Dust Extraction Maintenance SWMS

Dust extraction systems are critical engineering controls in manufacturing facilities that handle wood, metal, silica, flour, and other dust-generating materials. Without regular maintenance, these systems degrade through filter loading, duct blockage, fan wear, and seal deterioration, reducing their effectiveness and potentially exposing workers to dust levels above the applicable WELs. Maintenance work on dust extraction systems itself presents hazards including exposure to accumulated concentrated dust, combustible dust fire risk in filter housings, and falls from elevated ductwork. This template addresses safe maintenance procedures and performance verification requirements.

Legal Requirements

regulation

WHS Regulation 2025 Part 7.1 — Hazardous Chemicals and Part 4.7 — Plant

hrcw category

Plant maintenance with dust explosion risk

code of practice

Managing Risks of Hazardous Chemicals in the Workplace (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Concentrated dust exposure during filter replacement and hopper emptying	Acute respiratory exposure, sensitisation	Likely
Combustible dust fire in filter housing or dust collector	Equipment fire, potential dust explosion	Possible
Falls from elevated ductwork during inspection and repair	Fractures, head injuries, death	Possible
Electrical hazards from fan motors and control systems	Electrocution, burns	Unlikely
Reduced extraction effectiveness exposing workers to above-WEL dust levels	Chronic respiratory disease, cancer	Likely
Confined space entry into large dust collectors and hoppers	Engulfment, atmospheric hazards	Unlikely

Controls (Hierarchy of Controls)

Wear P3 respiratory protection during filter replacement and hopper emptying operations

Lockout and tagout extraction fans before entering filter housings or duct sections

Use HEPA-filtered vacuum cleaners to clean accumulated dust — never use compressed air

Conduct face velocity measurements at all extraction points quarterly using a calibrated anemometer

Replace filters according to manufacturer specifications and differential pressure readings

Inspect ductwork annually for blockages, leaks, and damage that reduce extraction performance

Use fall protection when accessing elevated ductwork and filter housings

Conduct annual thorough examination of the complete extraction system by a competent ventilation engineer

Recent Prosecutions

Orica Australia Pty Ltd$1,200,000

Workers exposed to hazardous dust without adequate ventilation or health monitoring.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

SafeWork SA prosecution$840,000

Inadequate engineering controls in manufacturing facility resulting in worker exposure to hazardous substances.

2024 — SafeWork SA Manufacturing Prosecution [2024]

What Your SWMS Must Include

✓Extraction system maintenance schedule with component-level inspection intervals

✓Face velocity measurement procedure and minimum acceptable values for each extraction point

✓Filter replacement criteria based on differential pressure and manufacturer specifications

✓RPE requirements for maintenance personnel during filter and hopper work

✓Annual thorough examination scope and competent person requirements

Need a Dust Extraction Maintenance SWMS?

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