Research reveals failures in tunnelling dust control and safety

by Chief Editor

Beyond the Slogan: The Battle Between Production and Protection

For decades, the construction and tunneling industries have operated under a paradox: a public-facing commitment to “safety first” paired with an internal drive for production at any cost. For workers like Hamish Studholme, a veteran tunneller, this gap between rhetoric and reality has had devastating consequences.

Studholme, who worked on major Sydney projects including the Lane Cove Tunnel, Rozelle Interchange and Western Harbour Tunnel, was diagnosed with silicosis—an incurable lung disease caused by inhaling crystalline silica dust. His experience highlights a systemic issue where production targets often override safety protocols.

The future of industrial safety depends on moving away from what researchers describe as “symbolic or performative” safety cultures. When the pressure to keep tunneling outweighs the implementation of dust control, the result is a latent public health crisis.

Did you know? Research has indicated that more than one in 10 tunnellers on three major projects are at risk of developing a deadly lung disease in their lifetime.

The Regulatory Gap: Why Surprise Inspections Matter

A critical trend emerging in occupational health is the demand for more rigorous, unannounced regulatory enforcement. Current systems are under fire for being too predictable, allowing employers to temporarily modify worksite conditions before inspectors arrive.

From Instagram — related to The Regulatory Gap, Kate Cole

Research conducted by Kate Cole, a PhD candidate at the University of Sydney, found that nearly half of surveyed industry stakeholders do not believe regulators are effective in promoting safe practices. This perceived failure in accountability creates an environment where safety measures are bypassed to meet deadlines.

To prevent further diagnoses, the industry must shift toward a model of “constant compliance.” This involves removing the “advanced notice” of inspections and treating tunneling hazards with the same severity as those found in mines and quarries.

Expanding the Scope: From Engineered Stone to Industrial Tunnelling

Recent policy wins, such as the widespread bans on engineered stone, indicate that legislative action can effectively eliminate silica risks. However, a dangerous blind spot remains: other high-exposure environments, particularly large-scale infrastructure projects.

The scale of the problem is immense. A 2022 forecast from Curtin University suggested that up to 103,000 Australians could develop silicosis due to workplace silica exposure. Whereas the focus has been on benchtops, the tunneling sector presents a similar, if not greater, risk.

The trend moving forward will likely involve a broader definition of “high-risk silica work,” forcing contractors to implement stringent dust mitigation strategies across all sectors, not just those involving engineered stone.

Pro Tip for Site Managers: Effective dust control isn’t just about providing PPE; it requires a top-down commitment where production schedules are adjusted to allow for proper ventilation and cleaning protocols without penalizing the workforce.

The Legal Tide: Accountability for Incurable Diseases

We are entering an era of increased legal accountability. As more workers are diagnosed with silicosis, the trend of suing former employers for medical costs and loss of earnings is expected to rise. Experienced tunnellers can earn upwards of $250,000 per year, making the financial stakes of these lawsuits significant.

Air Quality: Dust Control Research

The case of the M6 Stage 1 tunnel—where 13 workers, including a 32-year-old, were diagnosed with the disease since late 2021—serves as a warning. When “knowledge gaps” are replaced by evidence of “leadership failure,” the legal protections for contracting companies weaken.

Industry experts, including lawyers from Maurice Blackburn, argue that these findings should serve as a clarion call. The shift toward litigation is not just about compensation; it is a mechanism to force employers to prioritize health over profit.

Frequently Asked Questions

What is silicosis?

Silicosis is an incurable lung disease caused by the inhalation of tiny particles of crystalline silica dust, which scar the lungs and make breathing increasingly challenging.

What is silicosis?
Research Silicosis

Why is tunneling particularly risky?

Tunneling often involves cutting through rock and concrete, which releases high levels of respirable crystalline silica. If ventilation and dust suppression are inadequate, workers inhale these particles over long periods.

Can silicosis be treated?

Silicosis is incurable. Treatment focuses on managing symptoms and slowing the progression of the disease, but the lung damage it causes is permanent.

What are the main barriers to dust control in construction?

According to research, the primary barriers include intense time pressures to meet production deadlines, a lack of genuine commitment from management, and weak regulatory enforcement.

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