Mining operations generate significant amounts of airborne respirable dust and its prolonged exposure to workers may lead to several potential health risks. Hence, a study was conducted on different dust generating operations as well as different categories of workers, viz. Loaders, Drillers, LHD (Load, haul and dump) operators, Crusher operators, Conveyor belt operator, Sag Mill operator etc. in Hutti gold mines to assess the impact of dust and free silica exposure. Two rounds of field studies encompassing, totally 112 sampling points both personal and static dust sampling were carried out to determine dust concentration and free silica level in various workplaces. Results of the collected respirable dust samples for free silica analysis reveal that free silica content of nearly 48% of samples exceed 5% which necessitates determination of case specific maximum safe exposure limit (MEL) for respirable dust generated at these working places. Accordingly, for approximately one third of the results indicate that several workplaces exceed the maximum exposure limits (MEL) for dust and free silica, particularly affecting operators engaged in drilling, LHD, rock breaking and crushing operations etc. The findings highlight the urgent need for effective dust control measures and personal protective equipment to mitigate health risks associated with prolonged exposure. The paper deals with a case study detailing field investigations, results obtained thereof and its interpretation and analysis.