UK trade-and-hazard guidance by the Riskora Editorial Team
Cutting brick, block and stone with a disc cutter generates respirable crystalline silica (RCS) at concentrations that routinely exceed the UK Workplace Exposure Limit of 0.1 mg/m³ within seconds. The HSE has flagged construction silica exposure as a long-term killer — silicosis, COPD and lung cancer cases continue to climb. A bricklayer's RAMS that names 'dust mask' as the control is years out of date and will fail any post-2020 principal-contractor review. The current standard is on-tool water suppression plus M-class extraction, supplemented by an FFP3 mask only as a back-up.
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Control of Substances Hazardous to Health Regs 2002 (COSHH)
Regulations 6 & 7
Substances that can cause harm — including RCS — must be assessed and exposure prevented or, where prevention is not reasonably practicable, adequately controlled. The hierarchy in Reg 7(7) puts engineering controls above PPE.
HSE Workplace Exposure Limit (EH40)
RCS — 0.1 mg/m³ (8-hr TWA)
Exposure must be measured or modelled against the WEL. A blanket statement of compliance is not enough — the assessment basis must be in the RAMS.
Personal Protective Equipment at Work Regs 1992 (as amended 2022)
Regulation 4
RPE must be face-fit-tested to the wearer (Fit2Fit or equivalent), with records kept. Stubble/beard wearers must use a powered hood.
Every UK RAMS reviewer applies the hierarchy of controls in the order below. Defaulting straight to PPE is the single most common reason a RAMS fails review.
1. Eliminate
Order pre-cut bricks and blocks to coursing dimensions from the supplier. Use brick saws in an enclosed cutting bay rather than free-cutting on site.
2. Substitute
Substitute disc cutting for brick splitters or guillotines on standard cuts — zero dust generation.
3. Engineering controls
On-tool water suppression to all disc cutters (manufacturer-rated flow rate, not a garden mister). M-class extraction at the cutting station. Local exhaust ventilation with HEPA filtration in cutting bays.
4. Administrative controls
Designated cutting bay located downwind of working positions. Wet sweeping or M-class vacuum only — no dry brushing. Toolbox talk on COSHH risk and FFP3 fit.
5. PPE (last line)
FFP3 disposable mask (or powered hood for facial-hair wearers), face-fit certificate on file, eye protection, gloves.
Specifying 'FFP2 dust mask' or 'general purpose mask' as the primary control. RCS requires FFP3 minimum, fit-tested to the wearer, and only as a back-up to engineering controls. RAMS that miss the engineering hierarchy are routinely rejected by Tier 1 PCs.
An illustrative extract structured for principal-contractor review. Site-specific facts must be substituted and checked by a competent person.
All disc cutting will be performed in the designated cutting bay located 10m downwind of the working line. The bay is fitted with M-class LEV (Camfil HE-rated, 1500 m³/h) and on-tool water suppression to the manufacturer's flow rate (Stihl TS500i + Stihl water kit, 0.6 l/min minimum). Operatives are FFP3 fit-tested (3M 8835+, certificate ref RIS-BFT-2026-018). Dry sweeping is prohibited — all clean-down by M-class vacuum or wet wiping. Daily LEV check logged on inspection sheet.
Pre-shift LEV airflow check. Water suppression flow check (visual confirmation of wet cut). Fit-test certificate cross-check at sign-on. Annual LEV thorough examination (TExT) under COSHH Reg 9.
Is an FFP3 mask alone enough for silica?
No. Under COSHH Reg 7(7), engineering controls (water suppression and LEV) must be applied first. RPE is the back-up only. Relying on a mask alone is a classic enforcement target for HSE inspectors.
How long does a face-fit certificate last?
Best practice is annual re-testing, or whenever facial features change (weight loss, dental work, beard growth). Many principal contractors enforce a 12-month cycle as a contractual requirement.
Does cutting concrete block produce silica?
Yes — dense concrete blocks contain 10-30% silica by mass; aerated blocks can be lower but still produce respirable particles. All cementitious cutting must be treated as silica-generating.
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