Updated HSE Regulations For Silica Dust To Protect Workers At Risk

In March 2025, the Health and Safety Executive (HSE) updated its guidance on the health surveillance required for workers exposed to respirable crystalline silica (RCS). For anyone working in industrial, quarrying, and construction operations, this update is a critical reminder to review and reinforce dust management protocols, particularly when dealing with known sources of silica dust, such as cutting, grinding, drilling, and polishing activities involving concrete, brick, and stone.

The Risk Of RCS Exposure And Why Protection Matters

Exposure to crystalline silica dust is a serious occupational hazard. RCS is produced in large quantities during many common manufacturing, extraction, and installation processes, and the fine dust particles released are often too small to be seen under normal lighting. These can nevertheless be inhaled into the lungs, causing potentially irreversible damage. The risks associated with silica dust are well-documented, with prolonged exposure linked to severe conditions such as silicosis, lung cancer, and chronic obstructive pulmonary disease (COPD).

Understanding Your Legal Obligations Under COSHH

The Control of Substances Hazardous to Health Regulations 2002 (COSHH) places a clear legal duty on employers to control all substances deemed ‘hazardous to health’. This involves assessing the risks, implementing effective control measures, and, where necessary, providing health surveillance.

The updated respirable crystalline silica guidance from the HSE, G404, provides clearer advice on how to comply with COSHH duties relating to dust exposure:

1. Risk assessment: You must conduct a thorough risk assessment to identify where and when workers might be exposed to RCS. This includes tasks that may not seem obvious, such as cleaning up dust.
2. Health surveillance: Where there is a reasonable likelihood that workers could develop a silica-related disease like silicosis, you are legally required to provide a suitable health surveillance programme. This is not a substitute for effective control measures but a secondary check to ensure they are working.
3. Consult occupational health professionals: The guidance highlights the need to consult with occupational health experts where necessary to determine the appropriate level of surveillance, especially where an over-exposure may have already occurred.

Actions For Health And Safety Managers

The renewed focus on silica awareness and safety from the HSE on this issue presents an opportunity to strengthen your safety procedures. Fortunately, it is fairly straightforward to enhance your dust control strategy without disrupting operations.

Step One: Review And Update Your Risk Assessments

Start by reviewing your existing risk assessments for any tasks that generate dust. Consider the risks of crystalline silica in the materials being worked on and the duration of exposure. High-risk occupations, such as worktop manufacturing and installation, now require specific consideration.

Step Two: Prioritise Your Control Measures

The most effective way to protect workers is to control dust at its source. This can include:

1. Water suppression: Using wet-cutting methods significantly reduces the amount of airborne dust.
2. On-tool extraction: Attaching an industrial vacuum unit directly to the tool captures dust as it is created.
3. Respiratory Protective Equipment (RPE): When dust cannot be eliminated, providing suitable RPE is essential.

Step Three: Verify That Your RPE Is Fit For Purpose

RPE is only effective if it fits the wearer correctly. An incorrect fit can allow dangerous particles to leak in, providing a false sense of security. Face fit testing is a legal requirement to ensure that the selected mask provides an appropriate seal for the individual user. It is a simple but vital step in any respiratory protection programme. More information about respiratory protection equipment (RPE) and breathing apparatus can be found here.

Step Four: Educate Your Workforce

Workers must understand the dangers of crystalline silica dust and the importance of using control measures correctly, so make sure they know how to report health symptoms such as persistent coughing, shortness of breath, or frequent chest infections promptly. A well-informed team is an essential part of building a strong safety awareness culture in the workplace.

Book A Face Fit Test With Fire Safe International

Making sure that every member of your team has a properly fitting mask is an essential aspect of silica dust protection. For more information, please contact one of our experienced team members today, or click here to book your place on our qualitative face fit test operator training course.

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