Dust Collection System Installation SWMS

Dust collection system installation involves erecting large-diameter ducting, cyclones, baghouses and fans across manufacturing, joinery and processing facilities. The work combines structural steel access at height, welding and mechanical fitting of heavy plant, cutting into existing ductwork that may contain combustible dust residues (including wood, flour or metal fines), and terminations into three-phase motor control gear. Entry into hoppers, silos and large filter housings for internal fit-out is routine, and connections into existing extraction runs may involve legacy asbestos-containing gaskets or lagging in older NSW industrial premises.

This work is High Risk Construction Work under section 291 of the Work Health and Safety Regulation 2025 (NSW) — specifically risk of fall greater than 2 metres, work in or near a confined space, and work on or near energised electrical installations. Section 299 requires a Safe Work Method Statement be prepared before the work commences. Controls follow the hierarchy of control under section 36, supported by consultation under section 47 of the WHS Act 2011 (NSW) and review under section 302 of the Regulation.

Hazards identified

12 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Eliminate work at height where practicable by pre-assembling duct spools at ground level and lifting complete modules into position using engineered rigging.
2. 2Substitute mechanical fixing (bolted flanges, Nordfab-style clamp systems) for hot work on existing dust-laden ductwork; where hot work is unavoidable, isolate, clean and gas-test the affected section first.
3. 3Engineer fall protection compliant with AS/NZS 1891.4 — scaffold to AS/NZS 1576, EWPs operated to AS 2550.10, or engineered anchor points and travel-restraint before ladder use.
4. 4Confined space entry to AS 2865: written entry permit, continuous atmospheric monitoring for O₂, LEL and CO, mechanical ventilation, standby person and documented rescue plan before any hopper, silo or baghouse entry.
5. 5Combustible dust risk assessment prior to hot work; clean internal surfaces, verify with dust sampling, purge with inert gas or water-wash where required, and maintain a fire watch to AS 1674.1.
6. 6Electrical isolation to AS/NZS 4836 with lock-out/tag-out on motor starters, VSDs and MCC panels; all connection and commissioning by a licensed electrician working to AS/NZS 3000 with verified testing.
7. 7Presume asbestos-containing materials in ductwork installed pre-2004 until a competent asbestos assessor confirms otherwise; removal by licensed removalist under sections 419–434 of the WHS Regulation 2025 (NSW).
8. 8Silica and process dust controls to the workplace exposure standard: on-tool LEV, wet-cutting where feasible, and P2/P3 RPE selected and fit-tested to AS/NZS 1715 and AS/NZS 1716.
9. 9Lifting operations planned by a competent rigger; loads within rated capacity, exclusion zones enforced, and lifting gear inspected to AS 2550.1 before each shift.
10. 10Hot work permit system with fire extinguishers, welding screens, forced-air ventilation and welding fume RPE; PPE to AS/NZS 1337.1 (eye), AS/NZS 1801 (head), AS/NZS 2210.3 (foot) and AS/NZS 2161.3 (gloves).
11. 11Hearing protection to AS/NZS 1270 where noise exceeds the exposure standard in section 56 of the WHS Regulation 2025 (NSW); rotate tasks to limit exposure duration.
12. 12All workers hold CPCCWHS1001 (White Card) and are inducted to this SWMS; consultation conducted under section 47 of the WHS Act 2011 (NSW), and the SWMS is reviewed under section 302 of the WHS Regulation 2025 (NSW) whenever controls change, an incident occurs, or the work method is varied.

Applicable Codes of Practice

High-Risk Construction Work triggered

Worked example

A mechanical services contractor is engaged to install a new 15,000 m³/h dust collection system at a joinery in Wetherill Park, western Sydney. The scope includes a rooftop-mounted baghouse, 8 metres of vertical ducting through the factory roof, spiral ducting at 6 metres above the finished floor connecting to twelve machine hoods, and termination into a new VSD panel on the existing MCC. The site supervisor uses this SWMS to plan pre-assembly of duct spools at ground level, hires a 16 m knuckle-boom EWP for the overhead runs, and issues a confined space permit for internal welding of the baghouse hopper. An asbestos survey is commissioned on the 1990s-era extraction line being decommissioned. All electrical terminations are performed under lock-out by a licensed electrician after the joinery's production shift ends. The completed SWMS, permits and consultation register are provided to the principal contractor before work commences.

Related legislation

• Work Health and Safety Act 2011 (NSW)
• Work Health and Safety Regulation 2025 (NSW)
• Electricity Supply Act 1995 (NSW)
• Protection of the Environment Operations Act 1997 (NSW)
• Dangerous Goods (Road and Rail Transport) Act 2008 (NSW)
• Building and Construction Industry Security of Payment Act 1999 (NSW)

Frequently asked questions