Dust Control Measures for Crushing, Screening and Stockpiling Sites

Effective dust control at a resource recovery site is a layered system. No single control is sufficient on its own — water suppression alone will not protect a crusher operator if the cab seals are failing, and PPE alone will not satisfy a regulator if engineering controls are absent. The hierarchy of control sets the order: eliminate, substitute, isolate, engineer, administer, then PPE.

Water suppression is usually the highest-impact engineering control. Spray bars at primary and secondary crusher feed, at conveyor transfer points, at screen decks, on stockpiles and at loadout points significantly reduce respirable dust generation — provided water pressure, nozzle condition and droplet size are right. Suppression systems should be inspected before each shift and maintained on a documented schedule.

Enclosures and partial enclosures around crushers, screens and transfer points reduce fugitive emissions and let suppression work. Where full enclosure is impractical, wind breaks, baffles and curtains can substantially reduce dust escape. Conveyor covers and skirting at transfer points are inexpensive and frequently overlooked.

Local exhaust ventilation (LEV) on enclosed equipment, fitted with appropriate filtration, is the standard engineering control for indoor or partly-enclosed processes. LEV systems require documented commissioning, inspection (typically at least annually), and operator training.

Wheel washes, sealed haul roads, road sweeping and speed control reduce track-out and re-entrainment of settled dust — both significant contributors to ambient exposure on busy yards. Speed limits should be posted, enforced and recorded.

Stockpile management is often where good practice slips. Stockpiles should be kept at working height, watered down at the end of each shift in dry conditions, and oriented to reduce wind exposure where possible. Long-term stockpiles benefit from compaction, surface crusting agents or covers.

Plant cab integrity matters. For crusher, loader and excavator operators, a positive-pressure cab with a HEPA filter and intact door seals provides one of the highest-quality protections available. Cab pressure testing should be part of plant maintenance.

Administrative controls reinforce the engineering layer: defined exclusion zones, restricted access to high-dust areas, task scheduling that avoids high-exposure work at peak wind, and clear procedures for clean-up (no dry sweeping, no compressed-air cleaning of clothes or surfaces).

Respiratory protection sits at the bottom of the hierarchy because it relies on every individual wearing the right device, fitted correctly, every time. Where RPE is required, it must be selected per AS/NZS 1715, fit-tested, maintained, and supported by training.

Air monitoring closes the loop by confirming that the layered controls actually achieve the required exposure outcome. Where monitoring shows exposures approaching the standard, the upstream controls — not the PPE — are usually where the corrective action belongs.

AX4 conducts site-specific dust control reviews for resource recovery operators across South Australia, identifying the highest-impact control improvements and providing a prioritised action plan.

Related in this cluster: dust and silica risk overview, silica monitoring obligations, asbestos contamination risk, audit-ready documentation, and evidence-based WHS records.