Protecting Workers from Engineered Stone Hazards: Understanding Risks and Solutions

Engineered stone, a popular material in the construction and manufacturing industries, is prized for its durability, aesthetic appeal, and versatility. However, the very properties that make engineered stone desirable also pose significant health risks to workers. When cut, ground, or damaged, engineered stone could potentially release harmful substances, including respirable crystalline silica (RCS) and volatile organic compounds (VOCs), into the air. These substances can have severe long-term health consequences if not properly managed. This article explores the risks associated with engineered stone, provides insights into regulatory guidelines, and highlights practical solutions to protect workers.

What Is Engineered Stone?

Engineered stone is a composite material made from crushed natural stone (primarily quartz) bound together with resins, pigments, and additives. It is commonly used for countertops, flooring, and wall cladding in both residential and commercial settings due to its non-porous surface and resistance to stains and scratches.

Frequently Asked Questions about Engineered Stone

Q: How can I identify engineered stone?

Engineered stone typically has a uniform appearance with consistent patterns and colours. Unlike natural stone, which may have irregularities and variations, engineered stone looks more polished and homogeneous.

Q: Where is engineered stone used?

It is widely used in kitchens, bathrooms, and commercial spaces for countertops, tiles, and decorative finishes.

Q: Why is engineered stone hazardous?

When cut, ground, or damaged, engineered stone could potentially release harmful substances, including respirable crystalline silica (RCS) and volatile organic compounds (VOCs), into the air.

Health Risks of Working with Engineered Stone

Respirable Crystalline Silica (RCS)

RCS is a fine dust produced when engineered stone is cut or ground. Exposure to RCS can cause:

• Silicosis: An irreversible lung disease that leads to scarring of lung tissue.
• Chronic Obstructive Pulmonary Disease (COPD): A group of lung conditions that cause breathing difficulties.
• Lung Cancer: Prolonged exposure to high levels of RCS increases the risk of developing lung cancer.

Volatile Organic Compounds (VOCs)

The resins used in engineered stone often release VOCs, especially when the material is damaged or subjected to high temperatures. VOC exposure can lead to:

• Short-term effects: Eye, nose, and throat irritation; headaches; dizziness.
• Long-term effects: Damage to the liver, kidneys, and central nervous system.

Dust Exposure

Fine particulate matter from engineered stone can also contribute to respiratory issues, particularly in poorly ventilated workspaces.

Regulations in the UK

The UK’s Health and Safety Executive (HSE) has stringent guidelines to manage the risks associated with engineered stone. Key regulations include:

• Control of Substances Hazardous to Health (COSHH) Regulations 2002: Employers must assess risks and implement measures to control exposure to hazardous substances, including RCS and VOCs.
• Workplace Exposure Limits (WELs): The HSE sets specific limits for RCS and VOC exposure to ensure worker safety.
• Health Surveillance: Workers exposed to RCS must undergo regular health monitoring to detect early signs of silicosis or other conditions.

Solutions to Minimise Risks

To manage the risks associated with working with engineered stone, which generates harmful respirable crystalline silica (RCS) dust, the Hierarchy of Controls should be applied to minimise exposure effectively. Begin by eliminating the hazard where possible, such as avoiding the use of engineered stone or opting for alternatives with lower silica content. Where elimination is not feasible, substitute dry-cutting methods with wet-cutting or less hazardous processes. Implement engineering controls, such as local exhaust ventilation (LEV) systems and water suppression, to capture or reduce dust at its source. Support these measures with administrative controls, including comprehensive worker training, health surveillance, and limiting exposure duration through task rotation. Finally, provide and ensure the correct use of personal protective equipment (PPE), such as FFP3 respirators. Combining these approaches ensures a robust strategy to protect workers from silica-related health risks.

Engineering Controls

According to the hierarchy of control, first explore if the risk can be removed or sufficiently reduced.

• Wet Cutting Techniques: Using water to suppress dust during cutting and grinding operations.
• Local Exhaust Ventilation (LEV): Installing LEV systems to capture and remove airborne dust and VOCs at the source.

Personal Protective Equipment (PPE)

• Respiratory Protective Equipment (RPE): Providing workers with properly fitted respirators appropriate for the application and correctly fitted, to prevent inhalation of harmful particles.
• Protective Clothing: Ensuring workers wear dust-resistant clothing to minimise skin exposure.

Monitoring and Detection Tools

• VOC Detection: Photoionisation detection devices (PIDs), such as the Tiger XT VOC Detector from Ion Science, are reliable tools for generally identifying VOC concentrations in the workplace. Advanced sensor technology ensures accurate readings, helping employers maintain safe environments.
• Dust Detection: For RCS-specific monitoring, the Trolex Air XS Silica Monitor delivers accurate real-time data on airborne RCS content using innovative optical refraction technology (ORT). It calculates average RCS levels from particle counts via an adaptive algorithm, viewable on the instrument display or Trolex Breathe software - available to hire or purchase from Shawcity.

Trolex Air XS Real-Time Silica Dust Monitor

£12,995.00

The Trolex AIR XS Silica Monitor is designed to provide detailed, accurate and real-time data on airborne respirable crystalline silica (RCS) content based on the chosen installation environment.

Learn more

Training and Awareness

Employers should provide comprehensive training on the risks of engineered stone and the proper use of controls and equipment.

Frequently Asked Questions about Worker Safety

Q: What are the symptoms of silica exposure?

Early symptoms include coughing, shortness of breath, and fatigue. Prolonged exposure can lead to severe respiratory conditions.

Q: How often should air quality be monitored?

Air quality should be monitored continuously in high-risk areas and periodically assessed to ensure compliance with WELs.

Q: Can engineered stone be used safely?

Yes, with proper controls, training, and monitoring, the risks can be significantly reduced.

Engineered stone is a valuable material with widespread applications, but its health risks cannot be overlooked. By adhering to HSE guidelines, investing in cutting-edge detection tools like the Trolex Air XS real-time monitor and fostering a culture of safety, employers can protect their workforce while maintaining productivity.

For more information on monitoring solutions, contact Shawcity at 01367 899553 or email solutions@shawcity.co.uk.