Silica Exposure Control Plan Template — OSHA 1926.1153
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A written Silica Exposure Control Plan template aligned to OSHA 29 CFR 1926.1153 — the construction respirable crystalline silica standard. Every construction employer whose workers cut, grind, drill, demolish, mix, or otherwise disturb concrete, masonry, stone or any silica-containing material is legally required to maintain one. Built around Table 1 specified exposure control methods, the competent person designation, exposure assessment (objective data or performance/scheduled monitoring), respiratory protection program, housekeeping rules, and medical surveillance trigger.
Designed for: US construction GCs, concrete cutters, masons, demo contractors, drilling subs, abrasive blasters, tile setters, finishers and any employer with workers on silica-disturbing tasks
US (JSA) example document — Roof Tear-Off & Re-Cover — 482 Sandalwood Drive, Boise. Client: Sandalwood Homeowners Association. Site: 482 Sandalwood Drive, Boise, ID 83702. Scope: Tear-off of 2,400 sq ft of 3-tab asphalt shingles, replacement of damaged decking, installation of ice-and-water shield, synthetic underlayment and GAF Timberline HDZ architectural shingles. Works programmed over 6 working days with a crew of 4 roofers and 1 ground operative.
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Complete Guide to Silica Exposure Control Plan (US)
What is a Silica Exposure Control Plan?
A Silica Exposure Control Plan (ECP) is the written, employer-specific document required by OSHA 29 CFR 1926.1153(g) for every construction employer whose workers are engaged in tasks that disturb materials containing respirable crystalline silica. The plan identifies the silica-generating tasks, the specified exposure control methods (Table 1) or the alternative exposure assessment used for each task, the engineering controls and work practices, the respiratory protection required, the housekeeping rules, the procedures to limit access to high-exposure areas, and the designated competent person responsible for implementation.
When is it legally required?
OSHA 1926.1153 applies to all occupational exposures to respirable crystalline silica in construction. That means any work activity that cuts, grinds, drills, chips, breaks, mills, mixes, scrapes, or sweeps concrete, mortar, brick, stone, tile, asphalt-containing aggregate, terrazzo, sand or any material containing crystalline silica. The Permissible Exposure Limit (PEL) is 50 µg/m³ over an 8-hour TWA, with an Action Level of 25 µg/m³. The standard has been fully in effect for construction since June 23, 2017. Federal OSHA and state-plan OSHAs all enforce.
Who is responsible?
The employer must designate a competent person — capable of identifying existing and predictable silica hazards in the workplace and authorised to take prompt corrective action — to make frequent and regular inspections of job sites, materials and equipment to implement the written ECP. The competent person is typically a safety manager, project safety lead, or qualified foreman with formal training on the silica standard. The plan must be reviewed at least annually and updated whenever conditions change.
Where is it commonly used?
Every active US construction site involving concrete, masonry, tile, stone or aggregate work — vertical construction, tenant fit-out, demolition, civil/infrastructure, roadwork, residential renovation, restoration, swimming-pool installation, monument and headstone work. Required by OSHA across all 50 states; many state-plan OSHAs (California, Washington, Oregon, Michigan) enforce additional requirements on top of federal.
What a Complete Silica Exposure Control Plan Includes
- Employer name, plan effective date, last review date
- Designated competent person — name, training, contact
- List of all silica-generating tasks performed by the employer
- For each task: Table 1 control method OR alternative exposure assessment (objective data, performance method, scheduled monitoring)
- Engineering controls applied — water delivery, vacuum dust collection, enclosed cab
- Work practices applied — wet methods, tool selection, area restriction
- Respiratory protection: when required, what type (APF), fit testing, medical clearance
- Housekeeping rules — no dry sweeping or compressed air for silica dust where alternatives feasible
- Restricted access — how the employer keeps non-essential workers out of high-exposure areas
- Medical surveillance program — triggered for workers in respirator use 30+ days/year
- Training program — content per 1926.1153(i)
- Recordkeeping — exposure assessment, medical, training
- Plan reviewed at least annually and after change of materials, tasks, or equipment
What's included in this template
Header
Employer, plan date, competent person designation.
Silica-Generating Tasks
Inventory of every task the employer performs.
Exposure Control Method per Task
Table 1 row referenced OR alternative assessment summary.
Engineering Controls
Water delivery, vacuum dust collection, enclosed cab — by task.
Work Practices
Wet methods, tool selection, area restriction.
Respiratory Protection
When required, what type, fit testing, medical clearance.
Housekeeping
No dry sweeping or compressed air where wet/HEPA alternatives are feasible.
Restricted Access
How non-essential workers are kept out of high-exposure areas.
Medical Surveillance
Trigger (30+ days/year respirator), what's offered, frequency.
Training Program
Content per 1926.1153(i)(2), records.
Recordkeeping
Exposure assessment, medical, training retention.
Plan Review
Annual review date, version history, trigger reviews.
US Requirements and Best Practice
Legal expectations
- ● Written Exposure Control Plan — 1926.1153(g)(1)
- ● Designated competent person making frequent and regular inspections — 1926.1153(g)(4)
- ● Permissible Exposure Limit 50 µg/m³ 8-hr TWA; Action Level 25 µg/m³ — 1926.1153(c)
- ● Table 1 specified exposure control methods OR exposure assessment — 1926.1153(c)(1)/(d)
- ● Respiratory protection program where respirators required — 29 CFR 1910.134
- ● Restrictions on dry sweeping and compressed air for silica dust — 1926.1153(f)
- ● Medical surveillance for workers required to use a respirator 30+ days/year — 1926.1153(h)
- ● Training meeting 1926.1153(i)(2) elements
- ● Plan review at least annually — 1926.1153(g)(3)
- ● Recordkeeping per 1926.1153(j)
What inspectors typically look for
- ● Is the written ECP on site (not in a corporate office somewhere)?
- ● Does the plan name an actual competent person who is on the project?
- ● Is the task being observed listed in the plan with a Table 1 control method or documented exposure assessment?
- ● Is the engineering control actually working — water flowing, vacuum running, HEPA filter intact?
- ● Are workers using the correct respirator (per Table 1 or the assessment) with current fit testing?
- ● Has the employer enrolled qualifying workers in medical surveillance?
- ● Is dry sweeping or compressed air being used where wet methods or HEPA vacuum are feasible alternatives?
- ● Are training records on file for every worker performing silica-disturbing tasks?
Common compliance mistakes
- Generic 'silica policy' downloaded from the internet, no Table 1 reference
- Competent person named but never on site, or has had no silica-specific training
- Task being performed not in the plan at all (mid-project scope addition)
- Table 1 control method listed but engineering control not in use (saw running dry, vacuum disconnected, HEPA filter clogged)
- Wrong respirator for the task (APF 10 half-mask where Table 1 requires APF 25 PAPR)
- Workers using respirators 30+ days/year never enrolled in medical surveillance
- Dry sweeping with broom or compressed air to clean up silica dust at end of shift
- Plan never reviewed since 2017 publication — no record of annual review
- Training is a 5-minute toolbox talk — doesn't cover 1926.1153(i)(2) elements
Example Use Cases
5-person concrete cutting crew, tenant fit-out, downtown
Crew running walk-behind saws and handheld grinders for slab scoring and infill cutting. ECP designates the foreman as competent person. Each task mapped to Table 1: walk-behind saw uses continuous water (Table 1 entry, no respirator required indoors with adequate make-up air); handheld grinder uses tool with integrated water + HEPA vacuum (Table 1 entry, half-face P100 required for tasks longer than 4 hours). Restricted access boundary marked around the cut. Workers receive 1926.1153(i)(2) training before first task. No dry sweeping — HEPA vacuum and wet cleanup only.
Masonry restoration, historic facade, Northeast
Restoration mason tuckpointing 100-year-old brick. Task uses Table 1 specified control: handheld grinder with integrated water delivery and HEPA-filtered dust collection, with APF 10 half-face respirator for outdoor work less than 4 hours per shift. Competent person verifies water flow and vacuum function at start of shift and after every blade change. Medical surveillance enrolled because the mason uses respirator more than 30 days per year. Annual silicosis screening through occupational health provider.
Demo contractor, slab break-out, garage retrofit
Crew using hoe-rams and handheld breakers to remove slab in an underground garage with limited ventilation. Because Table 1 does not adequately cover the specific combination (enclosed environment, prolonged duration), employer uses the alternative exposure assessment method with objective data from a similar prior project, supplemented by area air monitoring on the first day. Engineering controls: water mist + portable HEPA air scrubbers. Respiratory protection: PAPR with HE filters (APF 1000) given enclosed conditions. Restricted access enforced with hard barriers and signage.
How to use this template
- 1
Inventory your silica-generating tasks
List every task the employer performs that disturbs concrete, masonry, stone, mortar, brick, tile or any silica-containing material. Be specific to actual scope, not generic.
- 2
Match each task to Table 1
Table 1 of 1926.1153 lists 18 common construction tasks with specified engineering controls, work practices and respiratory protection. Follow the Table 1 row and you don't need to perform your own exposure assessment.
- 3
If Table 1 doesn't fit, do an exposure assessment
Use objective data (published industry data or prior monitoring) OR the performance/scheduled monitoring method to characterise exposure for the task.
- 4
Implement engineering controls
Water delivery on the cut, HEPA-vacuum dust collection on grinders, enclosed cab on heavy equipment. The control must actually be working when the task is performed.
- 5
Select respiratory protection
Match APF to the assessment or Table 1 requirement. Fit testing, medical clearance, training per 1910.134.
- 6
Designate a competent person
Trained, authorised to take prompt corrective action, on the project and making frequent regular inspections.
- 7
Enrol workers in medical surveillance where required
Triggered for workers required to use a respirator under 1926.1153 for 30 or more days per year.
- 8
Restrict access to high-exposure areas
Barriers, signage, only essential workers admitted, all admitted workers using required respiratory protection.
- 9
Train workers per 1926.1153(i)(2)
Health hazards, specific tasks, engineering controls and work practices, medical surveillance program, contents of the standard. Records retained.
- 10
Review annually
Update when materials, tasks or equipment change. Document the review.
Common mistakes to avoid
- Generic 'silica policy' with no Table 1 reference
- Competent person named but not on site or untrained on silica
- Task being performed not in the plan at all
- Engineering control listed but not in use (saw running dry, vacuum disconnected, HEPA clogged)
- Wrong respirator for the task (half-mask where Table 1 requires PAPR)
- Workers using respirators 30+ days/year never enrolled in medical surveillance
- Dry sweeping or compressed air for silica dust cleanup
- Plan never reviewed since publication — no annual review record
- Training is a brief toolbox talk that doesn't cover 1926.1153(i)(2) elements
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Why templates have limitations
Templates provide a solid starting point, but they require manual editing to match your specific site conditions, hazards, and work activities. This can be time-consuming and important site-specific risks may be missed if sections are left generic.
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