What Is Silica Dust and Why Is It Dangerous?

Over the past year, the dangers of silica dust have received significant attention across Australian media. Headlines have highlighted the alarming rise in cases of silicosis, especially among younger workers, and the long-term risks associated with common building materials. For many in the construction industry, this has brought an old hazard into a sharp new focus.

At RVT, we know how vital it is to stay on top of workplace health. If you are managing large-scale construction sites or looking after a team in a high-risk environment, you are likely already aware of the basics. What is now becoming increasingly clear is that managing silica dust exposure calls for action backed by the right equipment and support.

What Is Silica Dust?

Silica dust, or respirable crystalline silica (RCS), is produced when materials containing silica are disturbed. These materials include engineered stone, concrete, bricks, tiles, and even some types of mortar. When these are cut, ground, drilled, or crushed, they release fine particles so small – 100 times smaller than a grain of sand – that they are invisible to the naked eye.

Silica dust exposure is not confined to just one type of task or trade. It is produced across a wide range of work activities, many of which are common on Australian construction and industrial sites. These include using power tools to cut, grind or polish stone surfaces, particularly engineered or natural stone countertops. Activities like excavation, earth moving, and tunnelling also disturb materials that release fine dust into the air. Road construction, mining, and quarrying operations are frequent contributors, as are tasks such as brick cutting, concrete grinding, and demolition work, especially when dry-cutting methods are used.

Inhalation of these airborne particles is where the risk begins. Unlike common dust that settles quickly, silica dust lingers. Once inhaled, it can become deeply embedded in the lungs. Over time and with repeated exposure, this can lead to serious health conditions. According to Lung Foundation Australia, up to 600,000 Australian workers are exposed to silica dust at work, especially those in the construction, manufacturing, quarrying, tunnelling and mining industries.

Why Is Silica Dust So Dangerous?

The real danger lies in the size of these dust particles. Because they are so fine, they bypass the body's natural defences and travel directly into the lungs. Here, they can cause inflammation, scarring, and permanent damage.

Silica dust exposure has been linked to a range of serious diseases. The most well-known is silicosis, an incurable lung disease that can develop after as little as a few weeks of high exposure. Lung cancer is another major concern, along with chronic bronchitis, emphysema, and even kidney disease.

Alarmingly, the rates of silicosis are rising. Some experts are comparing this crisis to the early days of the asbestos epidemic, which have consequences that are not just physical but also emotional, financial, and, in too many cases, fatal.

The Human Cost: Real Stories and Stats

Behind every statistic is a story. The Cancer Council estimates that '230 people will develop lung cancer each year as a result of past exposure to silica dust at work.'

When someone is affected by silica dust, it impacts more than just their ability to work. Families carry the burden of ongoing care, lost income, and long-term health management. The dangers of silica dust go far beyond the construction site.

Legal Duties and Workplace Responsibilities

In Australia, employers have a clear legal obligation to manage health and safety risks. Under Work Health and Safety (WHS) regulations, that means identifying hazards, assessing the level of risk, and implementing measures to control exposure. This also includes providing workers with information, training, and supervision.

What You Can Do to Minimise the Risk

There are several ways to reduce silica dust exposure. At the top of Safe Work Australia’s Hierarchy of Controls is elimination, which involves removing the hazard altogether. While not always feasible, this might include avoiding materials with high silica content altogether.

When elimination isn’t possible, the risks are minimised in the next steps in the hierarchy: Substitution, Isolation, and Engineering Controls.

Substitution involves using safer alternative materials where possible, such as lower-silica products instead of engineered stone. In fact, WHS regulations have introduced tighter controls around engineered stone in 2024. It bans the manufacture, supply, processing and installation of all materials containing at least 1% crystalline silica, including engineered stone benchtops, panels, and slabs.

Isolation involves physically separating workers from dust-generating activities. This could mean using barriers, remote-controlled machinery, or scheduling tasks when fewer people are on site.

Engineering controls come next and are critical for minimising exposure during unavoidable tasks. These include using water suppression methods, ventilation systems, and dust extraction systems that contain dust at the source before it becomes airborne. Administrative controls support these efforts by implementing safe work procedures, limiting time spent in high-exposure areas, and ensuring workers receive proper training around silica hazards.

At the base of the hierarchy is PPE (personal protective equipment). This includes respirators and protective clothing, which are essential in many settings but should be used in conjunction with higher-level controls.

For large-scale projects, RVT offers a wide range of compliant dust suppression and extraction solutions to help you keep your workforce healthy.

How We Can Help

At RVT, we understand the pressures you face when managing high-risk environments. From ever-changing safety regulations to the growing focus on employee wellbeing, it can feel like a lot to juggle. That is where we come in.

RVT is here to be your partner in silica dust management. Whether you are managing a long-term project or responding to new compliance requirements, we can help you reduce exposure to workplace hazards, meet regulations, and protect your people.