Silica Dust in the Workplace: Essential Steps to Mitigate Risk

Silicosis, a preventable yet fatal lung disease, is caused by inhaling respirable crystalline silica (RCS) dust—fine particles released during the cutting, grinding, and drilling of materials such as engineered stone. With growing media scrutiny and renewed regulatory focus, employers face more pressure than ever to ensure their workers are protected against such risks. The recent death of 28-year-old stonemason Wessam al Jundi highlights a troubling increase in silicosis cases among younger workers, with sixteen reported since last year including one person as young as 24. These cases are mostly found in small workshops, who often do not have readily available access to professional health and safety advice, underscoring the urgent need better occupational hygiene interventions.

Steps for Managing Silica Dust in the Workplace

The UK COSHH regulations detail a three step approach which can be effectively applied to RCS dust control:

Step 1: Assess

Factors such as task intensity, work environment, duration, and frequency all influence dust levels. High-energy tools like saws and grinders quickly produce dust, especially in enclosed spaces. But even outdoor use can lead to significant exposure. Suitable and sufficient risk assessment lays the foundation for effective dust control by ensuring that all subsequent measures address the most hazardous aspects of the work environment.

Step 2: Control

To effectively manage silica dust, it’s crucial to first minimise its generation. The most effective methods are those that reduce dust at the source::

• Material Selection: Using pre-cut materials or low-silica options whenever possible.
• Lower-Powered Tools: Using block splitters instead of cut-off saws.
• Wet Cutting: Applying water to control dust particles during cutting.

Secondary controls may be needed to prevent dust from becoming airborne:

• On-Tool Extraction: Local exhaust ventilation (LEV) systems capture dust directly from tools. Extraction units must meet suitable filtration standards, particularly when recirculating back to the workplace
• Effective housekeeping: Decontaminate areas using wet methods such as low-pressure water and wet sweeping, or vacuum methods
• Additional Containment: Enclose high-dust activities to limit dust spread to other areas and reduce risk for nearby workers.
• Commercial Laundering: Avoid contaminated clothing spreading dust in the home by washing clothes in the workplace or using a commercial laundry service.

Respiratory Protective Equipment (RPE) is required to control residual risk, but cannot be considered adequate control by itself without primary and secondary controls in place. RPE should:

• Have an assigned protection factor (APF) of at least 20, meaning it limits inhaled dust to one-twentieth of ambient levels. It should also carry a UKCA or CE marking and be compatible with other PPE requirements.
• Be suitable and comfortable for prolonged wear.
• Fit securely, with face-fit testing essential for tight-fitting masks. When using tight-fitting masks, users must be clean-shaven for a reliable seal.

Alongside primary and secondary dust control methods, supplementary control measures such as task rotation to aid in limiting individual exposure. Additionally, comprehensive training on dust risks, the correct use of dust controls and operating procedures empower workers to operate safely, ensuring that controls are used effectively and consistently.

Step 3: Review

Regularly reviewing control measures is essential to ensuring sustained protection. Employers should conduct routine inspections to confirm that work methods and equipment, including extraction units and respiratory protection equipment (RPE), adhered to and maintained. Maintenance of all equipment should be documented and scheduled according to manufacturer guidelines, whilst disposable RPE should be replaced each shift. Supervisors should observe that staff are using equipment and RPE correctly and following proper work methods to minimise exposure. Employee involvement in this process helps identify issues quickly, as they are often the first to notice equipment malfunctions or gaps in control measures.

Dust exposure monitoring can verify the ongoing effectiveness of controls, and exposure monitoring should be undertaken by an experienced Occupational Hygiene provider.. Health surveillance programmes may be required to detect early signs of silicosis or other dust-related conditions, set up in consultation with an occupational health professional. These comprehensive reviews not only support regulatory compliance but also demonstrate a proactive commitment to safeguarding worker health.

Why Act Now?

Addressing silica dust hazards is a complex challenge that goes beyond basic compliance; it demands a nuanced, multi-faceted approach to ensure effective control and monitoring. Recent silicosis fatalities underscore how quickly dust exposure can impact worker health, whilst regulatory and public scrutiny increases. For employers, implementing a comprehensive safety program—including dust monitoring, control measures, and health surveillance—can be daunting, especially as each workplace has unique risks and needs.

This is where occupational hygiene consultancies like Envirochem are invaluable. We offer tailored solutions, from on-site dust exposure assessments and air sampling and guidance on effective dust control measures, to RPE fit testing. By partnering with Envirochem, employers gain access to expertise that supports ongoing compliance, reduces risk, and fosters a safer workplace.

For more information on how Envirochem can assist, visit our Occupational Hygiene Services page or get in touch with one of our experts today.