Knowby
Silica Dust: Working with Engineered Stone
Engineered stone is ground stone such as crystalline silica and combined with resin. The crystalline silica content in stone bench tops can vary widely depending on the type of stone used.
Engineered stone is ground stone such as crystalline silica and combined with resin. The crystalline silica content in stone bench tops can vary widely depending on the type of stone used.
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<h4>Exposure to respirable silica dust can lead to the development of:</h4> <ul> <li>Silicosis (an irreversible scarring and stiffening of the lungs)</li> <li>Accelerated silicosis.</li> <li>Progressive Massive Fibrosis (PMF)</li> <li>Chronic Obstructive Pulmonary Disease (COPD) often observed as emphysema and bronchitis</li> <li>Lung cancer</li> <li>Kidney disease</li> <li>Auto-immune diseases</li> </ul>

Exposure to respirable silica dust can lead to the development of:

  • Silicosis (an irreversible scarring and stiffening of the lungs)
  • Accelerated silicosis.
  • Progressive Massive Fibrosis (PMF)
  • Chronic Obstructive Pulmonary Disease (COPD) often observed as emphysema and bronchitis
  • Lung cancer
  • Kidney disease
  • Auto-immune diseases
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<h4>Fabrication and Installation</h4> <p>RCS exposures can occur when processing engineered stone such as cutting, grinding, sanding and polishing during the fabrication and installation of stone bench tops.</p> <p>Fabrication workers are at higher risk compared to installers because they carry out dust producing activities for most of their shift.</p>

Fabrication and Installation

RCS exposures can occur when processing engineered stone such as cutting, grinding, sanding and polishing during the fabrication and installation of stone bench tops.

Fabrication workers are at higher risk compared to installers because they carry out dust producing activities for most of their shift.

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<p>Installers still need to follow good work practices using wet methods, good ventilation and RPE. Where no cutting, grinding, sanding or polishing of the benchtop occurs during installation then no RCS will be released.</p>

Installers still need to follow good work practices using wet methods, good ventilation and RPE. Where no cutting, grinding, sanding or polishing of the benchtop occurs during installation then no RCS will be released.

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<p>Uncontrolled DRY processing which includes cutting, grinding or polishing is not allowed. Dust control measures MUST be in place. These tasks require tools equipped with water suppression or exhaust ventilationsystems built into the tools. Engineering controls must be implemented.</p>

Uncontrolled DRY processing which includes cutting, grinding or polishing is not allowed. Dust control measures MUST be in place. These tasks require tools equipped with water suppression or exhaust ventilationsystems built into the tools. Engineering controls must be implemented.

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<h4>Water Suppression (1)</h4> <p>Only use tools and machinery that have been specifically designed for use with water attachments:</p> <ul> <li>Use bridge saws fitted with water attachments to suppress dust when cutting slabs.</li> <li>Use water suppressed routers, water jet cutters or bridge saws to complete sink and stovetop cut outs.</li> </ul>

Water Suppression (1)

Only use tools and machinery that have been specifically designed for use with water attachments:

  • Use bridge saws fitted with water attachments to suppress dust when cutting slabs.
  • Use water suppressed routers, water jet cutters or bridge saws to complete sink and stovetop cut outs.
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Water Suppression (2)

  • Use hand-held angle grinders fitted with multiple water feeds to deliver water to the cutting disc and point of contact with the stone.
  • Use water suppressed wet-edge milling machines or polishing machines.
  • Use polishers with a centre water feed to polish or grind stone.
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<h4>Water Suppression (3)</h4> <ul> <li>Use an adequate number of water feeds directed at the material and/or tool to prevent visible dust during the process</li> <li>Maintain an adequate water pressure to make sure water is reaching the material and/or tool</li> <li>Control water spray from water suppressed tools and machinery using guards, plastic flaps or brush guards</li> </ul>

Water Suppression (3)

  • Use an adequate number of water feeds directed at the material and/or tool to prevent visible dust during the process
  • Maintain an adequate water pressure to make sure water is reaching the material and/or tool
  • Control water spray from water suppressed tools and machinery using guards, plastic flaps or brush guards
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Water Suppression (4)

  • Prevent workers from being able to turn water suppression systems down or off during operation.
  • Ensure water used for dust suppression is clean.
  • Recycled water should be treated through a system that includes an appropriate micron filter.
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<h4>Local Exhaust Ventilation (1)</h4> <ul> <li>Only use tools and machinery that have been specifically designed for local exhaust ventilation attachments.</li> <li>Install fixed, portable or flexible capturing hoods to capture dust at the point of generation. Best results are with tools designed with extraction build in.</li> </ul>

Local Exhaust Ventilation (1)

  • Only use tools and machinery that have been specifically designed for local exhaust ventilation attachments.
  • Install fixed, portable or flexible capturing hoods to capture dust at the point of generation. Best results are with tools designed with extraction build in.
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Local Exhaust Ventilation (2)

  • Use hand tools (for example drills, circular saws, grinders) equipped with on tool dust extraction, which typically consists of a shroud and a suction attachment point. The tool must be connected via the attachment point, to an M or H class rated vacuum or dust extraction system fitted with a disposable bag
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<h4>Isolate workers from dust generating processes (1)</h4> <ul> <li>Provide distance between the work process and the worker (for example operators positioning when using bridge saws or routers)</li> <li>Provide distance between workers using powered hand tools and other workers at the workplace</li> </ul>

Isolate workers from dust generating processes (1)

  • Provide distance between the work process and the worker (for example operators positioning when using bridge saws or routers)
  • Provide distance between workers using powered hand tools and other workers at the workplace
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Isolate workers from dust generating processes (2)

  • Provide physical barriers between different workers and workstations to prevent the water mist moving into other work areas or towards other workers.
  • Provide workers with a separate room or area away from the fabrication area for food preparation and dining.
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<h4>Work Practices (1)</h4> <ul> <li>Use routers or water jet cutters for sink and stovetop cut outs and edge or surface polishing machines for edge polishing.</li> <li>Wet slabs before cutting, grinding or polishing to aid with dust suppression.</li> <li>Capture all water generated from water suppressed processes through curbing and channelling.</li> </ul>

Work Practices (1)

  • Use routers or water jet cutters for sink and stovetop cut outs and edge or surface polishing machines for edge polishing.
  • Wet slabs before cutting, grinding or polishing to aid with dust suppression.
  • Capture all water generated from water suppressed processes through curbing and channelling.
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Work Practices (2)

  • Prevent water pooling and drying on surfaces leaving dry dust deposits.
  • Wash hands and face thoroughly before eating, drinking or leaving the workplace.
  • Launder dusty or contaminated work clothes at the workplace or use a commercial laundry to avoid taking them home.
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<h4>Cleaning and Housekeeping (1)</h4> <ul> <li>No dry sweeping or compressed air to clean surfaces or clothing.</li> <li>Implement daily and thorough housekeeping and cleaning procedures for water slurry and settled dust.</li> </ul>

Cleaning and Housekeeping (1)

  • No dry sweeping or compressed air to clean surfaces or clothing.
  • Implement daily and thorough housekeeping and cleaning procedures for water slurry and settled dust.
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Cleaning and Housekeeping (2)

  • Use low pressure water, wet sweeping or with dry dust in certain cases, M class rated vacuum cleaner fitted with a disposable bag, to clean floors, walls and other surfaces. Check with your local regulator.
  • Regularly clean vehicle track or high use areas and keep them wet during the day.
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Cleaning and Housekeeping (3)

  • Provide hoses for cleaning between tasks.
  • Place wet slurry in a container, bag or bin with a lid for disposal.
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<h4>Personal Protective Equipment (1)</h4> <ul> <li>Provide workers with gum boots, waterproof jackets or aprons to protect from water splashes and prevent contamination of clothing .</li> <li>Decontaminate clothing by removing excess dry dust, in certain cases, with M class vacuum cleaner fitted with a disposable bag, before leaving processing area.</li> </ul>

Personal Protective Equipment (1)

  • Provide workers with gum boots, waterproof jackets or aprons to protect from water splashes and prevent contamination of clothing .
  • Decontaminate clothing by removing excess dry dust, in certain cases, with M class vacuum cleaner fitted with a disposable bag, before leaving processing area.
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Personal Protective Equipment (2)

  • After each shift, workers can change their clothing that has been contaminated with silica dust and these should be washed separately from other clothing.
  • Launder dusty or contaminated work clothes at the workplace or use a commercial laundry to avoid taking them home.
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<h4>Respiratory Protect Equipment (RPE) (1)</h4> <ul> <li>Suitable RPE must be worn with the appropriate level of protection.</li> <li>Check the SDS or supplier’s recommendations. Air monitoring can be used to determine the levels of exposure and the appropriate RPE.</li> </ul>

Respiratory Protect Equipment (RPE) (1)

  • Suitable RPE must be worn with the appropriate level of protection.
  • Check the SDS or supplier’s recommendations. Air monitoring can be used to determine the levels of exposure and the appropriate RPE.
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Respiratory Protect Equipment (RPE) (2)

  • Powered Air Purifying Respirators (PAPR) like those shown in the picture, using a P3 filter, are much more effective than negative pressure respirators as they eliminate the concerns of poor face fit from beards & stubble, as well as different shaped faces.
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<h4>Fit-testing of Respirators (1)</h4> <ul> <li>Best practice means workers must pass a fit-test before they start wearing a tight-fitting respirator.</li> <li>Fit-testing measures the effectiveness of the seal between the respirator and the wearer’s face.</li> <li>Facial hair can stop a tight-fitting respirator from sealing correctly.</li> </ul>

Fit-testing of Respirators (1)

  • Best practice means workers must pass a fit-test before they start wearing a tight-fitting respirator.
  • Fit-testing measures the effectiveness of the seal between the respirator and the wearer’s face.
  • Facial hair can stop a tight-fitting respirator from sealing correctly.
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Fit-testing of Respirators (2)

  • Men must be clean-shaven or only have facial hair that doesn’t sit beneath the seal or interfere with the valve.
  • Loose fitting respirators don’t need to be fit-tested.
  • Fit-test should be repeated each year.
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<h4>Training must be provided by a competent person, and cover the following topics:</h4> <ul> <li>Why RPE is required</li> <li>When RPE is required to be worn</li> <li>How RPE works</li> <li>The limitations of RPE</li> <li>How to correctly put on and take off RPE</li> <li>How to conduct a FIT CHECK</li> <li>How to clean and maintain RPE</li> <li>When and how to replace filters</li> <li>How and where to store RPE</li> </ul>

Training must be provided by a competent person, and cover the following topics:

  • Why RPE is required
  • When RPE is required to be worn
  • How RPE works
  • The limitations of RPE
  • How to correctly put on and take off RPE
  • How to conduct a FIT CHECK
  • How to clean and maintain RPE
  • When and how to replace filters
  • How and where to store RPE
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Risk Assessments - Air Monitoring (1)

Air monitoring can be used to check on respirable silica dust levels and the effectiveness of the controls and work practices.

Monitoring must be performed by a competent occupational hygienist. Check the website

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Best practice with controls, results in exposures below 50% Safe Work Australia Exposure Standard (WES) for respirable crystalline silica. Exposures must be below the WES.

Check the website

Results must be provided to the workers and made available for the medical practicioners.

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Workers must be trained and aware of the:

  • Health hazards of respirable silica dust
  • How to use and maintain the water assisted equipment and / or extraction systems to prevent release of dust.
  • How to wear and maintain RPE, see RPE training
  • Housekeeping and washing overalls
  • Clean-up with water and vacuum cleaners
  • Health Monitoring
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Health Monitoring of Engineered Stone Workers (1)

The health monitoring requirements for workers exposed to RCS from engineered stone dust is dependent on local State/Territory guidelines.

For example, in QLD and WA it is a requirement for any workers involved in fabrication or installation of stone benchtops to have health monitoring.

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Health Monitoring of Engineered Stone Workers (2)

Where it is not regulated, it is recommended that health monitoring is performed when exposures are not controlled to below 50% Safe Work Australia Exposure Standard (WES) for respirable crystalline silica.