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November 2019

Controlling dust with

on-tool extraction

This guidance advises PCBUs how to choose, use and maintain

an on-tool extraction system to control dust.

Some of the most common construction and

manufacturing jobs create high levels of dust.
These jobs often involve the use of power tools
like cut-off saws, grinders, polishers, breakers
and sanders.

As a PCBU, you have a duty to complete a risk

assessment. You also have a duty to eliminate risks.
If this is not reasonably practicable, use the hierarchy
Direction
of controls to minimise the risk of dust exposure
Suction hose of air flow
to workers.

Risks presented by breathing in dust

FIGURE 1: On-tool extraction
Regularly breathing in dust can cause diseases like:
–– lung cancer Each part is critical to the system’s effectiveness and
–– asthma level of dust control.
–– chronic obstructive pulmonary disease Complete on-tool extraction systems are available but
(COPD, including emphysema and other some parts (especially extraction units) can be used
breathing difficulties) with other tool makes and models.
–– silicosis (including accelerated and acute silicosis).
For effective dust control, it’s important to choose
parts that are compatible. Involve workers in selecting
Choosing an on-tool extraction system a system that’s right for the task.
On-tool extraction is a type of local exhaust ventilation
(LEV) system which is fitted directly onto the tool. Tools and accessories
The system has several parts: Limit the amount of dust created by choosing appropriate
–– the tool tools and accessories. Choose sanding blocks/pads or
–– captor hood grinding discs with enough holes to allow dust to be
extracted through them.
–– extraction unit, and
–– hoses.
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Captor hood –– Ensure the unit is emptied regularly and safely.
See ‘During use’ below for more information.
The hood captures the dust as it’s produced and is
–– Check that the unit has enough waste capacity
the most important part of the LEV system. It’s often
for the task.
manufactured as part of the power tool but can also
be retro-fitted to existing equipment.
Hoses
HOW TO CHOOSE THE RIGHT ONE Hoses connect the captor hood to the extraction unit.
Poor design or damage to the hood will significantly
affect dust control. Check that the hood: HOW TO CHOOSE THE RIGHT ONE
–– is designed for the tool and the task (seek guidance Check that the hose:
from the manufacturer or supplier) –– is the right construction, diameter and length for
–– sits as close as possible to the work surface when the work and the extraction unit
in use, as dust will escape through any gaps –– fits securely to the hood and the extraction unit.
–– is easy to use and doesn’t interfere with the
work unnecessarily.
Using an on-tool extraction system
Extraction unit Providing the right equipment isn’t enough to control
dust risks. The equipment must also be operated
The extraction unit is like an industrial vacuum. correctly and be properly maintained. Pay particular
It removes dust from the captor hood, filters it, attention to each stage as follows:
and collects it for safe disposal. Selecting the right
extraction unit is key to successfully controlling dust.
Before use
HOW TO CHOOSE THE RIGHT ONE PROVIDE TRAINING FOR WORKERS
Extraction units can be used interchangeably on some Workers must have the right information, training,
tools but the unit must be suitable for the tool and the task. instruction or supervision before using on-tool
extraction. This includes information about:
–– The extraction unit should be suitable for the
toxicity level and hazardous nature of the dust being –– selecting the right on-tool extraction system
extracted, as well as its size and type. Manufacturers –– pre-use checks
of construction material can advise whether the dust –– ongoing maintenance
produced by their products is classified as L (Low),
–– how to use the system correctly
M (Medium), H (High) class or non-hazardous.
-- L class – dust representing a low risk –– other controls that may be needed (eg respiratory
protective equipment and how to use/fit it properly)
-- M class – dust representing medium risk
–– common faults, how to spot them, and the action
-- H class – dust representing high risk.
to take
–– Extraction units that conform to these classifications
–– what to do if there’s a problem.
provide effective and certified extraction and
containment of hazardous dust. They have special
labels, operators’ manuals and, where applicable,
During use
low-airflow alarms and additional features for dust FOLLOW OPERATING INSTRUCTIONS
containment and disposal. Make sure the extraction unit is used in the right way:
–– FOR CRYSTALLINE SILICA DUST (known to –– Before work starts, check the unit is undamaged and
cause cancer): Use an H-class vacuum cleaner in in good working order.
accordance with Standard AS/NZS 60335.2.69, fitted –– Ensure sufficient consumables are available including
with a filter that can achieve an efficiency of 99.995% filters, filter bags and disposal bags.
(eg H14 HEPA filter complying with Standard AS 4260).
–– Ensure workers follow the agreed methods of work
This includes working in someone’s home (eg to fit a
and the manufacturer’s instructions.
bench). Workers should not use a household vacuum
cleaner to remove this dust. –– Ensure the captor hood is as close as possible to the
work surface.
–– Check that the extraction unit creates and maintains
enough air suction to cope with the amount of dust –– Ensure the tubing is securely connected to the captor
created (manufacturers and suppliers can advise) – hood and extraction unit. Use an adaptor if needed.
it needs to remove the dust as fast as it’s created. Do not use tape.

–– Lots of fine dust can quickly clog filters. Choose

a unit with pre-filters, built-in ‘back-flushing’ filter
cleaning mechanisms, or similar devices.

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–– The unit should be emptied regularly: More information
-- use the correct disposable waste bags
8 key things for workers to know:
-- bags should be sealed and placed in Controlling silica dust in the workplace
the correct waste container
-- if bags are designed for single use, Safety alert
do not empty them to recycle them Accelerated silicosis
–– If the unit has a refillable container (instead
of using bags), make sure to control your Quick guide
exposure to the dust when emptying it. Silica dust in the workplace
–– Clean the unit regularly. Wipe it down daily.
Do not use compressed air to clean the unit. Standards
–– Do not let dust build up on working parts. AS/NZS 60335.2.69 Household and similar electrical
appliances – Safety particular requirements for wet
and dry vacuum cleaners, including power brush, for
Maintaining an on-tool extraction system
commercial use
Regular checks/maintenance AS 4260 High efficiency particulate air (HEPA) filters
Ensure that the system works properly every time. – Classification, construction and performance
It is good practice to carry out regular maintenance
checks at least once a week, and record the results.
You may have to do checks more frequently if there’s
a high risk of the equipment being damaged.

Focus on:
–– damage to parts such as the hood or ducting.
Repair or replace damaged parts straight away
–– maintaining the extraction unit’s airflow:
-- follow manufacturer’s instructions
-- check that the airflow indicator and any
built-in cleaning mechanisms work properly
-- replace filters when needed
–– replacing worn cutting discs.

Inspection and testing

Equipment needs proper servicing and testing to
ensure it remains effective. For more information,
contact the manufacturer or supplier, or ventilation
engineers or occupational hygienists, if you’re unsure.

Cordless tools
The general principles of the above standards also
apply to cordless tools with integrated filtered extraction
devices. However, these units don’t fall under the L, M
or H classification system, so their suitability should be
checked with the manufacturer before using them to
extract dust.

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