Respirable crystalline silica (RCS) is one of the most significant occupational health risks confronting Australian industries today. When workers cut, grind, drill, process or tunnel through silica-rich materials, microscopic silica particles become airborne. Once inhaled, these fine particles can penetrate deep into the lungs and cause silicosis – an incurable and potentially fatal disease marked by progressive scarring of lung tissue.
Alarmingly, silicosis is increasingly seen among both younger and older workers. Estimates suggest up to 600,000 workers are exposed annually, with approximately 250 cases of lung cancer and 350 new cases of silicosis attributed to RCS exposure every year. These figures are estimates, and actual numbers vary between studies.
But silicosis is only part of the picture. RCS exposure is also linked to lung cancer, chronic obstructive pulmonary disease (COPD), kidney disease and autoimmune conditions.
An ABC article in September 2025 revealed that 292 Queensland workers who developed deadly lung diseases after being exposed to dust at mines, construction projects and worksites had their cases recorded on the state’s Notifiable Dust Lung Disease Register in the previous year. Of those, 121 were diagnosed with chronic obstructive pulmonary disease, and 96 had respiratory cancers.
What is Silicosis?
Silicosis is a chronic, incurable lung disease caused by the cumulative inhalation of respirable crystalline silica (RCS). When inhaled, these fine particles cause inflammation and progressive scarring (fibrosis) of lung tissue, reducing lung function and potentially leading to premature death.
How Silicosis Develops
- Inhalation of fine particles: Silica dust particles, up to 100 times smaller than a grain of sand, can bypass the nose and upper airways and reach deep into the lungs.
- Immune response and toxicity: The body’s immune system tries to engulf and remove these particles. However, silica is toxic to white blood cells, which release inflammatory chemicals when they die.
- Fibrosis formation: This persistent inflammation stimulates scar tissue (fibrosis) to form. Over time, the lung tissue becomes stiff and less able to expand, reducing oxygen exchange.
- Progressive impairment: As fibrosis worsens, oxygen absorption becomes increasingly restricted, making everyday activities difficult.
Symptoms
- Persistent cough, initially dry but possibly becoming productive
- Shortness of breath (first on exertion, later at rest)
- Wheezing or noisy breathing may develop
- Chest tightness or discomfort when trying to take a deep breath
- Fatigue and reduced exercise tolerance due to lower oxygen levels.
Symptoms usually appear only after significant lung damage has occurred. Regular health surveillance is essential to detect early changes before symptoms develop.
Diagnosis and Monitoring
- Health Surveillance: Routine occupational medical assessments are the primary method for detecting silicosis in asymptomatic workers.
- Spirometry: Useful for assessing overall lung function but not sensitive for early silicosis changes are usually evident only at advanced stages.
- Imaging:
- ILO-standard chest X-ray can show nodules or fibrosis but may miss early disease.
- High-Resolution CT (HRCT) is the most sensitive imaging method, revealing small changes not visible on X-ray
- Blood Tests: Not diagnostic for silicosis, but can help exclude other conditions with similar symptoms.
Treatment:
Silicosis cannot be cured, and lung damage from respirable crystalline silica (RCS) exposure is irreversible. Management, therefore, focuses on slowing disease progression, preventing further exposure, treating complications, and improving quality of life. Management approaches include removal from further RCS exposure, specialist respiratory care, pharmacological treatments, oxygen therapy and psychosocial support such as counselling.
Who is at risk of developing Silicosis?
Industries and Roles Most at Risk
- Engineered stone fabrication and installation
- Road and tunnel construction
- Mining and quarrying
- Manufacturing involving stone, concrete, and brick processing
High-Risk Tasks
- Angle grinding, jackhammering, and chiselling of concrete or masonry
- Crushing, loading, hauling, and dumping of rock
- Cleaning activities using pressurised air
- Paving and surfacing commercial spaces
- Dry cutting or drilling of brick, concrete, or stone without effective dust suppression
What can be done to prevent Silicosis in the workplace?
Steps can be taken to improve the health outcomes for workers who are exposed to airborne crystalline silica. These include controlling environmental factors and work practices to minimise exposure to crystalline silica and periodic health surveillance:
- Identifying silica through a safety data sheet, a label or other sources;
- Monitoring workplace air for RCS;
- Selecting the best means for controlling the risk (including containment, ventilation, signage and respiratory protective equipment);
- Annual health surveillance for workers’ exposure to RCS;
- Keeping accurate records of exposure duration and intensity for each person with RCS;
- Freuqently reviewing existing control measures for RCS and;
- Having a continuous induction, information, training and supervision program for workers.
For most workers exposed to RCS, wet cutting and grinding, adequate ventilation and using personal respiratory equipment goes a long way to controlling these risks.
Health Surveillance for workers exposed to crystalline silica
Under the WHS Act, PCBUs must provide health monitoring for any worker who performs ongoing work with crystalline silica substances where there is a significant risk to their health from RCS exposure. A program of health surveillance should include:
- Pre-employment: Baseline health and exposure assessment, including collection of demographics, medical and occupational history information; baseline spirometry and imaging.
- Periodic (annually): Monitoring of lung function, reporting/investigation of symptoms and referral to a specialist if abnormalities are detected.
- Exit: Required at the end of employment. A report is provided to the worker and PCBU.
Workplace Exposure Standards (WES)5,6,7
Australia has workplace exposure standards (WES) that cover approximately 700 chemicals (of which silica is one). A workplace exposure standard lists the maximum upper limit prescribed by legislation for exposure to a chemical in the workplace.
A mandatory exposure standard has been in place for many years under Australia’s Workplace Health and Safety Regulations. However, the exposure standard was halved in 2020 from 0.1 mg/m³ to 0.05 mg/m³.
Safe Work Australia states that: Workers must not be exposed to levels of RCS greater than 0.05 mg/m3 over an eight-hour working day, for a five-day working week.
This change was made to better protect workers following a silicosis crisis in the engineered stone sector and growing advocacy from unions, medical experts, and medical bodies such as the Thoracic Society of Australia and New Zealand. A Monash University Study into silicosis cases in engineered stone workers also highlighted the need for more stringent controls.
What is the take-home message for Employers?
No single approach to preventing crystalline silicosis for workers exposed to RCS is adequate on its own (apart from elimination and substitution – this is unattainable in some workplaces). However, a combination of safe work practices to minimise a worker’s exposure to RCS and regular health surveillance to detect changes in lung function early will make a significant difference to the number of workers affected by crystalline silicosis in the long term.
For employers, managing RCS risks is both a legal obligation and a moral duty. Australia’s regulatory environment has tightened significantly, with lower exposure limits, mandatory health surveillance, and, in some cases, bans on high-risk materials such as engineered stone. Non-compliance exposes organisations to substantial financial penalties, reputational damage and, most importantly, harm to their workforce.
How can KINNECT help?
Implementing a Silicosis Health Monitoring Program is an important step in ensuring the health and safety of your workers. KINNECT can help you establish a program that not only keeps your employees safe but also meets your legislative requirements.
Contact us for an obligation-free discussion on how KINNECT can help set up your Silicosis Health Monitoring Program.
References:
- ABC: Hundreds of new dust-related lung disease cases recorded in Queensland – ABC News;
- SafeWork Australia. Crystalline Silica and Silicosis: Silica – What is crystalline silica | Safe Work Australia;
- Worksafe Queensland: Respirable crystalline silica (general) | WorkSafe.qld.gov.au
- SafeWork Australia. Health Monitoring For Exposure to Hazardous Chemicals: Health monitoring guidelines
- SafeWork Australia: Workplace Exposure Standards for Airborne Contaminants: https://www.safeworkaustralia.gov.au/exposure-standards
ABOUT US
SERVICES
QUICK LINKS
CONTACT US
