Mining›SWMS

Crusher Operation SWMS

Crusher operations in mining present severe entrapment, atmospheric, and noise hazards that require rigorous controls during operation, blockage clearing, and maintenance. Workers can become trapped in crusher chambers during bridging events when material blocks the feed and they attempt to clear it without implementing lockout-tagout. Silica dust generated during primary, secondary, and tertiary crushing routinely exceeds workplace exposure limits without adequate dust suppression, and noise levels near crushers commonly exceed 100 dB(A). The silica WEL reduction from 0.05 to 0.025 mg/m3 in December 2026 will require crusher operators to significantly upgrade dust suppression and extraction systems. This SWMS covers jaw, cone, and impact crusher operation and maintenance.

Legal Requirements

regulation

WHS Regulation 2025 Part 5.2 — Plant; Part 8A — WEL; Part 4.7 — Noise

hrcw category

Work involving powered mobile plant, hazardous chemical exposure (silica dust)

code of practice

Managing Risks of Plant in the Workplace; Managing Respirable Crystalline Silica (binding July 2026)

section 26a binding

Yes — Both codes binding July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Entrapment in crusher chamber during blockage clearing	Fatal crush injuries from material release or crusher start-up	Unlikely
Silica dust from crushing quartz-bearing rock	Silicosis, lung cancer	Likely
Noise exposure exceeding 100 dB(A) near operating crushers	Permanent noise-induced hearing loss	Likely
Struck by material ejected from crusher feed or discharge	Fatal blunt trauma, fractures	Possible
Falls from crusher platforms and access ways during operation and maintenance	Fatal falls, fractures, head injuries	Possible

Controls (Hierarchy of Controls)

Implement lockout-tagout on all crusher energy sources before any person enters the chamber for clearing or maintenance

Install water spray dust suppression at crusher feed, discharge, and transfer points

Provide P2 respiratory protection for all personnel working near crushers during operation

Enforce mandatory hearing protection in crusher operating zones — minimum Class 5 rated

Install guards on all crusher access points with interlocked gates preventing access during operation

Use remote monitoring and control to minimise operator time in proximity to operating crushers

Maintain handrails, kickboards, and non-slip surfaces on all crusher platforms and access ways

Recent Prosecutions

Crusher entrapment fatality — NSW quarry$520,000

A worker was fatally crushed inside a jaw crusher after entering the chamber to clear a blockage without implementing lockout-tagout. The crusher was restarted remotely by another operator who was unaware anyone was inside the chamber.

2023 — NSW Resources Regulator Prosecution Database

What Your SWMS Must Include

✓LOTO procedure for crusher chamber entry specifying all energy sources to be isolated

✓Silica dust suppression specifications for each crusher stage including spray locations and flow rates

✓Noise management zones around crushers with mandatory hearing protection requirements

✓Blockage clearing procedure prohibiting chamber entry without full LOTO implementation

✓Fall prevention measures for all crusher platforms and access ways

Need a compliant Crusher Operation SWMS?

Our WHS consultants develop crusher operation SWMS with LOTO procedures, silica dust controls mapped to the incoming WEL, and noise management plans.