Silica Dust Work SWMS
Cutting, drilling, grinding, or chasing silica-containing materials — concrete, stone, engineered stone, brick, ceramics — across construction, manufacturing, and mining. Covers respirable crystalline silica (RCS) exposure controls and the 1 December 2026 WEL transition to 0.025 mg/m³.
SWMS variants reference your state's WHS legislation. Instant download after payment.
This SWMS covers the full scope of respirable crystalline silica (RCS) work on Australian construction and manufacturing sites — cutting, drilling, grinding, coring, chasing, polishing, and demolition of concrete, stone, engineered stone, brick, tile, ceramics, autoclaved aerated concrete, fibre-cement, and mortar. It is written for concrete cutters, stonemasons, tilers, bricklayers, demolition labourers, carpenters coring masonry, and any worker operating cut-off saws, core drills, angle grinders, wall chasers, or rotary hammers on silica-bearing materials. Every activity in this document has been authored against the Safe Work Australia Code of Practice "Managing the risks of respirable crystalline silica from construction and manufacturing work" (2024) and the national engineered-stone ban that took effect on 1 July 2024.
Silica work is the single most enforced health hazard on Australian construction sites in 2026. It is high-risk construction work under Schedule 1 of the WHS Regulation 2025 (NSW): Category 10 — demolition of a load-bearing structural element — is triggered during concrete-cutting penetrations through slabs and load-bearing walls, and Category 13 — work involving a hazardous substance above the exposure standard — is triggered wherever dry cutting, grinding, or percussive work is performed without adequate on-tool extraction. The current Workplace Exposure Limit for respirable crystalline silica is 0.05 mg/m³ (8-hour TWA); this value steps down to 0.025 mg/m³ from 1 December 2026 under the national WEL harmonisation. Under Section 299 of the WHS Regulation a SWMS must be prepared before this work commences, kept available at the workplace, and given to the Principal Contractor on request. The 2020 $1.13 million accelerated-silicosis payout to a Queensland engineered-stone worker and the doubling of accepted silicosis claims nationally from 2018–2024 drove the engineered-stone ban; this SWMS reflects that post-ban baseline, not the pre-2024 regime.
Hazards identified
12 hazards covered, sorted by priority.
Accelerated silicosis, chronic silicosis, lung cancer, and permanent loss of lung function; engineered-stone workers have developed progressive massive fibrosis after 2-5 years of exposure.
Silica concentrations 10-50 times the WEL within minutes of dry cutting concrete or stone with an unextracted angle grinder; irreversible lung damage begins at far lower exposures than the WEL.
Exposure to high-silica (>90%) dust during the only activities still permitted — removal, repair, minor modification — under the engineered-stone licensing framework; breach of the manufacture/install ban attracts prosecution.
Silica transported home on clothing, boots, and vehicle interiors has caused silicosis in family members and co-workers who never operated a cutting tool.
Re-aerosolisation of settled silica at concentrations often exceeding the original cutting exposure; a banned practice under the 2024 Code of Practice.
Radiographic disease onset in 18-30 months of continuous engineered-stone exposure; lung transplant is the only survival pathway in advanced cases.
Noise-induced hearing loss (cut-off saws routinely exceed 105 dB(A)) and hand-arm vibration syndrome from prolonged grinder and rotary-hammer use.
Slip and fall injuries on slurry-covered slabs; electrical risk where 240 V extension leads sit in standing water during wet cutting.
Silica is a Group 1 IARC carcinogen and a documented cause of chronic kidney disease, rheumatoid arthritis, scleroderma, and systemic lupus in chronically exposed workers.
P2 half-face respirators fail to protect workers at exposures above 10× the WEL; PAPR or supplied-air is mandatory in high-exposure indoor cutting and engineered-stone removal.
Undetected overexposure continues for months or years; without baseline and 2-yearly low-dose CT chest imaging, silicosis is detected too late for intervention.
Fatigue-driven decisions to bypass wet cutting or extraction under schedule pressure; sustained mental health harm in trades workers who have witnessed colleagues diagnosed with silicosis.
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Eliminate engineered stone. Manufacture, supply, processing, and installation of engineered stone has been prohibited nationally since 1 July 2024 under the model WHS Regulations. Only removal, repair, and minor modification of in-situ engineered stone remain permitted, and only under the relevant state engineered-stone licensing framework.
- 2Substitute lower-silica materials where design permits — fibre-cement sheeting, porcelain, natural stone with lower crystalline-silica content, or prefabricated off-site cut components that remove silica work from the construction site entirely.
- 3Wet cutting is the primary engineering control. Use continuous water suppression at the blade or bit on every cut-off saw, core drill, wall chaser, and angle grinder; water flow rates per the tool manufacturer's specification, typically 0.5-1.5 L/min for hand tools.
- 4On-tool extraction is mandatory where wet cutting is impracticable. Use M-class (minimum) HEPA vacuum extraction captured at the tool shroud; H-class is required for engineered-stone dust and any cutting in enclosed indoor spaces. Filters must be shaken or pulse-cleaned between tasks and replaced at manufacturer intervals.
- 5Fixed LEV for indoor cutting bays. Stonemason benches, tile-cutting stations, and indoor grinding cells must have fixed local exhaust ventilation designed to AS/NZS 2243.8 capture-velocity criteria, tested annually by a competent person, with results retained for the life of the equipment.
- 6Enclosed, HEPA-filtered, positive-pressure cabins for all mobile plant operating in silica atmospheres — road saws, excavator-mounted breakers, skid-steer grinders. Cabin filters tested and replaced on a documented schedule.
- 7Air monitoring is mandatory under the 2024 Code of Practice. Personal sampling at the first performance of a task, when controls change, and at regular intervals thereafter using an SKC or equivalent sampler with cyclone pre-selector and analysis by NATA-accredited laboratory per NIOSH 7500 or MDHS 101.
- 8Health monitoring for all workers with reasonably practicable silica exposure: baseline low-dose high-resolution CT chest, spirometry, and ILO-B chest X-ray, then 2-yearly monitoring by a registered medical practitioner familiar with silicosis per the SMAAS (Silica Monitoring Australia and Applied Science) framework or equivalent state programme.
- 9Respiratory protection selection based on exposure: P2 half-face disposable for exposures up to 10× the WEL; P3 half-face or full-face cartridge for up to 50×; PAPR or supplied-air for engineered-stone removal, prolonged indoor dry cutting, and demolition. All tight-fitting respirators require quantitative fit testing per AS/NZS 1715:2009 and clean-shaven facial policy.
- 10The Workplace Exposure Limit for respirable crystalline silica is 0.05 mg/m³ (8-hr TWA) and steps down to 0.025 mg/m³ from 1 December 2026 under the national WEL harmonisation. From that date the framework also transitions from Workplace Exposure Standards (WES) to Workplace Exposure Limits (WEL). Controls must demonstrably maintain exposure below the prevailing WEL.
- 11No dry sweeping. No compressed-air cleaning. Clean up with H-class HEPA vacuum or wet methods only. Contaminated water is collected and disposed of through the silica-slurry waste stream.
- 12Decontamination regime: dedicated silica-work coveralls laundered commercially or disposed of as Type 5/6 disposable; boot wash and HEPA-vac of clothing at the work-zone boundary; no eating, drinking, or vaping in the work zone; showers before leaving site for high-exposure tasks.
- 13Restricted-access silica zone with physical barriers and signage in accordance with the 2024 Code of Practice. Only workers performing the task, wearing the specified RPE, and trained to the silica-awareness standard enter the zone.
- 14Silica-specific training, recorded and refreshed annually. Workers must demonstrate understanding of the hazard, the WEL, fit testing, engineering controls, air-monitoring results, and health-monitoring rights before undertaking silica work.
- 15Psychosocial controls per WHS Regulation 2025 r55A-55D: realistic cutting programmes that allow wet-cutting setup, mandatory rest breaks during prolonged cutting, two-worker teams for heavy cutting and grinding, and clear written procedures at the point of work. No workers under 18 on silica tasks.
- 16Daily pre-start toolbox talk covering the day's cutting programme, confirmed engineering-control status (water flow, extraction integrity), RPE fit confirmation, air-monitoring results to date, and emergency procedures for tool failure. Record attendance on the SWMS worker sign-on register.
Applicable Codes of Practice
Principal binding guidance covering the full hierarchy of silica controls, health and air monitoring, training, and worker consultation for all construction and manufacturing silica work.
Governs the narrow residual permitted activities — removal, repair, minor modification — following the 1 July 2024 national ban on manufacture and installation.
Baseline for HRCW categorisation, SWMS content, consultation, and principal contractor interaction on silica-bearing construction work.
Applies because respirable crystalline silica is a hazardous chemical with a Workplace Exposure Limit; governs air monitoring, health monitoring, and exposure control duties.
Cut-off saws, grinders, and core drills routinely exceed 105 dB(A); mandatory hearing protection and audiometric monitoring apply alongside silica controls.
Technical standard for RPE selection, fit testing, and maintenance — cited throughout for P2/P3/PAPR programme requirements.
Reference for annual LEV testing of fixed indoor extraction systems serving stonemason benches and tile-cutting stations.
High-Risk Construction Work triggered
Concrete cutting and coring through load-bearing slabs, walls, and columns is a demolition activity; wall-saw cuts for penetrations, expansions, and structural alterations routinely intersect load-bearing elements.
Respirable crystalline silica is a hazardous chemical with a Workplace Exposure Limit under Chapter 7 of the WHS Regulation; any cutting, grinding, drilling, or demolition that can generate RCS above the WEL is HRCW and triggers the air-monitoring duty.
Because this work triggers multiple HRCW categories, Section 299 of the WHS Regulation 2025 (NSW) requires the SWMS to be prepared before work commences, kept available on site for inspection, reviewed and updated if the work changes, and provided to the Principal Contractor on request. Failure by a PCBU to prepare or keep a current SWMS for HRCW is an offence under Section 300; maximum penalty for a body corporate is $36,000 per offence, and for an individual $7,200. Breach of the engineered-stone ban carries substantially higher penalties under the state engineered-stone licensing Acts, and a silicosis fatality can trigger industrial-manslaughter prosecution under WHS Act amendments now in force in every state.
Who this is for
- →Concrete cutters, road-saw operators, and core drillers engaged on civil and building construction projects.
- →Stonemasons, benchtop fabricators, tilers, and workers performing the residual permitted engineered-stone removal, repair, and minor-modification scope.
- →Demolition contractors and labourers working on concrete, brick, tile, and AAC structures.
- →Carpenters, plumbers, and electricians whose scope includes percussive drilling, chasing, or coring of silica-bearing materials.
- →Site supervisors, WHS leads, and principal contractor safety teams reviewing subcontractor silica SWMS.
What you receive
- ✓Editable Microsoft Word (.docx) document delivered within 24 hours of payment
- ✓Title page with PCBU name, ABN, site address, project, supervisor, and revision-date fields.
- ✓Signed approval block for PCBU, Principal Contractor, and nominated silica-controls supervisor.
- ✓Hazard register with the 12 hazards above, each with consequence, inherent risk, controls, and residual risk scored on a 5x5 likelihood-consequence matrix.
- ✓Hierarchy-of-control measures cross-referenced to the 2024 RCS Code of Practice and WHS Regulation sections on hazardous chemicals.
- ✓Air-monitoring and health-monitoring schedule template aligned to SMAAS and the 2024 Code of Practice.
- ✓Respirator selection table with quantitative fit-test record template per AS/NZS 1715:2009.
- ✓Worker sign-on register for daily acknowledgement including space for silica-awareness training references.
- ✓Legislation schedule pre-populated for NSW with variance tables for VIC, QLD, SA, WA, TAS, NT, ACT, including state engineered-stone licensing requirements.
- ✓Emergency contacts, incident-reporting procedure, and review-and-update log for tracking revisions when controls or scope change.
Worked example
A three-person concrete-cutting crew — one supervisor and two operators — is subcontracted to a Parramatta multi-residential project to cut a 1.8 metre wide service penetration through a 250 mm post-tensioned slab on Level 3. The supervisor completes this SWMS before arrival: the cut intersects a load-bearing slab (HRCW Category 10), and generated RCS without full controls would exceed the 0.05 mg/m³ WEL (HRCW Category 13). The crew uses a wall-saw with continuous water suppression at 1.5 L/min, M-class on-tool LEV on the finishing grinder, P2 half-face respirators with prior quantitative fit test, and a 3 m barricaded silica zone with warning signage. Personal air sampling is conducted by an occupational hygienist on day one — the TWA result returns at 0.018 mg/m³, well below the WEL. Both operators are enrolled in the SMAAS health-monitoring programme with baseline low-dose CT complete before commencement. Slurry is collected and disposed of via the licensed waste contractor. The SWMS is signed, handed to the Principal Contractor, and posted at the work area for the three-day duration of the penetration.
Related legislation
- Work Health and Safety Act 2011 (NSW) — Section 19 primary duty of care; Section 27 officer due diligence; Section 47 worker consultation; industrial manslaughter provisions under 2024 amendments.
- WHS Regulation 2025 (NSW) — r. 49 air monitoring; r. 50 control of hazardous chemical exposure; r. 298-300 SWMS for HRCW; r. 529A-529G engineered-stone provisions; r. 55A-55D psychosocial hazards.
- Engineered Stone and Other Stone Regulation 2024 (NSW) and equivalents in all other states — licensing, notification, and prohibited-processing provisions.
- Dust Diseases Authority Act 2005 (NSW) — workers' compensation for silicosis and related dust diseases.
- Environmental Planning and Assessment Act 1979 (NSW) — controlling dust emissions beyond the site boundary.
- Protection of the Environment Operations Act 1997 (NSW) — disposal of silica-slurry waste through licensed streams.
Frequently asked questions
Can I still cut, fabricate, or install engineered stone after 1 July 2024?
No. Manufacture, supply, processing, and installation of engineered stone are prohibited nationally from 1 July 2024. The only activities that remain permitted are removal, repair, and minor modification of engineered stone already installed before the ban, and only under the state engineered-stone licensing framework. This SWMS supports the permitted residual scope but does not authorise new installation.
What is the current Workplace Exposure Limit for respirable crystalline silica?
The current WEL is 0.05 mg/m³ as an 8-hour time-weighted average. From 1 December 2026 the WEL steps down to 0.025 mg/m³ under the national harmonisation, and at the same time the framework transitions from Workplace Exposure Standards to Workplace Exposure Limits. Controls must be demonstrably capable of holding exposure below the prevailing limit at all times.
Is a P2 disposable respirator sufficient for silica work?
Only for low-exposure tasks below 10 times the WEL. For prolonged indoor dry cutting, engineered-stone removal, or any task generating visible dust clouds, a P3 cartridge respirator, PAPR, or supplied-air system is required. All tight-fitting respirators must be quantitatively fit tested per AS/NZS 1715:2009 and the worker must be clean-shaven at every fit interface.
What air monitoring is required?
The 2024 Code of Practice requires personal air sampling at the first performance of a silica task, whenever controls change, and at regular intervals thereafter. Samples are collected using a cyclone pre-selector and analysed by a NATA-accredited laboratory per NIOSH 7500 or MDHS 101. Results must be provided to affected workers and retained for 30 years as exposure records.
What health monitoring must I provide my workers?
All workers reasonably expected to be exposed to silica must be enrolled in health monitoring. The standard programme is baseline low-dose high-resolution CT chest, spirometry, and ILO-B chest X-ray, then 2-yearly monitoring by a registered medical practitioner familiar with silicosis. The SMAAS programme is the most widely used framework in NSW and Victoria; equivalent state programmes apply elsewhere.
Is this SWMS compliant with the 1 July 2026 Section 26A changes?
Yes. From 1 July 2026, 34 approved Codes of Practice become legally binding under Section 26A of the amended WHS Act. This SWMS cites the currently-approved silica Codes, the Hazardous Chemicals Code, the Construction Work Code, and the Managing Noise Code — all of which are captured by the Section 26A binding list. No amendment is required for the 2026 transition; a review is recommended to align with the 0.025 mg/m³ WEL stepdown on 1 December 2026.