Cut Off Saw Dust Control

Cut off saws (disc cutters) generate extremely high levels of respirable dust when cutting concrete, block, or stone.
Respirable crystalline silica (RCS) is released when cutting masonry and can cause silicosis and lung cancer.
The COSHH Regulations 2002 require employers to prevent or adequately control exposure to hazardous dust.
The workplace exposure limit (WEL) for RCS is 0.1 mg/m³ — this is easily exceeded within seconds of dry cutting.
HSE have issued specific guidance stating that dry cutting of concrete and stone is unacceptable on UK sites.
Water suppression is the primary control — all cut off saws must have a functioning water attachment fitted.
On-tool dust extraction with an M-class or H-class vacuum is an alternative where water cannot be used.
RPE is required as a secondary control in addition to water suppression or extraction, not instead of it.
Dust exposure is cumulative — even short tasks without controls contribute to long-term irreversible lung damage.
Health surveillance including lung function testing is required for workers regularly exposed to silica dust.

Prevent silicosis	Silicosis is an incurable, progressive lung disease caused by inhaling fine silica dust from cutting masonry.
Legal requirement	COSHH 2002 requires dust to be controlled at source — dry cutting masonry is a breach of the law.
Cancer risk	RCS is classified as a human carcinogen — long-term exposure significantly increases the risk of lung cancer.
Protect bystanders	Dust clouds from uncontrolled cutting expose nearby workers too, not just the person using the saw.

Do

Don't

Use water suppression on every cut off saw operation without exception.
Check the water bottle or supply is connected and flowing before starting.
Wear a minimum FFP3 mask when cutting concrete, block, stone, or brick.
Position yourself and others upwind of the dust cloud wherever possible.
Use an M-class or H-class vacuum extraction where water is not feasible.
Attend health surveillance appointments for lung function testing as required.
Clean up cutting residue with a vacuum or wet sweeping, not dry brushing.
Select the correct blade for the material to reduce unnecessary dust generation.
Brief nearby workers before cutting so they can move clear or wear RPE.
Record dust-generating activities in the COSHH assessment for the task.

DON'T dry cut concrete, block, stone, or brick under any circumstances.
DON'T use the saw if the water suppression system is broken or empty.
DON'T rely on RPE alone as the only dust control for cutting operations.
DON'T cut indoors or in enclosed areas without forced ventilation in place.
DON'T sweep up cutting dust with a dry broom — it re-suspends the particles.
DON'T remove your RPE until you have moved clear of the dust cloud area.
DON'T allow bystanders to remain near cutting without appropriate RPE protection.
DON'T ignore symptoms such as persistent cough, breathlessness, or chest tightness.
DON'T use a dust mask below FFP3 rating for silica-generating tasks.
DON'T skip health surveillance — early detection of silicosis can slow progression.

See also: Respirable Crystalline Silica (RCS) | RPE Selection and Face Fit Testing

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