Concrete-Natural Stone Bench-top Installation Safe Work Method Statement

Dry cutting of engineered stone is prohibited in South Australia under specific regulations prohibiting manufacture and supply of engineered stone products from 2024, with other states implementing strict controls that effectively prohibit dry cutting through occupational exposure limits that cannot be met without wet cutting. While not universally prohibited by name in all jurisdictions, SafeWork authorities universally require that employers eliminate or minimise silica exposure so far as is reasonably practicable. Given that dry cutting generates silica dust concentrations exceeding the workplace exposure standard of 0.05 mg/m³ by 100+ times, it is considered not reasonably practicable to use dry cutting methods when wet cutting technology is readily available, affordable, and highly effective. SafeWork authorities have issued prohibition notices and undertaken prosecutions against stone businesses using dry cutting methods. Best practice and regulatory compliance requires wet cutting with continuous water suppression for all cutting, grinding, and drilling of engineered stone and natural stone materials. If unforeseen circumstances require cutting where wet methods genuinely cannot be implemented, extreme additional controls are required including complete isolation enclosures, supplied-air respiratory protection, air monitoring, and health surveillance - making dry cutting impractical and inadvisable in virtually all situations.

For stone benchtop installation work involving cutting, grinding, drilling, or polishing, P3 respirators providing 99.95% filtration efficiency are required as best practice given the extreme silica content of engineered stone (90-95%) and many natural stones. P2 respirators offering 94% filtration may be used for lower-risk activities such as installation without cutting, or for cleanup operations, but P3 provides superior protection for high-dust activities. Respiratory protection must be fitted to individual workers through quantitative or qualitative fit-testing to ensure adequate seal and protection factor. Disposable P3 respirators should be replaced after each use session or when breathing resistance increases. Reusable half-face respirators require replacement of P3 filters according to manufacturer schedules, typically after 40+ hours of use or when resistance increases. Full-face respirators providing P3 filtration plus eye protection are appropriate for heavy-duty fabrication work with sustained dust exposure. Workers must be clean-shaven in seal areas as beards prevent effective seal and compromise protection. All workers requiring respirators should receive respiratory protection training covering donning, fit-checking, use, maintenance, and storage. Respiratory protection is essential even when wet cutting and dust extraction are used, as these controls reduce but do not eliminate all dust. Health surveillance including baseline and periodic lung function testing and chest X-rays should be implemented for all workers with regular silica exposure.

Australian WHS legislation does not specify absolute weight limits for manual handling, instead requiring that risks be eliminated or minimised so far as is reasonably practicable. However, practical guidance suggests single-person lifting should not exceed 15-20 kg for frequent lifting, with team lifting used for heavier loads. For stone benchtop installation, the critical issue is that full benchtop slabs weighing 100-300 kilograms far exceed safe manual handling capacity regardless of team size. Stone slabs are awkward loads with limited grip points, smooth surfaces, and extreme weight concentrated in thin brittle sections prone to fracture if stressed. The Australian Code of Practice for Hazardous Manual Tasks emphasizes that if mechanical aids are available and practicable to use, they must be implemented in preference to manual handling. Vacuum lifters, A-frame trolleys, and other stone handling equipment are readily available, affordable, and standard practice in the stone industry, making manual handling of full slabs not reasonably practicable. For stone offcuts and smaller pieces, team lifting with minimum two persons should be used for pieces exceeding 25 kg, with three or more persons for heavier sections. Always assess manual handling risk before lifting considering weight, size, shape, grip points, distance to carry, presence of obstacles, and individual capability. When in doubt, use mechanical aids rather than risking serious back, shoulder, or crush injuries from attempting manual lifting of heavy stone materials.

Stone benchtop installation does not require specific trade licences in most Australian jurisdictions, unlike electricians or plumbers who need occupational licences. However, workers must hold a Construction General Induction Card (White Card) obtained by completing the CPCWHS1001 unit, which is mandatory before commencing any construction work. If using elevating work platforms (EWPs) for access in commercial installations, operators must hold a High Risk Work Licence for the specific class of EWP being used (typically WP class for boom lifts over 11 metres). If work involves operating mobile cranes to lift stone slabs on large commercial projects, crane operators must hold appropriate High Risk Work Licence for the class of crane. If installation requires cutting, core drilling, or other power tool use, workers should complete appropriate training though specific licencing is not required. Supervisors and business owners should consider undertaking Certificate III in Stonemasonry, Certificate III in Solid Plastering, or related qualifications to demonstrate competency, though these are not legally required for benchtop installation. All workers must be trained in the specific work activities they perform including manual handling, use of vacuum lifters and mechanical aids, silica dust controls, PPE use, and emergency procedures. Training should be documented with competency assessment confirming workers can safely perform tasks. Some commercial and government clients may require demonstration of qualifications, training records, and safety management systems as part of tender or contract requirements.

Stone benchtop fabrication waste including offcuts, dust, and slurry from wet cutting must be disposed appropriately, with some materials classified as hazardous waste in certain jurisdictions due to silica content. In South Australia, stone fabrication waste is classified as hazardous waste requiring disposal through licensed facilities and specialized tracking documentation. In other states, classification varies with waste generally accepted in construction and demolition waste facilities or specialized masonry waste facilities. Contact your state EPA or local waste authority for specific requirements. Stone offcuts larger than approximately 300mm x 300mm may have salvage value and can be sold or retained for small projects, repairs, or sample production. Smaller offcuts should be collected and disposed to appropriate facilities - never general household waste collection in residential areas. Stone dust and slurry from wet cutting operations should be collected in settlement tanks or filter bags, allowed to solidify, and disposed as solid waste to designated facilities. Never wash stone slurry down stormwater drains as the fine particles cause blockages and environmental contamination. Dried dust should be collected using HEPA-filtered vacuum equipment, with vacuum bags disposed as waste in sealed plastic bags to prevent dust release. Never use compressed air to clean stone dust which creates severe airborne exposure. Waste transport, if quantities exceed household volumes, may require licensed waste transporters depending on classification in your jurisdiction. Maintain records of waste disposal including facility receipts, waste tracking documentation if required, and contractor details demonstrating compliance with waste regulations.