Engineered Stone – Risk Controls

There is increasing public interest and awareness about the chronic health effects linked to silica dust exposure. This is following the recognition of accelerated silicosis among tradesmen working with engineered (artificial) stone, a material widely used in the fabrication of kitchen worktops.

Posted

11.11.2024

Written by

Morag McWilliam Dr Stephen Cowley Richard Bowen

Silicosis is a fibrosis of the lungs, an irreversible scarring, that results in symptoms including shortness of breath, cough and weight loss. Disability can progress and result in death. The risks of silica dust exposure have been known for many years but exposure to engineered stone dust is causing the disease in younger people than previously seen. Following recent deaths, the Senior Coroner for West London, Lydia Brown, has recently called for a “timetable for action” to tackle the dangers of cutting engineered stone.

As a result, there are a growing number of reports of silicosis sufferers in the press and online. Interestingly, many of these are accompanied by stock images of engineered stone being cut, ground or polished using a handheld angle grinder, illustrating the dust generation problem.

Obviously, such uncontrolled work on stone is unacceptable and the British Occupational Hygiene Society (the Chartered Society for Worker Health Protection) has issued guidance on measures to control dust. The Health and safety Executive (HSE) also provides guidance.

It is recommended that alternative means of cutting such as water jet cutters are used or only tools and machinery designed for the fitting of water for dust suppression are used. This does not mean, however, that there will be no dust exposure. Such controls will reduce dust as long as they are used properly at all times and receive regular maintenance. Controls can fail.

To improve control, and where water suppression cannot be used, local exhaust ventilation (LEV) can be used. However, it is really important that an LEV system has sufficient suction power (capture air velocity) and is always kept as close to the source of the dust as possible. On-tool (low volume, high velocity) LEV is generally more effective than a separate system.

Again, there will still be some dust and, regardless of the above control measures, it is likely that respiratory protection (a dust mask) will be required. Most people use a close fitting dust mask such as a disposable mask or, preferably, a reusable silicone rubber mask with filters.

However, users of these must have a fit test with the device they will use to ensure that they can achieve an effective seal around between their face and the perimeter of the mask. To achieve this, they must be clean-shaven. They will also require training and instruction in the use and maintenance of a reusable device. An alternative is a powered air device, but these are considerably more expensive and have higher maintenance needs.

In addition, anyone working with silica dust can also be exposed through the dust collecting on their workwear. Selection of appropriate PPE clothing that is designed to repel dust should be worn, and effective changing and cleaning protocols of workwear strictly followed.

So, control of dust is complicated, time consuming and can be costly and it is unlikely that exposure will be completely controlled.

Ultimately, whenever it is possible, it is always better to eliminate a hazardous substance or find a safer material to substitute for the hazardous one.

Australia, for example, has implemented a ban on the import and installation of engineered stone from 1^st July of this year.

Silica-free mineral materials, laminates, acrylic and natural stone are some of the alternatives available for use in place of engineered stone. These are not ‘safe’ but the exposure risks are lower. Control of exposure to dust is still required.

At the current time, the HSE will not be following Australia in banning the import and installation of engineered stone and has said that it considers such a ban unnecessary. The HSE argue that, with the application of the appropriate dust control measures, the risk will be adequately controlled.

It is our experience in workplaces, and in small businesses in particular, that the complexities and costs of risk management result in less than adequate levels of control. It is likely therefore that workers will continue to be exposed.

In considering this, what is not being so widely acknowledged in the current discussions around this topic is that, in recent years, silica has been scheduled as a carcinogen, i.e., has the potential to cause lung cancer.

In the UK, the designation of silica dust as a potential carcinogen means that exposure must be kept as low as reasonably practicable (ALARP). As such, if the material is not removed from use, workers undertaking work on engineered stone that could release dust must be protected by the most effective means possible.

If you need help understanding your or your employees’ risks when using artificial stone please get in touch with Dr Steve Cowley, Morag McWilliam or Rich Bowen at [email protected] or call 01530 412777