Engineered Stone Ban to Protect Workers from Silica Dust Exposure: The Global Milestone

Australia has banned the use, supply, and manufacture of engineered stone due to the release of fine silica dust that can cause deadly diseases and cancers when cut. State and federal workplace ministers have decided, upon a recommendation from Australia's workplace safety watchdog, Safe Work Australia, to fully ban engineered stone nationwide. This measure aims to safeguard the health and safety of workers exposed to crystalline silica content, marking a global milestone as Australia becomes the first country to take this step.

Quick summary: From July 1, 2024, engineered stone products cannot be manufactured, supplied, or installed anywhere in Australia. Exemptions apply to removal, repair, minor alterations, or disposal of engineered stone installed before this date, plus products containing silica levels below 1%. Employers must now shift toward safer benchtops and surfaces while supporting affected businesses through the transition.

The nationwide ban will take effect from July 1, 2024, with allowances for the removal, repair, minor alterations, or disposal of engineered stone installed before this date, and for products containing silica levels below 1%. This engineered stone prohibition pertains to the production, distribution, processing, and installation of engineered stone, excluding actions such as removal, repair, disposal, or minor modifications.

What is Engineered Stone?

Engineered stone, also referred to as quartz or artificial stone, is a composite material made from crushed stone bound together by an adhesive. Builders commonly use it for kitchen benchtops, bathroom vanities, and flooring due to its durability and aesthetic appeal. However, studies have shown that engineered stone contains high levels of crystalline silica.

Silica dust, also called respirable crystalline silica (RCS), is a type of mineral from natural materials like sand, stone, and rock. When workers cut, drill, or grind these materials into fine dust, particles release into the air. Fine particles can travel deep into the lungs, causing lasting harm to lung tissue.

The different types of engineered stones include:

• Quartz: The most popular type of engineered stone, composed of crushed quartz bound with resin, offering durability and a wide range of colours and patterns
• Granite: Engineered granite is formed by heat and pressure, providing a durable and versatile option for various applications
• Caesarstone: A brand of engineered stone known for its durability and uniform colours
• Essastone: Another type of engineered stone that offers affordability, durability, and a variety of colour options
• Litho stone: An engineered stone material that combines natural and artificial elements to provide resistance against scratches, stains, and heat
• Quantum Quartz: A type of engineered stone made up of 93% natural quartz along with bonding materials, offering durability and low maintenance requirements

Health Risks Associated with Silica Dust Exposure

The danger of engineered stone comes primarily from its high content of crystalline silica. Medical research confirms there is no safe exposure threshold once dust reaches the lungs. Long-term effects of exposure to crystalline silica include:

• Silicosis: A debilitating and often fatal lung disease characterised by inflammation and scarring of lung tissue, leading to reduced lung function and difficulty breathing
  • Acute silicosis: Rapid onset within weeks or months following very high exposure levels
  • Accelerated silicosis: Onset within 5–10 years following high exposure levels
  • Chronic silicosis: Onset after ten or more years of exposure to lower levels of silica
• Increased risk of lung cancer
• Pulmonary tuberculosis, particularly in areas where tuberculosis is endemic
• Airway diseases, such as chronic obstructive pulmonary disease (COPD)
• Autoimmune diseases

The most common industries where workers face crystalline silica exposure include:

• Construction Industry: Workers in construction encounter crystalline silica when cutting, grinding, drilling, or crushing materials like concrete, bricks, tiles, and mortar
• Mining Industry: Activities such as sand mining can release large amounts of crystalline silica into the air, posing a risk to exposed workers
• Manufacturing Industry: Production processes involving materials like concrete, cement-based products, rocks, sands, and clays can generate silica dust
• Foundries: Moulds for molten metals poured at foundries can contain silica, leading to exposure during casting processes
• Glassmaking Industry: Silica remains a common material used in glassmaking processes

Understanding the Prohibition on Engineered Stone

Why is engineered stone in the spotlight?

Engineered stone stands at the centre of discussions regarding occupational safety due to its widespread use across various industries, especially construction. Analysis shows no evidence that engineered stone with reduced silica content (e.g. 40% or 10%) offers any safer handling outcome.

Alternatives to Engineered Stone

Now that the ban on engineered stone is upcoming, exploring alternative options becomes essential. Some potential alternatives include:

1. Natural Stone: As mentioned, natural stones offer a sustainable and durable option for construction projects. They remain safer since they do not emit harmful chemicals and have a longer lifespan, making them cost-effective.
2. Recycled Materials: Using recycled materials such as glass or concrete can also serve as a sustainable alternative to engineered stone. Such materials get repurposed from waste, reducing the carbon footprint of construction projects.
3. Terrazzo: This composite material combines chips of natural stones, glass or other materials set in concrete or resin. It offers a similar aesthetic to engineered stone but with more environmentally friendly sourcing practices.
4. Solid Surface: Made from acrylics and minerals, solid surface materials remain durable, non-porous, and easy to maintain, with customisable colour and design options.
5. Porcelain Slabs: Porcelain slabs offer a lightweight, durable and sustainable option for countertops and other surfaces. Manufacturers make porcelain from natural materials such as clay and sand, and it can be recycled at the end of its lifespan.

Engineered Stone Prohibition's Impact

This ban carries various implications across different industries. They include:

• Disruption in the Market: The ban will disrupt the market for engineered stone products, impacting sectors that rely on these materials for construction projects such as kitchen benchtops, flooring, and other surfaces.
• Shift Towards Alternative Materials: With the prohibition in place, expect a shift towards alternative materials such as natural stone or composite options, which may come at a higher cost for consumers.
• Improved Worker Safety: One of the main reasons for the ban centres on improving worker safety. By removing potential exposure to silica dust from engineered stone products, employers can better protect workers' health from developing silicosis or other respiratory illnesses. Read more about how Australia bans engineered stone to protect workers for further context on this reform.
• Impact on Home Remodelling: Home remodelling projects that depend on engineered stone benchtops will require alternative solutions, potentially leading to higher costs and longer renovation times
• Economic Growth in Natural Stone Industry: The natural stone sector anticipates significant economic growth as demand for natural stones increases in response to the ban on engineered stone
• Environmental Sustainability: Natural stones offer a sustainable option for the construction sector due to their durability and environmentally friendly sourcing practices, contributing to environmental protection efforts

Global Initiatives

Australia has taken a significant step by becoming the first country to ban engineered stone. This decision comes in light of health concerns associated with crystalline silica exposure, which has led to a concerning increase in silicosis cases among workers who handle the material. While this proactive approach by Australia stands as the first of its kind worldwide, we hope more countries will follow suit to protect the health and well-being of workers across the construction industry.

How about the engineered stone installed before the ban date?

With the ban on engineered stone in Australia, several implications arise for existing installations. Homeowners with engineered stone products need not worry if they plan to leave them in place. However, those intending to remove or replace engineered stone products should be aware of new regulations. Some state governments now require individuals involved in the removal or demolition of engineered stone to hold a licence.

Safe Work Australia is also set to create a national framework to ensure safety for those handling engineered stone products installed before the ban. Learn more about related state-based reforms, including VIC government intensifying initiatives to protect workers from engineered stone risks, and how new regulations to protect Victorian workers from exposure to crystalline silica dust take effect. This initiative offers guidance for businesses and workers on the impact of WHS Regulations amendments, aiding adaptation to these changes.

Can I still work with engineered stone until the prohibition takes effect?

Until the ban on engineered stone comes into force, workers and businesses may engage with engineered stone under regulated conditions. Implement preventive measures for reducing exposure to crystalline silica that include:

Engineering Controls

• Use wet methods for cutting, drilling, grinding, or crushing materials containing silica to suppress dust.
• Implement local exhaust ventilation with high-efficiency particulate air (HEPA) filters to capture dust at the source

Administrative Controls

• Limit the time workers spend in areas with high silica dust levels.
• Rotate workers to reduce individual exposure levels

Personal Protective Equipment (PPE)

• Provide workers with respiratory protection such as N95 respirators or higher.
• Use protective clothing to prevent silica dust from contaminating clothes and skin

Hygiene Practices

• Prohibit eating, drinking, or smoking in dusty areas.
• Wash hands and face before eating, drinking, or smoking outside dusty areas

Tools for Ensuring Worker Safety

Australian Silica Dust Regulations

Australian regulations concerning silica dust remain strict and designed to protect workers' health. Employers must understand and follow these regulations closely, since exposure to silica dust can cause serious diseases like silicosis and lung cancer. Here are important considerations to ensure safety in industries handling silica-containing materials:

WHS Regulations and Codes of Practice

Employers must adhere to relevant WHS regulations and specific Codes of Practice for managing silica dust. These provide comprehensive guidelines on risk assessment, control measures, worker training, and health monitoring. For a detailed breakdown of recent changes, review our Silica Dust Code of Practice Update 2023. You can also find relevant information on the Safe Work Australia website and websites of your state or territory's work safety regulator.

Safe Work Procedures

Develop detailed safe work procedures specifically for tasks involving silica. These should outline hazard identification, wet methods for dust suppression, ventilation, appropriate PPE for the level of exposure, and emergency procedures. Businesses can refer to our guide on when a SWMS (Safe Work Method Statement) is required to determine documentation obligations.

Worker Training

Mandatory silica awareness training remains a requirement for specific occupations in certain territories (e.g., the ACT). Even where not mandated, all workers exposed to silica need thorough training covering hazards, safety procedures, PPE use, and emergency response.

Health Monitoring

Australian WHS regulations require health monitoring for workers at significant risk of silica exposure. This includes health questionnaires, lung function tests, and potentially other medical assessments.

Safety Management Systems

Management systems in the workplace include procedures for identifying and assessing exposure risks, implementing control measures, providing training and education for workers, and conducting regular air monitoring to ensure exposure levels stay within safe limits.

Risk Assessment

A risk assessment should be conducted to determine the level of exposure to silica dust in a specific workplace. This involves evaluating tasks and activities that may generate airborne silica particles, as well as identifying potential sources of contamination. Templates are available to assist in conducting a thorough assessment, and consulting with a safety professional for guidance remains recommended.

Silica-Related Products for Workplace Safety

Various products exist to help reduce or eliminate exposure to silica dust in the workplace. SafetyDocs by SafetyCulture offers comprehensive safety documents that include templates for risk management and control measures, training materials, and management plans. These documents can be customised to fit the specific needs of a workplace and provide guidance on minimising exposure to silica dust.

You can begin by utilising the following templates to help assess and control risks related to silica exposure:

• Silica Dust Safe Work Method Statement
• Silica Dust Management Plan
• Construction Management Plans
• Stone Fabricating SWMS
• Flooring Industry Suites

With SafetyDocs, worry no more about the safety of your workers, and ensure all necessary precautions are taken to reduce silica dust exposure. Prevent long-term health issues such as silicosis, lung cancer, and other respiratory diseases by implementing proper safety measures.

Stay compliant with the latest regulations and protect your workers. Don't wait until it's too late – take action now and prioritise the health and safety of your team. Contact us today to learn more about our templates and how we can support your workplace safety efforts.

Our team of experts remains dedicated to providing accurate and informative content. Craig Cruickshank, our senior HSEQ advisor at SafetyDocs by SafetyCulture, has reviewed this blog post to ensure the highest level of quality.

Learn more about Craig's work on LinkedIn for further industry insights.

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Please note that the above information is provided as a comment only and should not be relied on as professional, legal or financial advice.