.

6. Air Monitoring

Air monitoring may be required to verify that engineering controls are achieving adequate exposure reduction.

• A determination has been made (based on the risk assessment) as to whether quantitative air monitoring is required.
• Where air monitoring is required, it is conducted by a competent person using a method appropriate for respirable crystalline silica (e.g. gravimetric sampling with XRD analysis).
• Air monitoring results are compared against the WES of 0.05 mg/m³ TWA.
• Air monitoring records are kept and made available to workers and their representatives.
• Where monitoring shows exposures above the WES, additional controls are immediately implemented and monitoring is repeated to confirm effectiveness.
• Engineered stone businesses: Air monitoring is mandatory under the 2023 amendments. Confirm frequency and documentation requirements with your state regulator.

7. Exposure Standard Awareness

• The current WES for respirable crystalline silica (0.05 mg/m³ TWA) is documented in the risk assessment and SWMS.
• Workers, supervisors, and HSRs have been briefed on the WES and what it means in practical terms.
• The site has a process for escalating concerns when workers believe exposure controls may be inadequate.

8. Health Monitoring

• A determination has been made as to whether health monitoring is required for workers on this site (see FAQ below).
• Where health monitoring is required, it is arranged through a registered medical practitioner with experience in occupational lung disease.
• Workers have been informed of their right to access health monitoring at no cost to them.
• Health monitoring records are kept in accordance with privacy requirements and are not disclosed to other parties without the worker's consent.
• Workers are informed of their individual health monitoring results promptly.
• Where a health monitoring report identifies that a worker may have been harmed by silica dust exposure, the PCBU has taken action in response to the report.
• Engineered stone businesses: Mandatory health monitoring requirements under the 2023 amendments are confirmed and in place.

9. Housekeeping

Poor housekeeping is one of the most common causes of secondary silica dust exposure on worksites.

• Dry sweeping of silica dust is prohibited. Dry sweeping re-suspends settled dust and dramatically increases exposure.
• Compressed air is not used to blow down surfaces where silica dust may be present.
• Wet methods (wet mopping, damp wiping) or H-class HEPA vacuum systems are used to clean up silica dust and slurry.
• Silica dust waste and slurry are collected and disposed of as hazardous waste in accordance with local EPA requirements.
• Work areas are cleaned at the end of each shift and before access by other trades.
• Contaminated PPE (coveralls, gloves) is removed in the work area and bagged before leaving, to prevent contaminating other areas.

10. Signage and Site Demarcation

• The silica dust work area is clearly demarcated with barriers or tape.
• Signage is posted at all entry points to the work area identifying the hazard (silica dust), the required PPE (P2/P3 respirator), and access restrictions.
• Bystanders and other workers are excluded from the work area while silica dust work is in progress.

11. Worker Training

• All workers likely to be exposed to silica dust have received site-specific induction training covering the hazard, health effects, and required controls.
• Training covers: what silica dust is, what materials contain it, the health effects (including silicosis and lung cancer), the hierarchy of controls, how to use and maintain RPE, and what to do if controls fail.
• Training records (name, date, topics covered, trainer) are kept on site.
• Toolbox talks on silica dust are conducted when new silica-generating tasks commence or when there is a change to controls.
• Workers know how to report concerns about silica dust exposure to supervisors or the HSR.

State and Territory Variations

This checklist is based on the Model WHS Regulations and Safe Work Australia guidance material. Most states and territories have adopted the Model Regulations, but there may be differences in how the engineered stone amendments have been implemented.

Always verify current requirements with your state regulator, as enforcement priorities and additional guidance may vary.

Related guides

• Silica Dust SWMS Guide
• Hazardous Chemicals SWMS Guide

Frequently asked questions

Is dry cutting on a worksite still allowed in Australia?

Uncontrolled dry cutting of silica-containing materials is effectively prohibited under the Model WHS Regulations. Where dry cutting cannot be avoided, on-tool dust extraction (LEV) and appropriate RPE must be used. On-tool water suppression is the preferred control for most cutting tasks.

What respiratory protective equipment (RPE) is required for silica dust work?

A minimum of a fit-tested P2 respirator is required for most silica dust tasks. P3 or powered air-purifying respirators (PAPRs) are used for higher-risk work. Disposable dust masks that are not rated P2 or above provide no meaningful protection against respirable crystalline silica.

What are the silica dust exposure standards in Australia?

The workplace exposure standard (WES) for respirable crystalline silica is 0.05 mg/m³ as an 8-hour time-weighted average (TWA). This was halved from 0.1 mg/m³ in 2020. Engineered stone work is subject to additional controls under the 2023 amendments to the Model WHS Regulations.

When is health monitoring required for silica dust exposure?

Health monitoring is required where workers are, or are likely to be, regularly exposed to RCS at or above the WES, or where it is otherwise reasonably required. Mandatory health monitoring applies to all engineered stone work under the 2023 regulatory changes. It must be carried out by or under the supervision of a registered medical practitioner.

Get compliant before the inspector arrives

Managing silica dust is one of the most scrutinised areas of WHS enforcement in Australia. Regulators are conducting targeted inspections across construction, fabrication, and landscaping industries. Having your controls, training records, and SWMS in order before work commences — not after an incident — is your best protection.

Need WHS documentation built for your industry? Explore Blue Safe Online.

Disclaimer: This checklist is provided for general guidance only and does not constitute legal advice. WHS obligations vary by jurisdiction and workplace. Always consult your state or territory WHS regulator and seek independent legal or professional advice for your specific circumstances.