MSHA’s New Silica Rule Is Here—Is Your Mine Prepared?

MSHA has officially rolled out its long-anticipated silica rule, setting stricter exposure limits, requiring more rigorous monitoring, and tightening compliance standards. Ensure your operation is ready—our experts are here to help.

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Stronger Silica Standards: Keeping Your Miners Safe

The Mine Safety and Health Administration (MSHA) has introduced its Silica Final Rule—Lowering Miners’ Exposure to Respirable Crystalline Silica and Improving Respiratory Protection—under 30 CFR Part 60. This new “super rule” creates a unified framework that strengthens and consolidates previous respirable crystalline silica standards from Parts 56, 57, 75, and 77. Its goal: to reduce exposure to silica dust and lower the long-term health risks it poses to miners.

Mine operations must stick to a set exposure limit of 50 micrograms per cubic meter of air (μg/m³), averaged over an 8-hour shift. Along with this exposure cap, the rule requires sites to put dust prevention steps in place, check exposure, and provide full medical checks for workers. What will your mine operation need to do to stay compliant?

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Understanding MSHA’s Part 60 Silica Rule

Silica dust exposure has been a growing concern in the mining industry for decades, and this final rule is a direct response to the rising cases of silicosis, a lung disease caused by inhaling fine silica particles. Ultimately, these stricter standards aim to protect workers and hold operators accountable.

But this process can be overwhelming: more inspections, more paperwork, and bigger penalties. Mine operators must not only understand the new requirements–but quickly take action. Non-compliance is not an option, and it’s time to start preparing.

Enforcement is coming fast

  • Metal and nonmetal mines must comply by April 8, 2026.

  • Coal mines have until August 18, 2025—a four-month extension from the original April 14 deadline—to implement engineering controls, but must still meet exposure limits immediately. (Note: A temporary enforcement pause was issued on April 8, 2025.)

Key Compliance Requirements

To comply with MSHA’s silica rule, mine operators must implement a range of new health and safety measures:

    New Silica Exposure Limits

    MSHA has established a uniform permissible exposure limit (PEL) and an action level for all mines:

    • PEL: 50 µg/m³ over an 8-hour shift

    • Action Level: 25 µg/m³ over an 8-hour shift (triggers additional safety measures)

      Mandatory Reporting & Corrective Actions

      • Any overexposure must be reported to MSHA immediately.

      • Operators must take corrective measures to bring silica levels within safe limits.

      • Resampling is required to confirm that corrective actions were effective.

      • Detailed recordkeeping of all sampling and corrective measures is mandatory.

      Updated Respiratory Protection Standards

      • MSHA has adopted ASTM F3387-19 standards for respiratory protection.

      • Mines must implement a written respiratory protection program that meets these new standards.

      Exposure Monitoring & Sampling Requirements

      • Regular silica sampling is required to monitor miner exposure.

      • Operators must assess mining methods, equipment, and geological conditions that impact silica levels.

      • New ISO 7708:1995(E) standards define proper particle size sampling.

      • Sampling equipment must meet international respirable particle selection standards.

      Compliance Deadlines

      •  Coal mines: Exposure limits apply immediately; engineering controls required by August 18, 2025

      • Metal & nonmetal mines: Full compliance required by April 8, 2026

      Engineering & Administrative Controls

      • Primary control method: Engineering controls (e.g., ventilation, water sprays).

      • Secondary control method: Administrative measures to reduce exposure time.

      • Respirators: Must be used if silica levels exceed the PEL until other controls are effective.

      Medical Surveillance for Miners

      • Periodic medical exams must be provided at no cost to miners.

      • Exams must be conducted by a physician or licensed healthcare provider (PLHCP).

      • Goal: Early detection of silica-related health issues before they become severe.

      Are You Ready?

      Staying compliant isn’t just about avoiding penalties—it’s about protecting your workforce.

      Schedule a Compliance Consultation Now

      Compliance with MSHA’s Silica Rule:

      What You Need to Do

      Preparing for MSHA’s Part 60  silica standard requires a proactive compliance strategy. Mining operators must take immediate action to reduce silica dust levels and protect workers from long-term health risks.

      Compliance Strategies

      ✅ Assess silica dust levels through initial and ongoing exposure monitoring.
      ✅ Implement engineering controls like ventilation, dust suppression, and wet methods.
      ✅ Provide PPE & respiratory protection when exposure exceeds safe limits.
      ✅ Maintain accurate records of monitoring, corrective actions, and compliance measures.

      Compliance Deadlines & Penalties

      MSHA has set strict compliance deadlines based on mine type and size. Failure to comply can result in:

      ❌ Fines and costly penalties
      ❌ Work stoppages that impact operations
      ❌ Legal consequences for ongoing violations

      MSHA is actively enforcing these new standards through inspections and audits. Don’t wait—ensure your site is prepared.

      Schedule a site inspection

      Need Help Preparing for the Silica Standard?

      MSHA is not waiting to enforce this silica exposure rule, and neither should you. Take proactive steps to protect your workforce and avoid penalties. Let’s get your mine 100% silica compliant today.

      Why Compliance Can’t Wait

      Enforcement is coming fast, and non-compliance comes with consequences. MSHA has signaled strong enforcement of this rule, with increased inspections, penalties, and citations for violations. Beyond regulatory risks, failing to comply could mean:

      • Costly fines – MSHA penalties can quickly add up for non-compliant operators.

      • Operational delays – Shutdowns and production interruptions due to compliance failures.

      • Health & liability risks – Long-term exposure lawsuits and increased medical claims from affected workers.

      How MSHA Safety Services Can Help

      Navigating MSHA’s silica rule is complex, but you don’t have to do it alone. Our team of MSHA Safety Experts provides:

      • Silica Exposure Assessments – We’ll conduct on-site evaluations, air monitoring, and help identify any compliance gaps.

      • Training & Certification – We’ll work with your team to make sure they understand the new requirements.

      • Engineering & PPE Guidance – We’ll offer practical solutions to keep silica exposure below the action level.

      • Recordkeeping & Audit Support – We’ll assist with submitting the proper paperwork and staying organized for MSHA audits.

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        Silica Rule FAQs

        General Rule Questions

        Why did MSHA create a new silica rule?

        The rule was created in response to rising cases of silicosis and other silica-related illnesses among miners. MSHA determined that its existing standards were outdated and insufficient to protect miners from long-term health risks posed by respirable crystalline silica.

        When does the silica final rule take effect?

        The final rule took effect on June 17, 2024, but compliance deadlines vary by mine type:

        • Coal mines must comply with the exposure limit immediately and implement engineering controls by August 14, 2025. This deadline was originally April 14, 2025, but MSHA granted a 4-month extension to allow more time to adapt.
        • Metal and nonmetal mines must be fully compliant—including controls and medical surveillance—by April 8, 2026.
        What are the new permissible exposure limits (PELs) for respirable crystalline silica?

        The new PEL is 50 µg/m³ averaged over an 8-hour shift. MSHA also established an action level at 25 µg/m³, requiring additional safety measures before the PEL is exceeded.

        How does the new silica rule differ from MSHA’s previous standards?

        The new rule lowers the exposure limit, mandates regular monitoring, requires engineering controls, updates respiratory protection standards, and introduces mandatory medical surveillance—unlike the older standards which lacked these components.

        Sampling & Exposure

        How will MSHA determine if a mine is in compliance with the silica exposure limits?

        MSHA determines compliance through full-shift personal sampling of representative groups. Operators must collect at least two samples per group, followed by another round within three months. If limits are exceeded, corrective actions and resampling are required. MSHA may also conduct its own sampling.

        What is the difference between an “exposure limit” and an “action level”?

        The exposure limit (PEL) is 50 µg/m³ over 8 hours—the maximum allowed. The action level is 25 µg/m³. Reaching the action level triggers additional monitoring and controls, even if the PEL isn’t exceeded.

        What kinds of sampling will be required?

        Operators must conduct full-shift personal exposure sampling using approved equipment. Samples must follow NIOSH Method 7500 (or 7602/7603 for coal) and be analyzed by an accredited lab. Each representative group requires two initial samples and ongoing monitoring every three months if exposure stays above the action level.

        Will MSHA inspectors collect their own silica samples?

        Yes. MSHA inspectors may collect their own silica samples during inspections, which can be used to issue citations for overexposure.

        How often will operators have to collect samples?

        Two initial samples per representative group are required. If results exceed the action level, sampling must continue every three months. Operators must also conduct a qualitative review of exposure risks every six months to determine if resampling is needed.

        Dust Controls & Respirators

        What types of dust controls are mine operators expected to implement?<br />

        Operators must implement engineering controls such as ventilation, water sprays, and dust suppression systems. Administrative controls (like housekeeping and task limitations) can support these efforts but worker rotation is not allowed as a control method under the rule.

        When are respirators required under the new rule?

        Respirators are required only after sampling results show exposure above the PEL. Affected workers must wear P100 respirators (not N95s) starting the next shift. Respirators must remain in use until engineering controls bring exposure back below the limit.

        If a miner is wearing a respirator, can a sample still show an overexposure?

        Yes. Even with respirators, overexposure can occur—especially if engineering controls are ineffective. Respirators are a temporary measure and not considered a long-term compliance solution.

        What happens if an overexposure is found—even if controls and respirators were used?

        If overexposure is detected, MSHA must be notified. Operators must implement additional controls and continue using respirators. Follow-up sampling must confirm exposure is back below the limit to end respirator use.

        Medical Surveillance

        Which miners must be offered medical surveillance?

        Any miner reasonably likely to be exposed to respirable crystalline silica must be offered medical surveillance. This includes full-time workers and high-risk contractors involved in drilling, crushing, and hauling.

        What medical tests are required under the silica rule?

        Required tests include a chest X-ray, pulmonary function test, and a medical evaluation by a licensed provider. These must be completed within 60 days of employment and repeated periodically.

        Who pays for medical surveillance?

        The mine operator must cover the full cost of medical surveillance for eligible miners.

        Can a miner decline participation in medical surveillance?

        Yes. Participation in medical surveillance is voluntary, even though operators are required to offer it.

        What happens if a miner is diagnosed with a silica-related illness?

        If a miner is diagnosed with a silica-related illness like silicosis, MSHA may require the operator to review and update controls. Medical recommendations should guide decisions about the miner’s continued exposure.

        Enforcement & Compliance

        How will MSHA enforce the silica final rule?

        MSHA will enforce the rule through inspections, sampling audits, and citations. Violations may lead to 104(d) orders, which can halt operations. Enforcement may also be coordinated from MSHA’s headquarters.

        What penalties can operators face for non-compliance?
        • Citations and fines
        • Work stoppages
        • Orders for immediate corrective action
        • Liability exposure for silica-related health claims

        MSHA considers silica overexposure a serious health risk and will enforce compliance accordingly.

        Will there be any phase-in or grace periods for compliance?

        No grace periods are granted. Compliance deadlines are:

        • Coal mines: Immediate exposure compliance; engineering controls by August 14, 2025
        • Metal/nonmetal mines: Full compliance by April 8, 2026

        Operators should act now to avoid violations when enforcement begins.

        How should operators update their training programs to meet the new rule requirements?

        Training must now include:

        • Silica health risks and symptoms
        • New exposure limits and action levels
        • Proper use of respirators and controls
        • Medical surveillance rights and procedures

        At MSHA Safety Services, we can develop and deliver a custom training plan for your operation.

        Resources & Support

        Where can I find a copy of the Silica Final Rule, compliance resources, and the webinar presentation?

        You can find the full Silica Final Rule (30 CFR Part 60), fact sheets, and compliance resources on MSHA’s Silica Rule Resource Page: https://www.msha.gov/silica-final-rule-30-cfr-part-60-resources

        To revisit the webinar, watch the recording of “2025 Preparations for the Part 60 Silica Standard” here.

        Want help applying it to your site? Schedule a 15-minute call with DJ Schmutz to discuss your compliance strategy here.

        Will MSHA be providing compliance assistance materials for the silica final rule?

        Yes. MSHA offers official resources including fact sheets, guidance documents, and templates. These are available on the MSHA Silica Rule Resource Page: https://www.msha.gov/silica-final-rule-30-cfr-part-60-resources