Often referred to as this generation’s asbestos, crystalline silica is a key compliance issue in construction, building and mining, especially in light of the recent silica regulation update in 2024/2025.

Under the September 2024 silica regulation update (Chapter 8A of the WHS Regulations), Safe Work Australia has redefined risk thresholds, exposure limits and contractor responsibilities to provide greater protection for workers at risk of silica dust exposure. 

Whether you’re a contractor, project manager or procurement lead, we’re here to step you through the latest changes, so you understand your new responsibilities and how to stay compliant into 2026 and beyond. 

Chapter 8A explained: Key changes in the 2024 silica regulation update

On 1 September 2024, Safe Work Australia amended the model Work Health and Safety (WHS) Regulations to include a dedicated chapter on crystalline silica and silica processes, known as Chapter 8A. The changes reflect growing evidence linking respirable crystalline silica (RCS) to severe health conditions like silicosis, lung cancer and autoimmune disorders, even after short-term exposure.

The update introduces a new definition of ‘high-risk crystalline silica work’, which refers to any task where there is:

• Likely exposure to RCS above the workplace exposure standard (WES) (currently 0.05 mg/m³),
• Uncontrolled dry processing (e.g., cutting, grinding, polishing without suppression), and
• Lack of appropriate engineering controls or respiratory protection.

Beyond the new definition of high-risk processes, other key changes include:

• Mandatory crystalline silica risk control plans (CS-RCPs): For all high-risk work, Persons Conducting a Business or Undertaking (PCBUs) must now prepare a written crystalline silica risk control plan before work starts.
• Prohibition on uncontrolled dry cutting: A blanket ban on uncontrolled dry cutting of materials containing crystalline silica, regardless of the size or duration of the task.
• Enhanced health monitoring requirements: Baseline checks before high-risk work, ongoing respiratory reviews, and oversight by qualified occupational health practitioners.
• Recordkeeping and documentation requirements: PCBUs must now maintain detailed logs of the risk control plan, health monitoring records, fit-testing documentation for respiratory equipment and equipment maintenance and inspection logs.

Ultimately, Chapter 8A is designed to be enforceable, with stronger penalties for non-compliance like fines, site shutdowns, legal repercussions and even loss of government tenders. Navigating the new crystalline silica regulations can be challenging. That said, Control Hire’s team of qualified environmental consultants can help you ensure your worksite meets the latest air quality regulations with our real-time dust and gas monitoring services. 

April 2025 FAQs: What states are clarifying now

Although the new regulations came into effect several months ago, many PCBUs were left with questions surrounding the updated requirements. In response, many state-based WHS regulators, like WorkSafe Queensland, NSW Resources and SafeWork SA, released FAQs clarifying the new rules.

Here’s a quick rundown of some of the key FAQs concerning the new silica regulations.

What counts as high-risk crystalline silica work?

High-risk silica work includes any task that is reasonably likely to pose a health risk due to silica exposure. If there’s uncertainty about whether the work is high-risk, it must be treated as high-risk until proven otherwise.

What’s considered processing of a crystalline silica substance (CSS)?

Processing a crystalline silica substance (CSS) includes any activity that involves:

• Using power tools or mechanical equipment to crush, cut, grind, trim, sand, polish or drill a CSS;
• Operating roadheaders, mechanical screeners, or quarrying machinery on materials containing CSS;
• Tunnelling through CSS-containing rock or material; or
• Any other task, such as cleaning or maintenance work, that disturbs settled dust and is likely to expose a person to respirable crystalline silica (RCS) during the handling or manufacture of a CSS.

How do I ensure controlled processing of crystalline silica substances?

Processing is considered to be ‘controlled’ if control measures have been implemented to eliminate or minimise the risks that come with CCS processing. Common control measures include:

• Worker isolation from airborne dust,
• Sealed operator cabins with high-efficiency air filtration,
• Reliable water-based dust suppression techniques,
• Integrated on-tool dust extraction systems, and
• Targeted local exhaust ventilation to capture dust at the source.

What is considered effective dust suppression?

According to updated guidance, dust suppression is only considered “effective” when it meets all of the following:

• The system is integrated on-tool, e.g., a vacuum or water spray attached to the cutting or grinding equipment,
• It uses a H-class vacuum or equivalent with automatic filter cleaning,
• It’s used consistently and inspected regularly, and
• It reduces visible dust and measurable airborne RCS levels on site.

Basic water spraying or using a garden hose nearby is not considered sufficient.

Control Hire’s dust suppression cannons & Fog Lances are engineered to produce a fine mist with a mean droplet size of 50–60 microns — the ideal range for capturing airborne dust particles, including respirable crystalline silica (RCS). This precision atomisation maximises particle binding, preventing harmful dust from remaining airborne and improving air quality across construction, mining, and demolition sites. Our systems ensure compliance, safety, and environmental performance in any condition.

Luckily, Control Hire offers a range of dust control solutions, including compliant su extraction and class-1 monitoring systems.

What’s the role of air monitoring?

Real-time dust monitoring is recommended for high-risk sites, particularly where:

• Large crews are working across multiple locations,
• Work is being conducted in partially enclosed or poorly ventilated environments, or
• Subcontractors are cycling through short-term, high-dust tasks.

A qualified consultant should always complete air monitoring. At Control Hire, we offer dust and air quality monitoring services as part of our specialist dust and air quality consultation services. 

What tier-one contractors must do differently in 2026

Moving forward, tier-one contractors are embedding silica-safe procurement into their budgets and pre-qualification frameworks as they bid for major projects. This typically involves:

• Incorporating detailed pre-project dust management plans and, more specifically, crystalline silica risk control plans,
• Including silica-safe construction equipment as part of the tendering process, and
• Allocating specific dust monitoring and suppression equipment to each site. 

Stay silica-safe with Control Hire

Maintaining compliance with the updated silica regulations requires strong organisation and early planning. Whether you’re a tier-one contractor or a local construction company, you need to ensure you’re taking a proactive, fully documented approach to crystalline silica. 

Book a free consultation with Control Hire to discuss compliant dust management plans and reserve specialist dust control and monitoring solutions: