Silica dust remains one of the most significant occupational health hazards in Australian workplaces. Despite regulatory reform, industry bans and growing awareness, workers across Western Australia continue to face real exposure risks every day.
In short: Monitoring respirable crystalline silica is more important than ever in 2026
Respirable crystalline silica (RCS) is a very fine dust generated by working with silica-containing materials. These tiny silica dust particles are small enough to bypass the body’s natural defences and penetrate deep into the lungs, where they become trapped and can cause irreversible lung diseases.
Crystalline silica appears in everyday workplace materials such as concrete, sand, rock, bricks, tiles, mortar, engineered stone and mineral ore. Any activity that cuts, drills, crushes or grinds these materials can generate RCS dust, often in concentrations invisible to the naked eye.
Because of silica’s small particle size, relying on visible dust to judge exposure is unreliable and dangerous. The particles that matter most are far too fine to see. In 2026, concern continues around abrasive blasting, concrete cutting, drilling operations and high-energy grinding across WA’s construction, mining and manufacturing sectors.
All workplaces in WA must comply with the workplace exposure standard of 0.05 mg/m³, expressed as an eight-hour time-weighted average. This standard sets a regulatory ceiling, but it does not guarantee safety and good practice aims to keep exposures as low as reasonably practicable.
What is respirable crystalline silica and where is it found?
Crystalline silica is present in many common construction and industrial materials including concrete, bricks, tiles, mortar, natural stone, sand, sandstone and engineered stone. These materials are considered a crystalline silica substance if they contain at least 1% crystalline silica (by weight).
Silica content varies significantly between materials:
| Material | Typical crystalline silica content |
|---|---|
| Engineered stone | 80–95% |
| Sandstone | 70–90% |
| Granite | 25–60% |
| Concrete | 25–50% |
| Brick | 5–25% |
| Marble | ~5% |
Respirable crystalline silica refers to the fraction of airborne silica dust fine enough (typically particles under 10 micrometres) to be inhaled deep into the lungs. Respirable silica particles can penetrate deep into the lungs and become trapped there and are invisible to the naked eye.
Why silica dust remains a critical workplace health issue in 2026
Despite improved awareness and regulatory action, silica related diseases continue to emerge across Australia. By 2024, there were 56 cases of silicosis reported in WA since the 2018 reforms. Of those, 50 are linked to workers who handled engineered stone. Nationally, researchers project more than 83,000 future cases of silica-related disease under current exposure trends.
The main diseases associated with respirable crystalline silica exposure include:
- Silicosis (in acute, accelerated and chronic forms)
- Lung cancer
- Chronic obstructive pulmonary disease
- Progressive massive fibrosis
Symptoms may take years to appear and once damage occurs it cannot be reversed.
So why does silica dust remain a problem in 2026? New materials and products containing crystalline silica substances continue to enter workplaces and work processes are evolving faster than controls. Additionally, gaps are created by varied implementation across sites and businesses and legacy engineered stone still requires processing during repair or demolition.
Safe Work Australia introduced a national ban from 1 July 2024 on the manufacture, supply, processing and installation of engineered stone containing 1% or more crystalline silica. Stronger standards have also been introduced for handling of engineered stone.
Industries and activities with a high RCS risk
Respirable crystalline silica is relevant to multiple WA industries. About 4% of Australian workers are estimated to be at risk of exposure.
Mining and quarrying: Crushing and screening ore, drilling and blasting natural rock, earth moving on haul roads and loading and screening operations. Drilling in open-cut and underground mining settings can also produce sustained RCS exposure, particularly in poorly ventilated conditions.
Construction and civil works: Chiselling concrete, jack hammering, tunnelling, cutting, demolition, concrete or masonry excavation, laying pavers and cutting fibre-cement sheeting. Even repair and maintenance of concrete or masonry can generate RCS.
Engineered stone and benchtops: Bench saw cutting, edge profiling and polishing are all tasks that produce extreme exposures due to engineered stone’s 80–95% silica content.
Manufacturing: Bricks, tiles, ceramics, foundries and refractory materials all involve processing silica-containing materials.
Housekeeping tasks on the shop floor are frequently overlooked. Dry sweeping or using compressed air on dusty surfaces can re-suspend silica dust and significantly increase exposure, so clean up activities should use wet methods or HEPA-filtered vacuums.
Some abrasive blasting media and substrates generate respirable crystalline silica. Abrasive blasting with sand is prohibited in Queensland workplaces, and controls or prohibitions may apply in other jurisdictions.
Identifying silica hazards: beyond visible dust
Visible dust is a poor indicator of respirable crystalline silica risk. The particles that cause lung disease are too small to see and can remain airborne for extended periods.
Proactive hazard identification starts with reviewing safety data sheets and supplier information to determine the crystalline silica content in products and materials used on site. Map your workplace tasks and locations where RCS may be generated, including temporary works like refurbishments, shutdowns and maintenance. Also consider any task that involves power tools, cutting equipment or any processing of silica-containing materials.
Occupational hygienists from ENVSS can help identify less obvious silica sources. Transfer points, raw material handling, waste management areas and even vehicle movements across unsealed surfaces can all contribute to exposure.
Assessing silica dust risks and when monitoring is needed
Businesses and site managers must assess risks from processing crystalline silica substances. A proper risk assessment combines information about material silica content, task type (wet or dry, enclosed or open), frequency, duration, workforce size and existing controls.
Factors that elevate risk include:
- High-energy dry cutting or grinding
- Enclosed or poorly ventilated spaces
- Long task durations
- Multiple workers in close proximity
- Lack of effective engineering controls
Additional monitoring is required when there’s uncertainty about silica exposure levels. For example, personal exposure monitoring should be implemented when:
- New work processes, materials or tools are introduced
- New engineering controls need verification
- Workers raise health concerns or health monitoring results suggest a problem
Creating a silica risk control plan and implementing the hierarchy of controls
Employers must implement a documented silica risk management framework to protect workers. Furthermore, site managers must manage risks in line with the hierarchy of controls, prioritising elimination and substitution before relying on personal protective equipment.
A silica risk control plan must be developed for high risk tasks. Our team develops effective, tailored control plans that identify:
- Tasks and materials with potential to generate respirable crystalline silica
- Selected controls for each task
- Maintenance requirements and inspection schedules
- Responsibilities and accountability
We also assist with the design and implementation of engineering controls, including:
- Substitution: replacing high-silica products with lower-silica alternatives where feasible
- Wet methods: water suppression during cutting, grinding and drilling to effectively minimise exposure
- Local exhaust ventilation: on-tool extraction and process ventilation systems to capture dust at the source
- Isolation: enclosures, booths or barriers to separate dusty processes from other workers
- Automation: remote operation to separate workers from the dust source entirely
Administrative controls can work in tandem with these. Task rotation, restricted access zones and scheduling changes can all minimise exposure, but are not substitutes for engineered controls.
Respiratory protective equipment is your last line of defence. It requires correct selection, fit testing, maintenance and training to be effective.
What silica dust monitoring tells you about worker safety
Air monitoring provides objective data about what workers are actually breathing. Our monitoring process involves:
- Task observation and planning
- Placement of personal sampling equipment in the worker’s breathing zone
- Collection of respirable dust samples over a representative period
- Laboratory analysis for crystalline silica content
- Calculation of time-weighted average exposures
We compare all results against the workplace exposure standard and assess data to:
- Confirm whether workers are adequately protected
- Identify high-exposure tasks or work groups
- Evaluate the effectiveness of controls
- Inform updates to the silica risk control plan
This information is helpful for both compliance and practical risk management.
Worker health monitoring, training and engagement
Along with engineered and administrative controls, employers must provide health monitoring and training for workers at risk of exposure.
Health monitoring could include spirometry and periodic respiratory assessments or perhaps imaging for those with more significant exposure. Health monitoring is not a preventative measure; it can only identify early signs of silica-related disease.
Training, on the other hand, can be preventative and should cover:
- What crystalline silica and respirable crystalline silica are
- The health risks of silica dust exposure, including silicosis and lung cancer
- Correct use of local exhaust ventilation, wet cutting and other controls
- Selection, use and care of respiratory protective equipment
- How to comply with site-specific silica control procedures
Our team are able to advise and develop health monitoring and training programs for your staff.
How Environmental Site Services supports silica dust management in WA
Environmental Site Services is a Western Australian consultancy specialising in practical environmental monitoring and occupational hygiene. Our team works on active mine sites, construction projects and industrial facilities throughout WA.
Our RCS services include:
- Crystalline silica exposure assessment and task-based risk reviews
- Personal and static air monitoring for respirable crystalline silica
- Evaluation of engineering controls including local exhaust ventilation performance
- Development or refinement of site-specific silica risk control plans and control strategies
- Reporting that interprets monitoring data in the context of WHS duties and workplace exposure standards
Our experienced technicians, modern monitoring equipment and robust quality assurance provide defensible environmental data designed for the realities of WA’s business and regulatory frameworks.
Speak with an Occupational Hygienist Today
Environmental Site Services works alongside environmental and site managers to design practical, achievable monitoring programs rather than one-off tests. We help you manage risks with reliable data you can act on.
To discuss your respirable crystalline silica monitoring requirements, arrange a silica exposure assessment or request a proposal tailored to your site, get in touch.