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The Safe Work Australia Model Code of Practice for Managing Risks of Respirable Crystalline Silica in the Workplace sets out mandatory requirements for any Australian workplace where workers may be exposed to silica dust. The current workplace exposure standard (WES) is 0.05 mg/m³ over an 8-hour time-weighted average (TWA), and from 1 December 2026 this becomes a Workplace Exposure Limit (WEL) with stricter obligations to keep exposure as low as reasonably practicable. Here's what tradies, contractors and small business owners need to know to stay compliant.
If you work in construction, renovation, demolition or any trade that involves cutting, grinding, drilling or crushing stone, concrete, brick or masonry, this Code of Practice directly applies to you. It's not just another compliance box to tick — silica dust has claimed lives, and the updated 2025 Code raises the bar for how every person conducting a business or undertaking (PCBU) must manage the risk.
Crystalline silica is a naturally occurring mineral found in most rocks, sand, clay and soils. It's a major component of common building materials including concrete, bricks, tiles, mortar, sandstone and granite. The WHS Regulations define a crystalline silica substance (CSS) as any material containing at least 1% crystalline silica by weight (Source: Comcare — Crystalline Silica).
On its own, solid crystalline silica isn't dangerous. The hazard occurs when materials containing silica are mechanically processed — cut, ground, drilled, crushed, sanded or polished — releasing extremely fine dust particles into the air. These respirable particles are smaller than 10 micrometres (µm) in diameter, often smaller than 2.5 µm. To put that in perspective, a human hair is roughly 50–70 µm wide — respirable silica particles are up to 20 times smaller than that.
Because they're so tiny, these particles bypass your body's natural defences in the nose and throat and travel deep into the lungs, reaching the alveoli where oxygen exchange takes place. Once there, your body can't remove them, and they begin causing damage.
The amount of crystalline silica varies significantly between materials. According to SafeWork NSW, typical crystalline silica content by weight includes:
Sand and sandstone: 70–100%
Engineered stone: 93% or higher (now banned for benchtops, panels and slabs)
Concrete and mortar: 25–70%
Calcium-silicate bricks: 50–55%
Granite: 20–45% (typically around 30%)
Slate: 20–40%
Brick: up to 30%
Fibre cement sheets: 10–30%
Demolition dust: 3–4%
Marble: approximately 2%
(Source: SafeWork NSW — What Are Crystalline Silica and Engineered Stone)
If you're working with any of these materials and generating dust, you're working with a crystalline silica substance under the Regulations.
Prolonged exposure to respirable crystalline silica causes silicosis — a serious, irreversible and incurable lung disease. It can also increase the risk of lung cancer, chronic obstructive pulmonary disease (COPD), and kidney disease. Safe Work Australia states clearly that all silica-related diseases are preventable if exposure is eliminated or strictly controlled (Source: Safe Work Australia — New Model Code of Practice).
There are three recognised forms of silicosis:
Acute silicosis: Develops within weeks to a few years after short-term exposure to very high levels of silica dust. Causes severe inflammation and protein buildup in the lungs.
Accelerated silicosis: Develops after 3–10 years of moderate to high exposure. Causes inflammation, protein buildup and scarring (fibrotic nodules).
Chronic silicosis: Develops after long-term exposure to lower levels. Leads to fibrotic nodules, shortness of breath, and potentially progressive massive fibrosis.
(Source: Safe Work Australia — What Is Crystalline Silica)
The critical thing to understand is that silicosis has a latency period — you may not show symptoms for 5 to 20 or more years after exposure. By the time you're coughing and short of breath, the damage is already done and cannot be reversed. That's why prevention through proper controls is so important.
Safe Work Australia published the updated Model Code of Practice in August 2025, with minor amendments in November 2025. If you were familiar with previous silica guidance, here are the key changes that affect your business:
The current workplace exposure standard (WES) for respirable crystalline silica is 0.05 mg/m³ as an 8-hour TWA. This means workers must not be exposed to airborne silica concentrations greater than this over an 8-hour shift, for a 5-day working week.
From 1 December 2026, the WES becomes a Workplace Exposure Limit (WEL). The practical significance is that PCBUs will not only need to meet the limit — they must actively keep exposure as low as reasonably practicable (ALARP), even if levels are already below 0.05 mg/m³.
(Source: Safe Work Australia — Workplace Exposure Standard for Respirable Crystalline Silica)
The updated Regulations formally define a crystalline silica substance (CSS) as any material containing at least 1% crystalline silica by weight. This includes concrete, bricks, tiles, mortar, natural stone, fibre cement, and many other common construction materials. If you're working with a CSS and mechanically processing it (cutting, grinding, drilling, etc.), the Code's requirements apply to you.
The 2025 Code introduces the requirement for a formal Silica Risk Control Plan. This documented plan must outline how your business identifies, assesses and controls the risks from processing crystalline silica substances. It's a step up from simply having generic risk assessments — it must be specific to silica and the activities on your site.
We have developed a Silica Risk Control Plan template which can be easily adapted to suit your needs.
This is a big one for tradies. Dry cutting of materials containing crystalline silica is now explicitly prohibited under the updated Code. Dry cutting generates extremely high concentrations of airborne respirable silica — even brief exposures of 15 minutes at levels equivalent to five times the exposure standard can have significant health effects. Wet cutting or on-tool dust extraction must be used instead.
While separate from the general silica Code, it's worth noting that as of 1 July 2024, the manufacture, supply, processing and installation of engineered stone benchtops, panels and slabs is banned nationally. Limited exceptions exist for removal, repair and minor modifications of previously installed engineered stone, subject to strict controls and notification requirements.
Tight-fitting respiratory protective equipment (RPE) must now be fit-tested to ensure an adequate seal. Simply handing a P2 respirator to a worker without fit-testing is no longer acceptable. The Code specifies when fit-testing is required and what standards must be met.
The Code of Practice provides practical guidance for PCBUs on meeting their WHS obligations when workers may be exposed to respirable crystalline silica. Here's what it covers.
The first step is identifying whether crystalline silica substances are present and whether any processing activities generate respirable dust. Under the Code, common activities that generate silica dust include:
Cutting, grinding or drilling concrete, masonry or stone
Concrete grinding and polishing
Brick or stone cutting
Abrasive blasting with materials containing silica
Demolition work
Tunnelling and excavation in rock or sandstone
Manufacturing concrete or stone products
Clean-up activities such as sweeping or using compressed air to blow dust
If you're doing any of these activities, silica is likely present and you need to assess the risk.
To determine whether a product is a CSS, check the Safety Data Sheet (SDS) or product information from the manufacturer or supplier. If the SDS confirms the material contains 1% or more crystalline silica by weight, the full suite of CSS obligations under the WHS Regulations applies.
Once you've identified the hazard, you need to assess the level of risk to your workers. The Code requires you to consider factors including:
The type of CSS being processed and its silica content
The nature of the processing (cutting, grinding, drilling, etc.)
The frequency and duration of the work
The number of workers potentially exposed
The effectiveness of existing control measures
Previous air monitoring and health monitoring results
The Code emphasises a precautionary approach: if you're mechanically processing materials containing crystalline silica, you should assume exposure is occurring and implement controls. Don't wait for air monitoring results to confirm there's a problem before taking action.
This is where compliance gets practical. The 2025 Code follows the hierarchy of controls, which means you start with the most effective measures and only move to less effective options when higher-level controls aren't reasonably practicable:
1. Elimination: Can you avoid generating silica dust altogether? Consider using pre-cut materials, alternative materials that don't contain crystalline silica, or different construction methods that eliminate the need to process CSS on site.
2. Substitution: Can you substitute a less hazardous process? The most common and effective substitution in construction is wet cutting instead of dry cutting. Wet cutting dramatically reduces airborne dust concentrations and is now effectively mandatory under the Code, given the dry cutting prohibition.
3. Engineering Controls: These are your primary controls for most construction work:
Water suppression — wet cutting, water-fed tools, misting systems
On-tool dust extraction — fitted to power tools with HEPA-filtered vacuum systems
Local exhaust ventilation — capture dust at the source before it becomes airborne
Enclosed or semi-enclosed work areas — with mechanical ventilation
4. Administrative Controls: These supplement engineering controls and include:
Limiting the time workers spend in dusty areas
Rotating tasks between workers to reduce individual exposure
Establishing exclusion zones around dust-generating activities
Scheduling high-dust activities when fewer workers are nearby
5. PPE (Personal Protective Equipment): Respirators are your last line of defence, not your first. The Code is explicit: PPE must not be relied upon as the primary control measure. When respirators are used, they must be:
Minimum P2-rated for silica dust (higher protection may be needed depending on exposure levels)
Properly fit-tested for tight-fitting RPE
Correctly maintained and stored
Used in accordance with AS/NZS 1715 (Selection, Use and Maintenance of Respiratory Protective Equipment)
Under the 2025 Code, if your workplace involves processing crystalline silica substances, you must develop and maintain a Silica Risk Control Plan. This plan should document:
The CSS materials present at your workplace
The processing activities that generate silica dust
The results of your risk assessment
The control measures you have implemented (following the hierarchy)
Responsibilities for implementing and monitoring controls
Procedures for air monitoring and health monitoring
Training and supervision arrangements
Review and update schedule
This isn't a document you write once and file away. It needs to be a living document that's reviewed whenever work activities change, monitoring results indicate a problem, or an incident occurs.
If there's a significant risk of exposure to respirable crystalline silica despite control measures being in place, the WHS Regulations require PCBUs to provide health monitoring for affected workers. Health monitoring involves regular medical assessments to detect early signs of silica-related lung damage before symptoms develop.
The Code outlines when health monitoring is required, what assessments should be included, and how results must be managed and recorded. Early detection through health monitoring can make a real difference to a worker's long-term health outcomes — don't skip this step.
In some situations, you'll need to measure the concentration of respirable crystalline silica in the air to confirm your controls are working effectively and that exposure levels remain below the WES of 0.05 mg/m³. The Code provides guidance on when atmospheric monitoring is necessary, how to conduct it, and how to interpret the results.
Air monitoring should be conducted by a competent person — typically an occupational hygienist — using methods consistent with AS 2985 (Workplace Atmospheres — Method for Sampling and Gravimetric Determination of Respirable Dust).
Your workers need to know what they're dealing with. The 2025 Code requires PCBUs to provide:
Information about the health risks of exposure to respirable crystalline silica
Training on the specific control measures in place and how to use them correctly
Training on the proper use, fit-testing and maintenance of respirators
Training on dust minimisation practices (e.g., not using compressed air for clean-up)
Adequate supervision to ensure controls are being used as intended
A quick toolbox talk once a year isn't enough. Workers need to genuinely understand why silica is dangerous, what controls are in place, and how to protect themselves. Training records must be documented and kept up to date.
The Code and WHS Regulations require you to maintain records of:
Silica Risk Control Plans
Risk assessments
Air monitoring results
Health monitoring reports
Training records (including fit-test records for RPE)
Any incidents or near-misses related to silica exposure
Good documentation protects your workers and protects your business. If a regulator inspects your site or a worker raises a concern, having comprehensive records demonstrates that you're taking your obligations seriously.
While the Model Code of Practice is national, individual states and territories adopt and implement it through their own WHS legislation. Some states have introduced additional requirements:
From 1 October 2025, employers in New South Wales must register all workers undertaking high-risk silica processing activities on the Silica Worker Register within 28 days of the work commencing. This digital register helps identify workers who need vital health monitoring services and enables tracking of workers across different employers and sites.
(Source: SafeWork NSW — Work Safely with Crystalline Silica)
Other states may introduce similar registers — check with your state WHS regulator for the most current requirements.
The NSW Government's Small Business Rebate provides up to $1,000 to eligible businesses and sole traders who purchase and install equipment that makes their workplace safer — including dust extraction and suppression equipment for silica control.
If you're a tradie, contractor or small business owner working with materials that contain crystalline silica, here's your practical compliance checklist:
Identify where and when silica exposure might occur in your operations — list every CSS and every processing activity
Assess the level of risk to your workers for each activity
Develop a Silica Risk Control Plan documenting your hazards, risks and controls, you can get a user friendly template here
Implement controls following the hierarchy — water suppression and on-tool dust extraction should be your go-to solutions
Stop dry cutting immediately if you haven't already — it's prohibited under the Code
Ensure respirators are fit-tested for every worker required to wear tight-fitting RPE
Arrange health monitoring for workers with significant exposure risk
Train your workers so they understand the risks, know how to use controls, and can identify when something isn't right
Document everything — risk assessments, control plans, training records, monitoring results
Review regularly — your Silica Risk Control Plan should be updated whenever activities change or new information becomes available
The good news? Many of these controls aren't complicated or expensive. Water suppression costs next to nothing. Dust extraction attachments for your tools are a one-time investment. Proper training takes a few hours. Compare that to the cost of a worker developing silicosis, or your business facing prosecution for inadequate controls.
At Occupational Safety Solutions, we offer Safe Work Method Statement (SWMS) templates specifically designed for high-risk silica work activities. Our templates are fully updated for compliance with the 2025 Code of Practice and assist with implementing the right controls for your specific work.
SWMS updated for compliance with the 2025 Code of Practice include:
Deck and Pergola — Timber (for concrete footings)
Fencing — Steel (for post footings)
Fencing — Timber (for post footings)
Steel Awning, Carport or Pergola (for concrete footings)
We also offer a Silica Risk Control Plan template and WHS Management System templates that include risk assessment, incident and emergency management and training record templates to help you document your silica management procedures. Silica Risk Control Plan template
The current workplace exposure standard (WES) for respirable crystalline silica in Australia is 0.05 mg/m³ as an 8-hour time-weighted average (TWA). This means workers must not be exposed to airborne silica concentrations exceeding this level over a standard 8-hour shift. From 1 December 2026, this transitions to a Workplace Exposure Limit (WEL) with an additional obligation to keep exposure as low as reasonably practicable, even if levels are below the limit.
Yes. Under the 2025 Model Code of Practice, dry cutting of materials containing crystalline silica is effectively prohibited. Dry cutting generates extremely high concentrations of respirable silica dust — even brief 15-minute exposures can reach levels five times the exposure standard. Wet cutting or on-tool dust extraction with HEPA-filtered vacuums must be used instead.
A Silica Risk Control Plan is a documented plan required under the 2025 Code of Practice that outlines how your business identifies silica hazards, assesses risks, and implements control measures when processing crystalline silica substances. It must cover the specific CSS materials and processing activities at your workplace, the hierarchy of controls in use, health and air monitoring arrangements, training requirements, and review procedures.
Health monitoring is required under the WHS Regulations when workers are exposed to respirable crystalline silica and that exposure is reasonably likely to adversely affect their health. If your workers are regularly processing crystalline silica substances, even with controls in place, health monitoring should be provided. Monitoring helps detect early signs of lung damage before symptoms develop, when intervention can make the most difference.
For silica dust, the minimum respiratory protection is a P2-rated respirator. Higher levels of protection may be required depending on exposure levels and the type of work. Under the 2025 Code, all tight-fitting respiratory protective equipment must be fit-tested to ensure an adequate seal. However, PPE is the last line of defence under the hierarchy of controls — it must not be used as the primary or sole control measure. Water suppression and engineering controls must come first.
From 1 October 2025, employers in New South Wales must register all workers undertaking high-risk silica processing activities on the Silica Worker Register within 28 days of the work starting. This digital register helps identify workers who may need health monitoring services and tracks exposure across different employers and worksites. Employers operating under the Coal Industry Act 2001 are exempt from this requirement.
Most common construction materials contain some level of crystalline silica. Sand and sandstone contain 70–100%, concrete and mortar 25–70%, granite 20–45%, brick up to 30%, and fibre cement sheets 10–30%. Under the WHS Regulations, any material containing at least 1% crystalline silica by weight is classified as a crystalline silica substance (CSS) and subject to the Code's requirements when mechanically processed.
Compliance involves identifying all crystalline silica substances and processing activities in your workplace, conducting risk assessments, developing a Silica Risk Control Plan, implementing controls following the hierarchy (elimination through to PPE), arranging health monitoring where required, training workers, and maintaining thorough documentation. SWMS templates designed for specific silica-related activities can help you meet these requirements efficiently.
Safe Work Australia — Workplace Exposure Standard for Respirable Crystalline Silica
Safe Work Australia — What Is Crystalline Silica and Silicosis
SafeWork NSW — Work Safely with Crystalline Silica and Engineered Stone
Have questions about managing silica dust on your sites? Contact Occupational Safety Solutions on 1800 304 336 for free support and guidance on the right templates for your business. Simple Workplace Safety starts with understanding the risks and taking practical steps to manage them.
About the Author Andrew Watters is Managing Director at Occupational Safety Solutions with 18 years of experience in workplace health and safety across the Australian construction industry. This article has been reviewed against the Safe Work Australia Model Code of Practice (August 2025, updated November 2025) to ensure regulatory accuracy.
Disclaimer: This article provides general guidance based on the Safe Work Australia Model Code of Practice and should not be relied upon as legal advice. The Code of Practice must be adopted by individual state and territory jurisdictions to have legal effect. Always consult your state WHS regulator or a qualified WHS professional for advice specific to your circumstances.