Wood Dust in Manufacturing: How a Timber Workshop Reduced Risk and Improved Compliance

Sysco Environmental Ltd was commissioned to assess worker exposure to wood dust at a prominent manufacturing facility producing bespoke timber conservatories and orangeries. The multi-workshop site included CNC machining, assembly lines, sanding bays, and a timber mill.

As both hardwoods and softwoods were in use across the site, the assessment applied the stricter Workplace Exposure Limit (WEL) for hardwood dust in all areas, in line with EH40/2005 guidance. The purpose of this study was to measure employee exposure, evaluate control measures, and issue practical recommendations to ensure compliance with COSHH regulations.

Understanding the Risks: Wood Dust in Manufacturing

Wood dust is generated in high volumes during cutting, sanding, routing, shaping, and brushing. Manufacturing environments with high throughput and variable materials pose increased risk of uncontrolled exposure.

Health Effects of Wood Dust

• Acute exposure: Eye and skin irritation, persistent cold symptoms, nasal dryness.

• Chronic exposure: Respiratory sensitisation, asthma, and dermatitis. Hardwood dust is a Group 1 carcinogen, known to cause nasal and sinus cancers with long-term exposure.

Even non-exceeding exposure levels above 10% of WEL are considered significant for sensitising and carcinogenic substances under COSHH and must be reduced to ALARP (As Low As Reasonably Practicable).

Air Monitoring Results

Any exposure above 10% of the 2 mg/m³ limit for hardwood dust is considered significant for health surveillance and must be controlled. Levels above 100% indicate an exceedance of legal limits.

Key Site Observations

• Ineffective LEV systems on several tools, including DeWalt circular saws and spindle moulders.

• Compressed air was used for cleaning CNC equipment—generating avoidable dust clouds.

• Leaf blowers were used for general cleaning, dispersing settled dust into the air.

• RPE was available but not consistently used, and face-fit testing was not universal.

• Some sanding tools lacked compatible adaptors for on-tool LEV integration.

Control Measures Recommended

• Replace compressed air cleaning with HEPA-filtered vacuum systems or wet methods.

• Upgrade LEV systems and fit air flow indicators to ensure effectiveness.

• Introduce mandatory RPE zones and conduct regular face-fit testing.

• Implement a formal wood dust health surveillance programme for all exposed staff.

• Conduct regular COSHH refresher training for operatives handling hardwoods or sanding activities.

• Improve housekeeping protocols to eliminate dry sweeping and dusting.

Interesting Industry Insight

Did you know?
The UK woodworking industry employs over 90,000 people, and woodworking dust is one of the most commonly cited causes in occupational asthma claims. In bespoke manufacturing operations, where attention to detail means extended contact with surfaces, exposure can be especially pronounced—particularly during sanding and finishing.

Conclusion

The assessment at this bespoke manufacturing site revealed significant and, in some cases, excessive exposure to hazardous wood dust. While local extraction and general cleaning were present, several control gaps allowed airborne dust concentrations to exceed safety limits.

Sysco Environmental Ltd provided targeted, legally grounded recommendations to improve worker protection, enhance COSHH compliance, and reduce long-term health risks. With follow-up monitoring and implementation of controls, the facility can achieve a safer, healthier work environment for all operatives.