Managing Crystalline Silica Dust Safety

Zach Smith, National Secretary of the CFMEU, said engineered stone is the "asbestos of the 2020s". There's truth to this statement since working with engineered stone releases crystalline silica dust into the air. This dust is extremely dangerous and can cause serious health issues like lung cancer, silicosis, and other respiratory diseases.

In today's fast-paced world, we often focus on visible dangers and hazards that we can easily see and avoid. However, some of the most dangerous threats to health and wellbeing lurk in the shadows, invisible to the naked eye. One such hazard, frequently found across various industries and workplace settings, is respirable crystalline silica (RCS).

This insidious, microscopic menace poses a significant risk to millions of workers across the globe, contributing to severe and life-threatening health conditions such as silicosis, lung cancer, and chronic obstructive pulmonary disease (COPD). Despite its potential for harm, many people remain unaware of the true extent of the problem and preventative measures available to them.

Summary: Managing crystalline silica dust safety requires understanding what RCS is, recognising the workplace activities that generate it, following the correct safety controls under WHS laws, and applying the hierarchy of controls alongside health monitoring, air monitoring, and personal protective equipment. Below, we break down each element so employers and employees can build a compliant and effective safety strategy.

In this blog, we shed light on the hidden danger of respirable crystalline silica, exploring its sources, health risks, and vital steps employers and employees can take to protect themselves and coworkers. Whether you work in construction, mining, or manufacturing, or simply want to better understand the impact of RCS on our society, this blog provides valuable information to help you navigate workplace safety and health.

What is Crystalline Silica?

Crystalline silica is a type of silicon dioxide mineral present in many natural and man-made materials. It exists in two forms: non-crystalline and crystalline. The most common type is quartz (CAS 14808-60-7).

Silica concentration present in different rocks and rock products can vary. For example, marble and limestone typically contain about 2% silica. Natural sandstone can have as much as 95% silica, while engineered stone can contain up to 97%.

What is Respirable Crystalline Silica (RCS)?

Respirable Crystalline Silica (RCS) refers to microscopic particles of crystalline silica that become airborne during activities involving cutting, grinding, drilling, or crushing silica-containing materials. Crystalline silica is a common mineral found in materials such as sand, stone, concrete, mortar, and engineered stone.

The term "respirable" indicates that these particles are small enough to penetrate deep into the lungs when inhaled. RCS particles are generally less than 10 micrometres in diameter, allowing them to bypass the body's natural defence mechanisms and lodge in lung tissue. This can lead to various serious health problems over time.

Exposure to RCS is a significant occupational health hazard, particularly in industries such as construction, mining, manufacturing, and foundry work. Prolonged and unprotected exposure to RCS can result in various respiratory diseases and conditions, including silicosis, lung cancer, COPD, and kidney disease. To mitigate risks associated with RCS, employers and workers must follow proper safety guidelines and regulations, including implementation of effective control measures and monitoring of exposure levels.

Is Crystalline Silica Dust Toxic?

Yes, crystalline silica dust is toxic. According to a Curtin University report, an estimated 10,000 Australians will develop lung cancer due to silica dust exposure. This devastating statistic highlights dangers posed by crystalline silica dust. Exposure can lead to development of lung diseases such as silicosis, lung cancer, and COPD.

Listed below are health effects linked to silica dust exposure:

Silicosis

Silicosis is an incurable respiratory disease caused by inhaling silica dust. Symptoms include shortness of breath, coughing, chest pain, and fatigue.

• Acute silicosis: Occurs after short exposure to high levels of silica dust, leading to severe inflammation and protein outpouring into lung tissue.
• Accelerated silicosis: Can develop after moderate to high-risk levels of silica dust exposure for 3 to 10 years, leading to inflammation, protein buildup, and lung scarring (fibrotic nodules).
• Chronic silicosis: Can occur after long-term exposure to lower concentration levels of silica dust, leading to fibrotic nodules and shortness of breath.
• Progressive massive fibrosis: A severe form of chronic silicosis where fibrotic nodules in the lung aggregate.

Bronchitis

Bronchitis is a lung condition caused by inflammation of airways in the lungs. Causes typically include infection or exposure to irritants like silica dust. Symptoms include wheezing, shortness of breath, and coughing.

• Chronic bronchitis: A form of COPD that can result from long-term exposure to silica dust. Symptoms include increased mucus production and a persistent cough.

Lung Cancer

Exposure to crystalline silica dust can increase risk of developing lung cancer. Symptoms include coughing up blood, chest pain, and shortness of breath.

Emphysema

Emphysema is a lung condition caused by damage to the lungs' alveoli (air sacs). Causes can include smoking, air pollution, or exposure to silica dust. Symptoms include shortness of breath and a persistent cough.

Kidney Damage

Silica dust exposure can also cause kidney damage, leading to formation of kidney stones and decreased kidney function. Symptoms include abdominal pain, blood in urine, and nausea.

Scleroderma

This disease of connective tissue in the body can result in formation of scar tissue in skin, joints, and other organs, caused by long-term exposure to silica dust. Symptoms include skin thickening, joint pain, and stiffness.

Workplace Activities With High Exposure to Silica Dust

Crystalline silica is widely used to create several essential household items. It's used to fabricate kitchen and bathroom bench tops and make bricks and tiles. Certain plastics also contain small amounts of silica to provide greater strength and durability than standard plastic items.

Below are further examples of work activities where silica dust exposure may occur:

• Sandblasting
• Tuck-pointing/bricklaying
• Concrete cutting, drilling and grinding
• Demolition of concrete structures
• Mining and tunnelling operations
• Stone masonry and tile-setting
• Stone crushing and gravel screening
• Manufacturing of abrasive products
• Milling or grinding of cast iron, stainless steel or other metals containing silica
• Pottery making

Compliance with Silica Dust Regulations in Australia

Silica dust exposure is subject to rigorous regulatory requirements to ensure workers' health and safety. Employers must comply with Workplace Health and Safety (WHS) regulations in their respective States/Territories, including the following:

WHS Duties under the Code of Practice

While most states have codes of practice for managing risks of respirable crystalline silica from engineered stone in the workplace, Queensland's Industrial Relations Minister Grace Grace has given the green light to Queensland's latest Managing Respirable Crystalline Silica Dust Exposure in Construction and Manufacturing of Construction Elements Code of Practice 2022.

This Code is the first to specifically address silica dust in the construction sector, and is set for implementation in Queensland starting May 1, 2023. The Code encompasses all construction activities and production of materials like bricks, blocks, tiles, mortar, and concrete.

A code of practice provides practical guidance to achieve standards of health, safety, and welfare required under WHS laws. Duties under a code typically apply to different stakeholders, including persons conducting a business or undertaking (PCBUs), workers, and other relevant parties.

Workplace Exposure Standard (WES)

The Workplace Exposure Standard (WES) is a set of values ensuring safe working conditions for workers exposed to hazardous substances. WES values fall into three categories depending on the substance's critical effect type.

• Time Weighted Average (TWA): Measures average concentration of a substance in the workplace over an 8-hour day and 40-hour week.
• Short-Term Exposure Limit (STEL): Maximum concentration of a substance a worker can be exposed to for an average 15-minute period over a day without adverse health effects.
• Peak Limitation (peak): Maximum concentration of a substance a worker can be exposed to for a short period, such as 10 minutes.

Regulations state that persons conducting a business undertaking (PCBUs) must comply with exposure standards, not exceeding 0.05 mg/m3 (eight-hour time-weighted average). Furthermore, PCBUs must take all reasonable steps to:

• Ensure workers don't exceed this standard
• Monitor air quality using safe work practices
• Provide employees with adequate protective equipment

Air Monitoring

Air monitoring helps determine concentration of airborne respirable crystalline silica (RCS) to ensure levels don't exceed relevant exposure standards.

According to WHS Regulations and guidelines from Safe Work Australia, air monitoring should be conducted when:

• There is uncertainty about levels of respirable crystalline silica exposure and whether they fall within exposure standards.
• There have been significant changes to work processes, control measures, or the type of materials being used, which may impact RCS exposure levels.
• Effectiveness of implemented control measures needs evaluation.

Purposes of air monitoring include checking the following:

• Effectiveness of control measures
• Informing workers about their exposure patterns
• Determining what level of respiratory protection is necessary
• Informing health monitoring requirements

However, air monitoring alone does not prevent illness, and effective control measures must accompany it. Air monitoring should also be carried out by a competent person, such as an occupational hygienist, using appropriate sampling and analytical methods.

Health Monitoring for Workers

In Australia, health monitoring is required for workers who may be exposed to silica dust in accordance with WHS Regulations. Health monitoring aims to identify adverse health effects caused by exposure to hazardous substances, including crystalline silica. Providing health monitoring to at-risk workers is the responsibility of the person conducting a business or undertaking (PCBU).

According to Safe Work Australia's guidelines, health monitoring should be initiated for workers when:

• There is significant risk to a worker's health due to exposure to respirable crystalline silica.
• The worker is working with materials containing crystalline silica and exposure standards are likely to be exceeded.

Health monitoring typically includes:

• A review of the worker's work history and a medical examination, including a chest x-ray and lung function tests.
• Regular ongoing assessments and follow-ups, as recommended by the medical professional.

Always check with the relevant WHS authority in your jurisdiction for the most up-to-date information on health monitoring requirements.

Consultation

Regulations require PCBUs to consult, cooperate, and coordinate activities with all other duty holders who have WHS duties. For example, during installation of engineered stone, there may be multiple PCBUs involved, such as electricians, plumbers or cabinetmakers. These duty holders must collaborate to identify hazards and risks and decide who controls them best. Duties may overlap and interact when they share responsibility for protecting health and safety in the workplace.

Safe Work Method Statements (SWMS)

For high-risk construction work with potential to generate airborne silica dust, organisations must prepare a safe work method statement (SWMS) to ensure worker safety.

The PCBU must prepare an SWMS before any work involving cutting, grinding, trimming, drilling, sanding, or polishing activities that might generate RCS. The SWMS helps a PCBU communicate risks and how they'll manage them.

Managing Silica Dust Hazards

Silica dust hazards pose significant health risk to workers when exposure levels exceed safe limits. Workplaces should implement safety measures to minimise exposure, such as:

Hierarchy of Controls

PCBUs have specific duties to manage health and safety risks associated with using, handling, generating, and storing hazardous chemicals, including silica. Hierarchy of controls manages risks and exposure to silica in the workplace. This involves:

• Substitution: Choosing alternative materials with less silica, such as composite stone bench tops.
• Isolation: Designing specific areas for tasks that generate dust and ensuring appropriate worker positioning, using enclosures and automation to minimise dust exposure.
• Engineering controls: Installing equipment and systems that minimise risk of exposure to generated dust, such as local exhaust ventilation, water suppression (wet cutting), or tools with dust collection attachments.
• Implementing administrative controls: Establishing safe work procedures and providing personal protective equipment (PPE) to reduce daily exposure.
• If risks still exist, provide PPE, such as respiratory equipment, to protect workers from airborne dust. Equipment should be periodically tested and maintained per manufacturer's instructions.

Ventilation

Installing effective ventilation systems and using wet methods to minimise dust generation remains essential in controlling silica dust exposure. Local exhaust ventilation (LEV) should capture dust at the source, while general ventilation can help dilute airborne silica levels in the work area. For more information about ventilation, see Model Code of Practice: Managing risks of hazardous chemicals in the workplace.

Training and Education

Knowing how to work safely with silica remains critical for any business. Training workers on potential dangers of silica dust exposure represents the best way to ensure they understand associated risks. Workers must understand what silica dust is, its possible health effects, and control measures in place to protect them.

They should also be made aware of unsafe work practices that could increase their risk level and taught how to react if they observe unsafe practices occurring at their workplace. Finally, employees should be encouraged to immediately report hazards or health and safety problems so risks can be managed effectively.

Housekeeping

Good housekeeping of the work area is another important consideration in controlling silica dust. All floors, walls, and surfaces should be cleaned and vacuumed regularly to control dust levels. Workers should be provided with appropriate cleaning equipment and materials, such as vacuum cleaners, mops, and wet wipes, to maintain a clean and dust-free work environment.

The SWMS addresses housekeeping measures, along with other instructions to ensure worker safety is maintained. Additionally, employers must provide written instructions on identifying and reporting potential health risks associated with silica dust exposure.

Decontamination

Take precautionary measures when dealing with decontamination of dusty clothing and PPE. Regular cleaning reduces spread of silica dust. Vacuum cleaners fitted with HEPA filters remove dust from clothes and uniforms. Workers should also have access to areas where they can wash their arms, hands, faces and hair.

Workers should not take dusty clothes and PPE home for washing, as this increases risk of contamination. A commercial laundry service can be used if necessary. However, dampen clothes first and place them in a sealed bag with a label warning of contamination with crystalline silica.

Personal Protective Equipment (PPE)

Use of personal protective equipment (PPE) can help protect workers from silica dust exposure. Oversee employees to ensure they understand their training and utilise appropriate PPE accurately.

• Respiratory protective equipment (RPE): Using RPE such as dust masks, disposable respirators and half-face respirators protects workers from silica dust inhalation. Equip employees with correct RPE for their job and ensure RPE is regularly tested, maintained and replaced as needed.

Safety Documents

Detailed safety documents, such as a safe work method statement (SWMS) and job safety analysis (JSA), should be created for each workplace task involving silica dust. Employers must also use safety registers, checklists, and inspection reports to track employee safety compliance.

These documents should be detailed, updated regularly, and readily available for workers to reference. Providers, like SafetyDocs, offer templates to help you develop a safety management system and hazard control statement plans that cover all aspects of working safely with silica.

Make Safety Management and Compliance Easy With SafetyDocs

SafetyDocs by SafetyCulture provides a comprehensive range of safety document templates, including SWMS and management plans, to help you create tailored documents for your workplace. We provide businesses across all industries with a wide range of safety documents to assist in creating a comprehensive silica dust safety management plan.

Check out these safety documents to assist you with managing silica dust:

• Silica Dust Management Plan
• Silica Dust Safe Work Method Statement
• Personal Protective Equipment (PPE) Register
• Construction OHS:WHS Project Management Plan
• Hazardous Materials Policy (Asbestos, Lead, Silica)

Trust SafetyDocs to help manage risks associated with silica dust. Read our related article on the WorkSafe silica dust safety warning for further context on regulatory action, or explore our safety software solutions to streamline compliance across your organisation. Contact us today to find out more about our safety document solutions.

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.

Available for instant download and supplied in fully editable MS Word format for use in your business.

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