A dust risk assessment is the foundation of any compliant dust control programme. It is not optional — the Work Health and Safety Act requires you to identify workplace hazards and assess the risk they pose. Yet many Australian workplaces still conduct inadequate or generic assessments that fail to identify specific exposure scenarios.
This guide walks you through the seven-step process to conduct a thorough, actionable dust risk assessment.
What is a Dust Risk Assessment and Why is it Required?
A dust risk assessment is a systematic process to:
- Identify whether respirable crystalline silica (RCS) or respirable dust is present in your workplace
- Determine who is exposed and how often
- Evaluate the likelihood and consequence of exposure
- Decide whether exposure monitoring is necessary
- Identify control measures to reduce risk
It is required under the Work Health and Safety Act 2011 Section 32, which states that you (the PCBU — person conducting a business or undertaking) must identify hazards and assess associated risks.
A dust risk assessment is different from — and separate to — exposure monitoring. You must conduct a risk assessment before monitoring begins. The assessment informs your monitoring strategy.
When You Must Conduct a Dust Risk Assessment
- Before work begins — prior to any project, work task, or process involving potentially dust-generating materials
- When processes change — if you introduce new equipment, materials, or work methods
- After significant incidents — if a worker reports exposure concerns or an uncontrolled exposure event occurs
- Periodically — at least annually, or as specified in your WHS policy
- Before the December 2026 WEL transition — current assessments must be reviewed to determine readiness for new (likely stricter) exposure limits
Step-by-Step: How to Conduct a Dust Risk Assessment
Step 1: Identify Dust Hazards
What you do: List all materials, processes, and work tasks at your workplace that may generate respirable dust.
Materials that contain respirable crystalline silica (RCS):
– Concrete, mortar, cement
– Natural stone (granite, sandstone, limestone)
– Foundry sand, beach sand
– Bricks, clay products
– Diatomaceous earth, silica gel
– Asbestos-containing materials (containing erionite in some cases; also fibrous hazard)
Work tasks that generate RCS dust:
– Cutting, grinding, sawing concrete or stone
– Drilling, boring, or percussive work on rock or concrete
– Blasting and breaking concrete/rock
– Shotcrete application
– Demolition of concrete structures
– Bead blasting, shot blasting
– Foundry work (mould shaking, core handling)
– Tunnel or underground excavation
Work tasks that generate respirable dust (non-silica):
– Sweeping, vacuuming, or air-blasting dusty surfaces
– Handling mineral products (talc, mica, coal, wood dust)
– Grain handling, flour milling
– Textile manufacture
Template approach: Create a matrix listing all work areas/tasks and identifying which materials are present and which dust-generating activities occur.
Documentation: Photograph work areas to record current conditions and equipment. This becomes part of your risk register.
Step 2: Identify Who is Exposed
What you do: List all worker groups who have potential exposure to dust.
For each hazard identified in Step 1, determine:
- Primary workers — those directly doing the work (e.g., grinder operator, driller)
- Secondary workers — those nearby but not directly exposed (e.g., supervisor, labourer on-site)
- Bystanders — contractors, visitors, office staff who may transit the area
Example:
– Concrete grinding task: primary = grinder operator; secondary = site assistant and supervisor; bystanders = neighbouring workers, visitors
For each group, also consider:
– Duration of exposure — How long per shift are they exposed? (e.g., full 8 hours, 2 hours, or intermittently)
– Frequency — How many days per week? Is it daily or occasional?
Documentation: Create a simple table with worker roles, exposure duration per shift, and frequency.
Step 3: Assess the Risk
What you do: For each hazard + worker group combination, estimate the risk level.
Risk = Likelihood of exceeding WES × Consequence
Assess likelihood:
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High: The task generates heavy dust. Workers spend more than 2 hours per shift in the dust. No engineering controls (e.g., no water suppression, no local extraction) are currently used. Likelihood of exceeding WES = HIGH.
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Medium: The task generates moderate dust. Workers have some exposure (0.5–2 hours per shift), or engineering controls are partially effective (e.g., water suppression is used but not optimally). Likelihood of exceeding WES = MEDIUM.
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Low: The task generates minimal dust, or workers are exposed briefly (<30 minutes per shift), or effective controls are in place and well-maintained. Likelihood of exceeding WES = LOW.
Assess consequence:
RCS consequence is always significant (can cause silicosis, lung cancer, COPD over years). Typically scored as HIGH for occupational exposure.
Determine overall risk level:
| Likelihood | Consequence | Overall Risk |
|---|---|---|
| High | High | VERY HIGH → Immediate control implementation required; monitoring urgent |
| Medium | High | HIGH → Controls needed; monitoring likely required |
| Low | High | MEDIUM → Monitor to confirm; controls may be needed |
Example:
– Task: Concrete cutting indoors without water suppression. Worker exposure: 4 hours per day, 5 days per week. No extraction ventilation.
– Likelihood: HIGH (heavy dust, long exposure, no controls)
– Consequence: HIGH (RCS)
– Overall risk: VERY HIGH → Immediate water suppression + LEV implementation + baseline monitoring required.
Documentation: Include risk scores in your risk register. Be specific about why you scored each item (e.g., “HIGH because no water suppression and exposure is 4 hours per day”).
Step 4: Determine Whether Monitoring is Required
The uncertainty test: If you cannot confirm through reasonable investigation that workers are not exposed above the WES (0.05 mg/m³), you must conduct monitoring.
Reasonable investigation includes:
– Reviewing published exposure data for similar work (e.g., exposure literature, case studies)
– Consulting an occupational hygienist for their expert judgment
– Observing work practices and dust generation at your site
– Reviewing controls currently in place
When monitoring is mandatory:
– If risk is assessed as HIGH or VERY HIGH → Monitor
– If you are uncertain whether exposure exceeds WES → Monitor (the WHS Act requires you to gather sufficient information to manage the risk)
– After implementing new controls → Monitor to verify effectiveness
– If industry guidance suggests monitoring for your work type → Monitor
Monitoring pathway:
1. Commission baseline personal air sampling (4–6 samples from high-risk workers over 2–4 weeks)
2. Send samples to a NATA-accredited lab for gravimetric analysis + FTIR speciation
3. Compare results to WES (0.05 mg/m³)
4. If above WES → Implement or enhance controls; re-sample after 4–6 weeks
5. If below WES → Document findings; continue monitoring annually or after process changes
See Respirable Crystalline Silica Monitoring and Real-Time vs Gravimetric Monitoring for detailed monitoring guidance.
Step 5: Implement Control Measures
What you do: For each MEDIUM, HIGH, or VERY HIGH risk item, identify and implement controls using the hierarchy.
Control hierarchy:
- Elimination — Remove the need to work with the material (e.g., use pre-cast components instead of cutting concrete on-site; use synthetic aggregates instead of mined stone)
- Substitution — Replace the hazardous material with a safer alternative (e.g., use engineered stone with lower silica content; use pre-fabricated products)
- Engineering Controls — Isolate the hazard or use equipment to capture/suppress dust:
- Water suppression (wet cutting, wet grinding)
- Local Exhaust Ventilation (LEV) at the dust source
- Enclosed cabins (e.g., drill rig cabs with filtered air)
- Dust collection on power tools (sanders, grinders)
- Administrative Controls — Change work practices to reduce exposure:
- Rotate workers to limit individual exposure duration
- Schedule dusty work during low-occupancy periods
- Implement work method permits (SWMS) for high-risk tasks
- Personal Protective Equipment (PPE) — Respiratory protection as last resort:
- P2 filtering respirators for workers exposed above controls
- Fit testing and training required
- Not a substitute for engineering controls
Key principle: Work through the hierarchy from top to bottom. If Level 3 (engineering) is feasible, you must implement it before resorting to Level 5 (RPE).
Example: Concrete grinding
– Step 1 (Elimination): Can the work be eliminated? No, concrete must be ground.
– Step 2 (Substitution): Can the material be substituted? No, concrete is the substrate.
– Step 3 (Engineering): Implement water suppression (e.g., wet grinder) + dust extraction (e.g., grinder connected to high-efficiency particulate air [HEPA] vacuum). Verify effectiveness with testing.
– Step 4 (Admin): Limit grinding to 2 hours per worker per day (rotate operators).
– Step 5 (PPE): Supply P2 respirators as backup; mandatory if grinder or extraction fails.
Documentation: Record all controls in your risk register. Assign responsibility for implementation, timeline, and budget.
Step 6: Review Control Effectiveness
What you do: After implementing controls, verify that they work.
Methods:
– Exposure monitoring (see Step 4) — gravimetric sampling to confirm exposure has reduced below WES
– Real-time monitoring — portable instruments to track dust levels before and after control implementation
– Visual inspection — observe that engineering controls are being used correctly (e.g., grinder is connected to extraction, water suppression is flowing)
– Equipment maintenance records — verify that LEV systems, fans, and filters are serviced regularly
Frequency:
– Immediately after control implementation (1–2 weeks): real-time screening or initial gravimetric sampling
– 4–6 weeks after: follow-up gravimetric sampling to confirm WES compliance
– Annually: ongoing monitoring to ensure controls remain effective
– After process changes: repeat monitoring
Documentation: Keep copies of monitoring reports in your risk register. Update risk scores if monitoring shows exposure has reduced.
Step 7: Document and Review
What you do: Create a written dust risk assessment and update it regularly.
Content of written assessment:
1. Identification of dust hazards (materials and tasks)
2. Worker exposure assessment (who is exposed, duration, frequency)
3. Risk assessment results (likelihood, consequence, overall risk level)
4. Decision: Is monitoring required? Why or why not?
5. Control measures implemented (hierarchy applied, timeline, responsibility)
6. Monitoring results (if conducted)
7. Training and information provided to workers
8. Review date and revision history
Documentation format: A written document (e.g., Word, PDF) that is:
– Specific to your workplace (not generic)
– Signed by the responsible manager
– Communicated to workers
– Reviewed at least annually or after process changes
Retention: Keep the assessment for a minimum of 5 years, plus indefinitely for any year in which monitoring or health surveillance was conducted.
Review triggers:
– Annually (as per WHS policy)
– After a serious incident or near-miss involving dust
– If new equipment or work processes are introduced
– If monitoring results show unexpected levels
– Before the December 2026 WEL transition (to ensure readiness for new limits)
Avoiding Common Risk Assessment Mistakes
Mistake 1: Generic assessment — Using a template that is not specific to your workplace. Avoid this by documenting actual tasks, materials, and work practices at your site.
Mistake 2: No monitoring follow-up — Assessing risk as “medium” but never conducting monitoring to verify. If you assess risk as medium or higher, monitoring is almost always warranted.
Mistake 3: Overlooking secondary workers — Forgetting to assess exposure for supervisors, labourers, and bystanders. Include all workers in your matrix.
Mistake 4: No control implementation timeline — Identifying controls but not assigning a responsible person or due date. Accountability drives action.
Mistake 5: Infrequent reviews — Conducting the assessment once and never updating it. The assessment must be living; update it as work changes.
Mistake 6: Ignoring exposure uncertainty — If you are uncertain whether exposure exceeds WES, that uncertainty warrants monitoring. Don’t assume it is low just because you don’t have evidence of high exposure.
Frequently Asked Questions
Q: Who should conduct the risk assessment — me or a professional?
A: You (the employer) are responsible for the assessment. You can conduct it yourself if you have sufficient knowledge, or engage an occupational hygienist (e.g., AIOH member) to support. Many workplaces use a combination: a hygienist conducts the technical assessment, and management approves and implements it.
Q: Can I use a generic template for risk assessment?
A: A template is a helpful starting point, but your final assessment must be specific to your workplace. Identify your actual hazards, tasks, and worker groups. A generic assessment that doesn’t reflect your operations is not defensible.
Q: How often do I need to review the risk assessment?
A: At minimum, annually. Also review after significant work changes, after incidents, and in response to new regulatory requirements (e.g., December 2026 WEL transition). Document all reviews and changes.
Q: What is the difference between risk assessment and exposure monitoring?
A: Risk assessment is a management tool — you identify hazards and estimate risk level. Exposure monitoring is measurement — you collect air samples to quantify actual exposure. The assessment informs your monitoring strategy; monitoring validates your assessment.
Q: If my risk assessment shows “low risk,” do I still need to monitor?
A: If you are confident based on published data or expert judgment that exposure is below WES, monitoring may not be necessary immediately. However, if circumstances change (new equipment, different materials, process changes), reassess and monitor. Best practice is to conduct baseline monitoring even for “low-risk” work, to establish a baseline and detect future changes.
Q: How does the December 2026 WEL transition affect my current risk assessment?
A: Current assessments are based on the WES (0.05 mg/m³). The new WEL (exact values pending) is expected to be equal to or stricter than the WES. Review your assessment now and anticipate that control improvements may be needed to meet the WEL. See Silica WEL 2026 for guidance.
Q: What should I do if monitoring results show exposure above the WES?
A: Immediately: (1) Inform affected workers, (2) Review controls and identify why they were inadequate, (3) Implement or enhance engineering controls (e.g., improve ventilation, add water suppression), (4) Conduct follow-up monitoring within 4–6 weeks, (5) Continue monitoring until exposure is consistently below WES. See Silica Exposure Exceeds Limit: Australia for detailed guidance.
Q: Can I delegate the risk assessment to a supervisor?
A: The PCBU (employer) is legally responsible for the assessment. You can involve supervisors, safety reps, and workers in the process, but the employer must approve the final assessment and ensure it is implemented.
HowTo Schema Summary
How to Conduct a Dust Risk Assessment (Condensed Steps):
- Identify dust hazards (materials and tasks)
- Identify exposed workers (duration and frequency)
- Assess risk (likelihood × consequence)
- Determine if monitoring is required
- Implement controls (using hierarchy)
- Review control effectiveness
- Document and review regularly
Summary
A dust risk assessment is the starting point for a compliant and effective dust control programme. By following these seven steps, you will:
- Identify all RCS and dust hazards at your workplace
- Understand who is exposed and how much exposure they receive
- Make informed decisions about whether monitoring is necessary
- Implement appropriate controls that actually reduce exposure
- Build a defensible compliance record with documented evidence of risk management
Many workplaces can conduct a basic assessment themselves using this guide. More complex workplaces (e.g., construction sites with multiple tasks and high-risk operations) benefit from engaging an occupational hygienist to ensure thoroughness and compliance.
At Anitech, we conduct risk assessments for Australian workplaces and support implementation of controls and monitoring programmes. We also train management and supervisors to understand dust risks and contribute to ongoing risk management.
Ready to conduct your assessment? Start with Step 1 today. If you need support, contact our team for a professional risk assessment and compliance review.
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FEATURE (1200×630px): Seven-step visual flowchart showing the risk assessment process (Step 1: Identify → Step 2: Expose → Step 3: Assess → Step 4: Monitor? → Step 5: Control → Step 6: Review → Step 7: Document). Circular arrows indicating ongoing review. Neutral workplace imagery.
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BODY_1 (800×450px): Small business owner or site manager reviewing a dust risk register document with a peer or supervisor, documenting findings. Caption: “A thorough, documented risk assessment is the foundation of WHS compliance and worker protection.”
