DUS/Specific/TBT-DUS-005

Cutting Concrete and Block

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Cutting Concrete and Block

Toolbox Talk Record

Ref: TBT-DUS-005  |  Issue: 1  |  Date: March 2026
PresenterProject
LocationDate

What?

  • Cutting concrete, block, and masonry generates high levels of respirable crystalline silica dust.
  • Silica dust causes silicosis, chronic obstructive pulmonary disease, and lung cancer.
  • Disc cutters, angle grinders, and wall chasers are the most common dust sources on site.
  • Dry cutting produces far more airborne dust than wet cutting and should be avoided.
  • The workplace exposure limit for silica is 0.1 mg/m3 over an 8-hour time-weighted average.
  • COSHH 2002 requires employers to assess silica exposure and implement effective controls.
  • Water suppression reduces dust by up to 90% when used correctly during cutting.
  • On-tool extraction systems capture dust at source and must use H-class vacuum units.
  • RPE alone is not sufficient — it is the last resort after engineering controls.
  • Health surveillance including lung function testing is required for regular silica exposure.

Why?

Prevent lung diseaseSilicosis is irreversible and progressive — even short exposure causes lasting damage.
Legal dutyCOSHH requires employers to control silica dust below the workplace limit.
Cancer riskRespirable crystalline silica is classified as a Group 1 carcinogen by IARC.
Health surveillanceEarly detection through spirometry prevents workers developing disabling disease.
Do Don't
  • Use water suppression on all disc cutters and concrete saws during use.
  • Fit on-tool extraction connected to an H-class vacuum for indoor cutting.
  • Carry out a COSHH assessment before any concrete or block cutting work.
  • Wear RPE with a minimum APF of 20 as an additional control measure.
  • Ensure RPE has been face-fit tested for the individual wearer.
  • Cut outdoors and downwind of other workers wherever possible.
  • Clean up dust with an H-class vacuum — never dry sweep silica dust.
  • Attend health surveillance including lung function tests as scheduled.
  • Inspect water suppression systems and extraction filters before each use.
  • Rotate tasks to limit individual exposure time to cutting operations.
  • DON'T dry cut concrete, block, or masonry under any circumstances.
  • DON'T sweep up silica dust with a broom — it re-suspends the particles.
  • DON'T use RPE as your only control — engineering controls must come first.
  • DON'T use a domestic vacuum — only H-class units filter silica dust safely.
  • DON'T cut indoors without both extraction and ventilation in place.
  • DON'T ignore a persistent cough or breathing difficulty — report it promptly.
  • DON'T skip face-fit testing — poorly fitting RPE provides little protection.
  • DON'T allow other workers to stand in the dust plume during cutting.
  • DON'T remove the water supply on suppression-equipped tools.
  • DON'T eat, drink, or smoke in dusty areas without washing hands first.

See also: Respirable Crystalline Silica (RCS) | On-Tool Extraction Systems
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