Why mining companies are wasting resources on silica compliance - and how to fix it

The recent update to the silica rule has sent mining companies into high gear as they scramble to meet the new permissible exposure limit (PEL) for respirable crystalline silica. 

With the April 2025 deadline fast approaching for coal facilities, safety and health leaders are under pressure to ensure that their operations fall below the 50 µg/m³ permissible exposure limit, calculated as an 8-hour time-weighted average (TWA). 

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Lack of exposure data leads to guesswork and expensive controls

One of the biggest challenges facing companies is the lack of detailed data on what’s driving overexposure. Most rely on shift-average sampling, which gives a general sense of exposure levels, but not the granular detail needed to identify the root causes. 

Is it a particular process causing a spike in silica dust? Employee behavior? Or maybe a malfunction in dust control systems? 

The current one-size-fits-all approach to data collection leaves safety leaders guessing, resampling, and guessing again.

When companies implement engineering controls based on shift average samples, they risk either of two outcomes.

1. Success at a high cost: The controls reduce exposure, but they’re likely more than what’s necessary. While the dust problem is solved, it comes at a steep price that may have been avoidable with more specific data.
2. Back to square one: Sometimes, the controls don’t fix the issue. You’ve spent time and resources on solutions that don’t work, and now you’re not only out the money but also dangerously close to missing the compliance deadline.

Small, inexpensive fixes can be a game-changer

Here’s the good news: we’ve worked with many mining operations that have managed to meet the new PEL with surprisingly small, inexpensive changes.

A common culprit? Dry sweeping and compressed air. These activities stir up a lot of dust and can quickly push exposure levels beyond the allowable limits.

Sometimes, a simple adjustment in employee training or behavior modification—such as eliminating dry sweeping in favor of vacuuming —can have a dramatic impact on reducing exposure.

Focusing on these more minor fixes not only brings exposure levels down, but does so without derailing budgets or operations.

How to identify the root cause of over-exposures using data

The key to finding these smaller fixes lies in having the right data. Traditional shift-average sampling leaves you guessing at what’s happening over the course of the day. But with real-time, minute-by-minute data, you can pinpoint exactly when and why exposure levels spike.

Our wearable sensors stream dust data continuously to the cloud, capturing a range of sizes simultaneously. You get detailed measurements throughout the shift, allowing you to build a cumulative timeline where you can visualize how quickly exposures rise and fall. 

With body cam footage or in-app notes, you can add crucial context to the exposure—so when you see an exposure spike, you’ll know whether it was caused by a specific task, equipment failure, or employee action.

Instead of guessing which part of your operation is causing the problem, you can now see exactly when exposure spikes occur and what’s driving those silica exposure spikes.

“With shift average samples, we don't know what's contributing to exposures. But using APT's real-time particulate monitoring, we're able to understand which tasks contribute the most to their exposure, and justify with data where we need to put our money and effort.”- Health & Hygiene Manager
Leading Canadian mining company

Another bonus? You can set up stationary zone monitoring to keep workers out of high-exposure areas. This prevents unnecessary exposures before they happen, and it also allows you to catch failing engineering controls before the issue becomes visible.

Leaders are already using data for silica compliance— it’s time to act

Forward-thinking companies are already using granular data to manage their silica exposure and ensure compliance with the new rule. By adopting these technologies, they’ve moved beyond guessing and into a data-driven approach that delivers results without over-engineering solutions.

With the compliance deadline fast approaching, now is the time to act. Don’t wait until the final hour—leverage the power of real-time data to find the right solutions, avoid unnecessary costs, and meet the new PEL well before the deadline.

Watch our video demo or contact us to discuss your application with our air quality experts.