Protecting Your Maintenance Crew from Dust!

June 26, 2025

Recently highlighted at the latest IQA Health and Safety conference in Brisbane, one of the primary activities generating the highest exceedance of respirable dust comes from the support and maintenance teams working on fixed plants—surprisingly even more than processing and crushing. We have compiled a list of activities that we think may lead to these exceedances, along with strategies to improve their safety.

Activities Contributing to Dust Generation:

1.Crushing and Screening:


  • Regular maintenance of crushers and screening plants, including replacing worn parts or clearing blocked screens, can release dust into the atmosphere.


2. Material Handling:


  • Maintenance tasks on conveyor systems, transfer points, and loading/unloading equipment may create dust, particularly with issues such as belt wear, blockages, or spills.


3. Mobile Plant:


  • Maintaining vehicles like loaders and haul trucks—including tire changes, brake maintenance, and cleaning—can also generate dust.


4. Cleaning and Housekeeping


  • Enclosed Cabins: The maintenance and cleaning of enclosed cabins on machinery can release accumulated dust.
  • General Cleaning: Sweeping or using compressed air to clean machinery and work areas can send dust into the air.


5.Additional Factors


  • Changing Filters: Cleaning and replacing filters can release accumulated dust particles from the surrounding area.
  • Spillage: Materials spilled around the plant during production or maintenance can create airborne dust.
  • Wind and Weather: Wind can carry dust from maintenance activities, especially when not adequately controlled, while weather conditions can influence dust dispersion.
  • Excessive dust can also cling to clothing and be transported home, potentially impacting others outside of the workplace. Additionally, dust can harm machinery by causing wear, blockages, and engine damage.

Control Measures

Engineering Controls

Controlling dust at the source with dust suppression systems, such as Polo Citrus, offers several advantages over attempting to manage airborne dust particles. 


Here are some challenges associated with addressing dust once it has entered the air:

  • Airborne dust particles may settle in and around the plant.
  • Dust is typically managed using water misting systems.
  • When dust is suppressed with water on the quarry floor, it can create slip hazards, be collected by loaders, and spread throughout the facility, potentially contaminating stockpiles. Once dried, it can be re-entrained by wind and movement, creating additional dust hazards.

Benefits of Using Polo Citrus to Keep Dust at the Source

  • Fewer filter changes are required.
  • Uses less water than traditional misting systems, resulting in less blocked or blinded mesh, reduced carryback on belts, and less buildup on tail drums that need maintenance attention.
  • Minimizes dust accumulation on maintenance access points, handrails, engines, and other equipment.

Other Engineering Controls

  • Enclose machinery at transfer points, with covers, skirts, enclosed hoods and screen housing
  • Dust extraction/collection at transfer points
  • Use of windsocks at the discharge point of stockpile conveyors
  • Reduce the height the material falls to the stockpile by lowering conveyors as low to the ground where possible or allowing the stockpile to grow to a height where the pile is close to the conveyor height and then maintaining that height
  • Reduce stockpile size
  • Change the configuration of the plant
  • Spraying of stockpiles with water or polymer such as Polo Citrus Dust Bind
  • Monitor wind direction and wind strength 
  • Cover loads on trucks before they leave site 
  • Manage dust fall, so it does not fall around plant where machinery, such as loaders, can stir up the dust
  • Utilise recognised dust control/suppression methods best suited to the material and type of work being done. Take into consideration the direction and strength of the wind, the amount of water used, and where the dust will settle if it is knocked down once airborne

Administrative Controls

  • Thorough induction training and regular up to date training and information on the risks and how to manage dust
  • Warning signs around plant and in common areas
  • Rotation of workers, and restriction of the time spent exposed to the dust
  • Maintenance work systems that include wash down of plant before work commences
  • Maintain work site and office through regular cleaning and dusting, minimise dust being carried on clothes and shoes 
  • Pre-start inspections protocol for things such as cabin cleanliness and sealing of doors and windows, and the function and cleanliness of the air conditioner including filters
  • Communication of dust monitoring results
  • If air cleaners are to be blown out / cleaned, ensure a procedure is in place to protect workers from inhaling the dust in the filters or get them cleaned off site by a reputable company

Personal Protective Equipment (PPE)

  • Easily accessible PPE for all staff
  • Staff are trained on how it works, the most appropriate PPE for the task and that it is fitted correctly
  • Maintain and care for PPE and ensure it is in good working order

Conclusion

Ensuring the safety and health of maintenance crews in environments with high dust exposure is of utmost importance. By identifying the activities that contribute to dust generation and implementing effective control measures, we can significantly reduce the risk of respiratory and other health issues. This proactive approach not only protects the individuals who are directly exposed but also enhances the overall safety culture within the workplace.

Continuous Improvement and Monitoring

It's essential to continuously monitor dust levels and the effectiveness of implemented controls. Regular audits and feedback loops can help identify areas for improvement. Utilizing advanced monitoring technologies and adapting to new solutions will ensure that the dust control strategies remain effective over time.

Commitment to Safety

Creating a culture of safety where every team member is aware of the risks and actively participates in mitigating them is crucial. Regular training, clear communication, and management support are key components in fostering this environment. By prioritizing safety and health, companies not only comply with regulations but also demonstrate their commitment to their workforce's well-being.

Future Considerations

Staying informed about dust suppression controls and being open to adopting new practices can further enhance safety measures. Additionally, as regulations evolve, maintaining compliance with updated standards will be vital for continued protection of maintenance crews.


In conclusion, tackling dust exposure in maintenance activities requires a comprehensive approach that includes engineering, administrative, and personal protective measures. By addressing these challenges head-on, we can create safer working conditions and promote a healthier workplace for all employees.