The use of engineered stone in kitchens and bathrooms has increased significantly over the past decade, with quartz kitchen worktops increasing in popularity. While the finished product presents no risk once installed, the processes involved in cutting, shaping and polishing engineered stone can expose workers to very high levels of respirable crystalline silica (RCS).

Medical professionals in the UK are now reporting cases of accelerated silicosis linked to engineered stone exposure, highlighting the need for improved awareness, control measures and worker protection.

What is engineered stone, and why does it present a risk?

Engineered stone, often referred to as quartz, is manufactured by combining crushed stone with a resin binder. The resulting material offers consistent appearance and durability and has become a popular alternative to natural stone.

However, engineered stone typically contains more than 90% crystalline silica, compared with less than 45% in natural granite. This significantly higher silica content means that when engineered stone is cut or polished, the amount of hazardous dust released can be far greater.

The risk is not the material itself, but the dust generated during processing.

 

Understanding respirable crystalline silica (RCS)

Silica is a naturally occurring mineral found in many common materials, including:

• Engineered stone
• Granite and other natural stone
• Concrete
• Mortar
• Sand
• Soil

When materials containing silica are cut, drilled or polished, fine dust particles are released. The smallest of these particles is known as respirable crystalline silica (RCS).

RCS particles are:

• Too fine to see in normal lighting
• Able to penetrate deep into the lungs
• Capable of causing serious and irreversible damage, even at relatively low exposure levels

Silicosis and other serious health effects

Silicosis is a progressive and incurable lung disease caused by inhaling silica dust, usually over time. Once established, the condition can continue to worsen even after exposure stops.

Common symptoms include:

• Persistent cough
• Shortness of breath
• Fatigue and weakness

As the disease progresses, everyday activities such as walking or climbing stairs can become extremely difficult. In severe cases, individuals may become housebound.

Exposure to silica dust is also associated with an increased risk of other serious conditions, including:

• Chronic obstructive pulmonary disease (COPD)
• Lung cancer
• Tuberculosis and other chest infections
• Pulmonary hypertension
• Heart failure
• Kidney disease

Recent UK cases linked to engineered stone have shown that silicosis can develop after only a few years of exposure, particularly where dry cutting and inadequate controls are used.

Exposure limits and why control is critical

The current UK and EU workplace exposure limit for respirable crystalline silica is 0.1 mg/m³ averaged over an eight‑hour period. Other countries operate lower limits, reinforcing the importance of reducing exposure as far as reasonably practicable.

It is important to recognise that there is no safe level of silica dust inhalation. Any exposure carries risk, and the objective must always be to minimise exposure as far as possible.

Controlling silica dust exposure

Preventing silicosis relies on applying the hierarchy of control, with priority given to engineering and process controls.

Key measures include:

Engineering and workplace controls

• Use wet cutting methods when working with engineered stone
• Install effective local exhaust ventilation and dust extraction
• Ensure dust suppression systems are correctly positioned at the cutting point
• Regularly inspect, clean and maintain ventilation equipment
• Avoid dry sweeping or dry brushing
• Use wet cleaning methods or HEPA‑filtered vacuum systems
• Never use compressed air to clean surfaces or clothing

These controls are essential and should always be implemented before relying on personal protective equipment.

The role of respiratory protective equipment (RPE)

Respiratory protective equipment (RPE) provides additional protection.

For silica dust, RPE should:

• Provide a UK Assigned Protection Factor (APF) of at least 20
• Use high‑efficiency particulate filters

Suitable options may include:

• FFP3 disposable respirators
• Half masks fitted with P3 filters
• Full face masks fitted with P3 filters
• Powered air purifying respirators (PAPR) with TH2PSL or TM2PSL performance or higher

Fit testing and facial hair

Tight‑fitting respirators must be fit tested on each wearer, using the exact make, model and size of mask. Wearers must also be clean‑shaven in the area of the face seal.

Workers with facial hair should consider loose‑fitting PAPR systems, which do not rely on a tight face seal to provide protection.

Training, maintenance and RPE programmes

RPE will only provide the intended level of protection when it is:

• Correctly selected
• Properly fitted
• Used as instructed
• Regularly maintained
  
   

Workers should be trained to:

• Understand RPE markings and expiry dates
• Carry out pre‑use checks
• Maintain and store equipment properly
• Exchange and replace filters in accordance with operational procedures, to include:
  • When the packaging Shelf Life / Expiry date has concluded.
  • If the filter is submerged in water, it becomes wet or damp. Ingress of excessive moisture, liquids, cleaning solutions or visibly contaminated
  • If the filter becomes damaged in any way (shape or form) or rattles when shaken.
  • If breathing becomes difficult, excessive or laboured.
  • If you can taste/smell the environmental hazard or atmosphere
  • You can feel the effects (signs and symptoms) of the potential hazard

Powered respirators require additional training on battery management and airflow checks.

A structured RPE programme is essential to ensure ongoing protection.

Secondary Exposure and the Importance of Decontamination

During cutting, shaping and polishing processes, airborne silica dust can settle on hair, clothing and exposed skin. Without appropriate decontamination or removal procedures, this can lead to secondary exposure, even after work has finished. When working with engineered stone, dust levels can quickly build up around the operator, increasing the need for effective exposure controls and suitable respiratory protection. 

Employers are encouraged to engage with competent air detection, identification, monitoring and sampling providers, as the data gathered can provide valuable insight into actual exposure levels. These findings can then be used to review and strengthen existing risk assessments, particularly where controls may be outdated or no longer effective.

Reducing risk through awareness and good practice

The increased silica content of engineered stone means an increased potential risk to workers if controls are not in place. The most effective protection comes from eliminating or reducing dust at source, supported by appropriate RPE where necessary.

By improving awareness of silica risks and applying robust control measures, employers can significantly reduce exposure and help protect workers from preventable, life‑changing diseases.