Watch out for the invisible dust when processing artificial stone

Artificial stone is mainly used as kitchen countertops and tabletops as well as wall panelling in bathrooms. It consists of silica (up to 93%) and synthetic resins for binding. Working with artificial stone with cutting and grinding tools, generates dust with very high proportions of silica. Breathing in this dust leads to considerable health risks. Exposure to respirable crystalline silica is associated with cancer development but also with inducing chronic lung diseases (silicosis, COPD). Therefore, it is crucial to minimise dust exposure during any processing as much as possible. If not sufficiently possible, it is most important to shorten the dwelling time of dust at the workplace and to only unequip respiratory protection after the work space has been sufficiently aired out.

Things you should know!

The risks

Quartz or silica artificial stone still consist up to 93% of silica with synthetic resins to bind it. Any processing of artificial stone by cutting, drilling or grinding with tools generates dust of ultrafine respirable crystalline silica particles which are found to cause lung cancer and may facilitate fast induction of silicosis. Especially on construction sites in course of renovation, further hazardous substances can additionally occur, for example asbestos containing tile adhesives or asbestos containing flooring and wall covering.

Combined Dust extraction needed

Due to the high concentration of silica within the material, processing artificial stone needs in most cases a combination of different technical protection measures. The most effective measure is dust extraction at the processing point. High efficiency in the dust collection at this point leads straight to low concentration in front of your nose. But if you are for example grinding edges or cutting arches or uneven materials, it will not be sufficient and it is mandatory to combine the point extraction with local exhaust ventilation.

Dust removal from air takes time

If dust particles are not bound and evacuated, they will float in the air for a very long time. Bigger particles are visible and will relatively fast precipitate as a dust layer. Finer and ultrafine particles are not visible and float in the air for many hours. In absence of sufficient air exchange within the workplace the particles even concentrate in the air. Working with wetting techniques still generates fine small particles bound to fine waterdrops that float in the air. These aerosols evaporate at room temperature quite fast and the dust particle remains floating in the working air. Therefore, wetting itself needs to be complemented with an aerosol and dust binding at the machine and room ventilation. This is most likely be guaranteed at dedicated workplaces in your company that are especially designed for these tasks.

The main hazard:

The ultrafine and non-visible particles that linger in the workplace air for hours represent the problem! They penetrate deeply into the lungs and are not filtered in the nose. They can lead to inflammation and induce changes in the lung tissue that may ultimately lead to lung cancer years after inhaling the invisible particles.

Your employer’s duties to protect you!

Your employer carries the responsibility that you are safe before, during and after processing artificial stone.

• Hazard and risk assessment: Your employer has to perform and regularly update the risk assessment for your workplace and task. This includes potential risks sources such as silica content of the disturbed composite material, insufficient capture of generated dust at the machines and tools being used, and workplace conditions leading to limited general or natural ventilation.
• Substitution check: If not specifically mandated by the client, your employer may check whether composite material with lesser silica content (e.g., natural stone) or silica-free material can be used.
• Technical and organisational measures: Your workplace has to be designed and equipped to promote and support your safety and well-being. For the task of cutting artificial stone, it is foremost necessary to work with machines that have efficient dust capture or in case of wet technique a good aerosol binding. If capture of dust and aerosols at the machine is not sufficient, stationary workplace need additionally local exhaust ventilation (LEV) and non-stationary workplaces need additional air filtering (e.g., through use of negative pressure units (NPU)). A proper room ventilation safeguards dust reduced working in adjacent workplaces.
• Personal protection: Personal protective (PPE) that has to be provided by your employer includes eye, hearing and respiratory protection as well as safety wear for dust-generating tasks. For example, wearer of glasses should prefer using ‘rubber half masks’ with changeable filters as these tend to need little adjustments efforts and show less leaking in the nasal area after one initial selection process.
• Qualification, instruction and motivation: Regular instructions from your employer is necessary to keep you up-to-date on safely cutting or elsewise disturbing artificial stone. He should motivate you in any case to consequently make use of safe working procedures.

Your own duties to support your own and your colleague’s protection!

• Measures that resulted from the risk assessment: You yourself are empowered to reduce any risk for yourself and your fellow colleagues when processing artificial stone by strictly following rules and standards that you have been instructed about and that are furthermore laid down in the operating instructions.
• Dust extraction is the key technical measure: You use any machinery or tools that eliminate dust at the source, regardless of whether the task is only short. You use ventilation of the workplace and take care that the ventilation is not unnecessarily blocked. Keep in mind that it is best to process the material with ventilated machines in the workshop and avoid processing operations on site (for example in the kitchen or bathroom) as much as possible.
• Check and wear PPE: You use your safety wear and eye, hearing and respiratory protection as intended and check prior to every use of the equipment whether they are fully functional.
• Identify risks early and act in a preventive manner: You react instantly when you recognise something is not working properly, like for instance air suction is missing or poor.

Take-home message

Exposure to quartz dust poses a serious health risk during the task of processing artificial stone. This hazardous fine dust remains in the air for hours after work has ended unless there is effective dust collection at the machining equipment and proper ventilation of the work area. Whenever possible, use an exhaust system directly at the source. This is the most efficient way to ensure that as little dust as possible reaches your lung. The spray mist produced during wet processing also contains dust that can enter your lungs. Always work in well-ventilated areas or use ventilation/air filtration equipment. And finally, always wear the required personal protective equipment. Take care of your health—build a future for yourself!