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Dust Extraction Maintenance SWMS

Dust extraction systems are critical engineering controls in manufacturing facilities that handle wood, metal, silica, flour, and other dust-generating materials. Without regular maintenance, these systems degrade through filter loading, duct blockage, fan wear, and seal deterioration, reducing their effectiveness and potentially exposing workers to dust levels above the applicable WELs. Maintenance work on dust extraction systems itself presents hazards including exposure to accumulated concentrated dust, combustible dust fire risk in filter housings, and falls from elevated ductwork. This template addresses safe maintenance procedures and performance verification requirements.

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SWMS variants reference your state's WHS legislation. Instant download after payment.

Legal Requirements

regulation

WHS Regulation 2025 Part 7.1 — Hazardous Chemicals and Part 4.7 — Plant

hrcw category

Plant maintenance with dust explosion risk

code of practice

Managing Risks of Hazardous Chemicals in the Workplace (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

HazardConsequenceLikelihood
Concentrated dust exposure during filter replacement and hopper emptyingAcute respiratory exposure, sensitisationLikely
Combustible dust fire in filter housing or dust collectorEquipment fire, potential dust explosionPossible
Falls from elevated ductwork during inspection and repairFractures, head injuries, deathPossible
Electrical hazards from fan motors and control systemsElectrocution, burnsUnlikely
Reduced extraction effectiveness exposing workers to above-WEL dust levelsChronic respiratory disease, cancerLikely
Confined space entry into large dust collectors and hoppersEngulfment, atmospheric hazardsUnlikely

Controls (Hierarchy of Controls)

Wear P3 respiratory protection during filter replacement and hopper emptying operations
Lockout and tagout extraction fans before entering filter housings or duct sections
Use HEPA-filtered vacuum cleaners to clean accumulated dust — never use compressed air
Conduct face velocity measurements at all extraction points quarterly using a calibrated anemometer
Replace filters according to manufacturer specifications and differential pressure readings
Inspect ductwork annually for blockages, leaks, and damage that reduce extraction performance
Use fall protection when accessing elevated ductwork and filter housings
Conduct annual thorough examination of the complete extraction system by a competent ventilation engineer

Recent Prosecutions

Orica Australia Pty Ltd$1,200,000

Workers exposed to hazardous dust without adequate ventilation or health monitoring.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

SafeWork SA prosecution$840,000

Inadequate engineering controls in manufacturing facility resulting in worker exposure to hazardous substances.

2024 — SafeWork SA Manufacturing Prosecution [2024]

What Your SWMS Must Include

✓Extraction system maintenance schedule with component-level inspection intervals
✓Face velocity measurement procedure and minimum acceptable values for each extraction point
✓Filter replacement criteria based on differential pressure and manufacturer specifications
✓RPE requirements for maintenance personnel during filter and hopper work
✓Annual thorough examination scope and competent person requirements

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