As part of our ongoing testing programme in real-world scenarios, we recently visited a local company manufacturing specialist refractory materials. During the visit, our in-house Occupational Hygienist conducted personal exposure monitoring using traditional techniques as stipulated in MDHS 101/2 – Crystalline silica in respirable airborne particulates, alongside our AIR X Particulate Monitors.

“We were approached by the workshop health + safety manager so they could seek a deeper understanding of our real-time particulate monitoring technology. We offered an on-site trial, pairing our AIR X products with traditional exposure monitoring. The results were highly encouraging, and the collaboration marked the beginning of a strong working relationship.”

Joe Marais, Trolex Product Development Manager

Personal sampling was conducted on one of the Mill Operators as they filled bags with materials containing crystalline silica. 2 AIR XS units were positioned either side of the Operator’s work area, and the resultant respirable crystalline silica (RCS) levels were recorded in real time.

In line with standard Occupational Hygiene practice, the personal samplers were retrieved from the Operative, processed, and submitted to an external accredited laboratory for analysis of both respirable dust and RCS exposure concentrations.

The analytical results indicated that the Operative was exposed to 0.101 mg/m³ of RCS during bagging activities. At the same time, the AIR XS units returned average RCS results of 0.118 mg/m³ and 0.079 mg/m³ respectively. The data provided valuable insights into the operative’s behaviours based on exposure profiles during the assessment period.

On the results, the client commented:

“We were exploring ways to improve our understanding of airborne exposure in real time, and the AIR X trial offered exactly that. Compared to traditional monitoring, which gave us just a single data point, the real-time exposure profile illuminated work patterns and pinpointed specific sources of particulates throughout the shift. It provided a level of insight we hadn’t seen before and opened the door to more informed decision-making.”

This comparative result not only demonstrates how AIR XS performs in line with traditional monitoring techniques, but also highlights its importance in interpreting operative behaviours, the impact of resting periods, and the design of control measures.

• Respirable Crystalline Silica is one of the most hazardous types of dust workers can be exposed to. RCS forms many types of natural materials such as stone, sand and rock, and is generated when these materials are cut, ground or made fine through various different workplace processes. 

• Common industries exposed to RCS: Construction, mining + stone working 

• Asbestos dust is generated through the damaging of asbestos-containing materials such as cements, tiles and other products in manufacturing environments. When airborne, asbestos dust is easily inhaled due to its small size and scars deep into the lungs, causing lung diseases. 

• Common industries exposed to asbestos dust: Construction, demolition + manufacturing

• Substances and ingredients which are used to make pharmaceutical products can often create high levels of hazardous dust during processes such as milling, pressing, blending and grinding. API dusts can include organic compounds, metal powders and combustible properties. 

• Common industries exposed to API: Chemical Manufacturing + Pharmaceutical 

• Coal dust is generated in various underground environments when coal is being mined for, in rocks and other natural structures and materials. Cutting, grinding and blasting rocks makes coal dust easily inhalable, especially in environments with limited ventilation or space, such as underground. 

• Common industries exposed to coal dust: Mining, quarrying, gold (open-pit) mining + tunnelling 

• Construction dust can be generated from any kind of construction activity, whether cutting, drilling, mixing materials, building infrastructure, or other processes. Materials like stone, cement, sand and brick generate fine, respirable materials which create high levels of construction dust. 

• Common industries exposed to construction dust: Construction + quarrying 

• Grain dust is created when using barley, wheat and other natural materials from farming and harvesting. These processes in agriculture, as well as the manufacturing of grains in food production lead to grain dust exposure, generated from handling, transferring, milling and mixing grain. 

• Common industries exposed to grain dust: Agriculture + food production

• Flour dust is generated through mixing, cutting and handling flour, whether from initial farming and harvesting of crops, to processing it in food production. Exposure to flour dust can be dangerous, as its easily inhaled due to its small size and common use and worker exposure in food processing

• Common industries exposed to flour dust: Agriculture + food production 

• Textile dust is generated during apparel and clothing manufacturing due to processes such as drawing, carding, spinning, handling materials, and others, particularly due to the properties of wool, cotton and fibres. Occupational asthma and respiratory irritation is common for workers exposed to textile dust.  

• Common industries exposed to textile dust: Textile + apparel manufacturing 

• Fine metal particles generated through welding can lead to various occupational illnesses. Welding at high temperatures, above certain materials boiling point generates high levels of metal dust, particles and fumes which need to be effectively controlled during welding processes. 

• Common industries exposed to welding dust: Manufacturing + welding 

• Sawing, cutting and drilling into wood products often generates high levels of dust. This can be either hardwood dust, generated from oak or beech trees, or softwood dust, such as pine or fir trees. Exposure to hardwood dust can cause serious cancers, whilst softwood dust can cause respiratory irritation. 

• Common industries exposed to wood dust: Construction, forestry + woodwork 

By segregating processes which produce large volumes of dust, you can control the amount of dust your workers are exposed to. In some cases, it may even be possible to make the process entirely automated, meaning no workers are exposed to dust. Introducing a remote operation, e.g. a separate room or section within a facility meaning workers completing the dusty process never directly come into contact with the excess dust created. This process means that if workers have to complete a task which is likely to create excess hazardous dust, they spend as little, or if possible, no time exposed to the dust. 

In cases where segregation isn’t possible, extraction is an option to control excess dust. Local Exhaust Ventilation (LEV) systems can be built into machines or processes which create excess dust. LEV and extraction systems collect contaminants like dust and filter out the contaminants before they’re released into the air. This process can be used for multiple processes within the workplace such as storage bins, grinding mills, conveyors, mixing machines and many more, ensuring that when excess dust is created it does not come into direct contact with workers during these processes. 

Using less-toxic materials, where applicable, is another suitable method for controlling dust exposure in your workplace. For example, the use of pellets rather than powders, or replacing sand with garnet as abrasive blasting agent can allow workers to produce a similar end product during workplace processes whilst minimising risk of dust exposure. By substituting out materials for less toxic alternatives, workers can continue their processes throughout the day, at less, or almost no risk to their respiratory health.

The use of wet methods can provide almost no airborne dust during workplace methods. Damping down materials such as stone and concrete, which are used for many workplace processes and usually create high levels of dust when disturbed, can mean potential airborne dust is limited due to the particles binding together when wet. Similarly, methods of cleaning such as dry sweeping dust or compressed air lines can spread and disturb hazardous dust across the workplace, making it airborne and posing a threat to workers health, controlling excess dust and reduce the risk to workers. 

Excess dust is a consist problem in workplaces where highly dusty processes occur, especially if it is not possible to completely eliminate the risk of dust. By maintaining cleanliness, encouraging workers to work with care and instructing them how to control the dust produced in their work processes by following the methods mentioned, control of dust can become a regular process in the workplace. 

The ability to know in real-time when dust exposure limits are breached and to see all the data your real-time dust monitor picks up throughout your working day allows you to find the root of your dust problem. With Audio/Visual alarms and live readings for dust level breaches, you can deduce exactly which processes are causing excess dust levels. Similarly, by viewing data over full shifts and seeing when dust levels are highest, you can deduce what processes were completed at that time, to find the root of your dust problem. By finding the root of your dust problem, effective control measures can then be introduced. 

AIR X real-time particulate monitors have a single-user configurable Audio/Visual alarm that can be used to warn users of a specific particulate threshold breaches based on a chosen limit or value. For example, in the UK, the Workplace Exposure Limit for Respirable Crystalline Silica is 0.1 mg/m3 over an 8-hour period. A customisable alarm can be set on your TX8100 AIR XS Silica Monitor will alert you in real-time if the threshold is breached during your working day. This allows you and your workforce to work as normal throughout their day, knowing that you’ll be alerted as soon as you’re set limits are breached.  

Our real-time dust monitoring technology can be deployed as either fixed, area or personal monitoring, so workers in any location of your workplace can monitor for dust in real-time. This allows for all areas of the workplace to consistently monitor for excess dust, as well as deduce which areas of the workplace are at higher risk of dust exposure. Deploy the full range of AIR X particulate monitors alongside one another to provide the more accurate and reliable readings of dust levels, all in real-time, so your workers are protected across entire shifts, across the whole workplace. 

All our AIR X technology has supporting software, via desktop and in some cases mobile, to view all live and historical data. Breathe Software allows you to view data as it happens and view up to 10-years’ worth of data, so you can consistently track any changes as they happen over time. By viewing all the data your dust monitor picks up, you can see when dust levels peak and from this deduce the most effective control measures that need to be introduced in line with what process cause the spike and where this was occurring.

The ability to know in real-time when dust exposure limits are breached and to see all the data your real-time dust monitor picks up throughout your working day means you can work in-line with the Hierarchy of Controls, to eliminate or substitute the hazard, and introduce control measures for excess dust. By finding the root of your dust problem through real-time dust monitoring, you can not only introduce dust control measures to eliminate or reduce exposure to dust but can also effectively monitor your control measures to see how effective they’re working, and make vital and supported business decisions if further changes are required. 

First and foremost, the benefit of seeing dust levels in real time is being able to deduce whether you, your workers and your occupational environments are safe. Respirable dust is smaller than 10 μm meaning it’s invisible to the human eye, yet it’s so finite that it can easily be breathed in and penetrate the lungs. You may be breathing in respirable dust and putting your respiratory health at risk without even knowing it. But with real-time dust data, you can know exactly how much dust you’re exposed to throughout your working day and introduce the necessary steps to protect your respiratory health. 

Real-time dust data isn’t just available for live readings in real time. Compatible with all our real-time monitoring technology, our Breathe Software collects and stores data for up-to 10-years, so you can see changes in your dust levels for the entire previous decade. You can track trends in the dust levels your workers are exposed to over a period of time in your working day, week, month or year and determine whether you and your workers have been exposed to potentially hazardous substances over that period.

Our dedicated real-time dust monitoring software allows you to personalise all the relevant settings for your Trolex real-time dust monitor. If the dust monitor is alarming you of dust levels irrelevant to your local legislative limits, it’s not necessarily going to protect you as effectively as if it’s alarming you of the dust levels in your local environment. Our Breathe software lets you set dust levels specific to your environment and workplace to ensure you’re constantly monitoring for dust levels in the most effective way possible.  

Real-time dust data allows you to see trends in your dust levels over a set period and subsequently introduce vital control measures to effectively manage and control dust. Our dedicated Breathe Software allows you to understand at what time peak dust levels were in your working day and deduce what activities were taking place during this time, so you can introduce relevant and effective control measures to prevent future dust from becoming airborne at this time. 

After introducing control measures, you can continue to use real-time dust data through our dedicated Breathe Software to see how effective these control measures are in controlling dust. If you can’t continually track dust levels over time, it’s impossible to know if your control measures are working effectively, which could cost money, time and most importantly harm your health and wellbeing. However, thanks to Breathe Software, you can see how dust levels are affected by introducing control measures and subsequently make vital decisions to continue to control dust exposure. 

Each year thousands of construction workers contract or die from respiratory diseases from exposure to dust, including silica dust. This can be due to direct exposure on site or simply by just working nearby the construction site, e.g. in a nearby office or cabin.  

Obviously, activities such as drilling, cutting and building generates dust, as raw materials such as brick and stone are disturbed and ground down, making fine dust become airborne, but dust also becomes a risk to workers nearby in other ways. 

Respirable Crystalline Silica (RCS) is less than 10µm in size, meaning that it’s not only easily inhalable, but is also fine and small enough to travel far distances effecting individuals not directly located near construction activities. 

Real-time silica monitoring with AIR XS provides transportable monitoring of respirable silica dust, with a measurement capacity of 1µm to 10µm to monitor across entire construction sites, in nearby offices and further a-field to protect everyone. 

With the ability to monitor in real-time, workers can gauge which activities are causing certain RCS levels at specific times in the day, e.g. if cutting stone causes higher levels of RCS, to then introduce effective control measures to limit RCS generation. 

In the UK alone, there are approximately 2.6 million manufacturing workers, working with various different materials. Approximately 20% of workers in the UK are affected by dust from stone, cement, brick or concrete across workplace processes. 

Manufacturing processes can involve anything from welding and joinery to grinding, cutting and polishing. It can entail all different types of raw materials such as metals and plastics, as well as clay, glass and sand which can all generate dangerous RCS. 

In manufacturing as a whole, which uses various different raw materials and often has multiple processes occurring at once, it’s important to be able to distinguish RCS from other dusts, in total dust loads and mixes, in real-time, both accurately and reliably. 

Real-time silica monitoring with AIR XS provides detailed information by examining multiple detection parameters for RCS in real time, including size, symmetry, and a series of optical markers unique to RCS particles, in total dust loads. 

An estimated 49.5 million miners worldwide are exposed to high concentrations of RCS during their work. Due to specific work processes, enclosed spaces and limited air quality, exposure to silica dust can have a big impact on mining and its workers. 

Processes such as drilling and blasting of materials, even more so during demolition of entire structures, generates high levels of dust, such as silica, due to brittle underground materials such as sand and rock being regularly disturbed. 

As well as this, due to the lack of ventilation and air quality underground, as well as the enclosed spaces which workers find themselves in, RCS can become easily inhaled, sometimes causing life-threatening respirable diseases. 

Real-time silica monitoring with AIR XS offers workers the ability to know exactly how much silica dust they’re exposed to, live and in real-time, no matter the environment they’re in, even including in noisy, high-volume workspaces with limited visibility. 

Real-time readings on device as well as live and historical data through BreatheXS software allows workplaces to subsequently introduce the correct and effective control measures to prevent further overexposure. 

Exposure to silica dust in quarries is not uncommon. Highly dusty processes, with heavy-duty machinery and large-scale vehicles not only generate dust from materials but also disturb settled dust on the ground, increasing the risk.  

Crushing, drilling and blasting of raw materials such as sand and stone can generate high levels of RCS. This dust in incredibly fine and invisible to the human eye, making it easily inhalable and airborne. 

With the wide-open spaces of quarrying, and various different activities and processes being undertaken, this fine dust can easily spread from one area to another, increasing the risk of exposure to it and subsequent associated health risks. 

Real-time silica monitoring with AIR XS ensures that all RCS is accurately monitored for, particularly of vast open areas of the quarry, to account for all workers who may be exposed to hazardous silica dust. 

Thanks to the transportable capabilities of AIR XS, multiple areas, all activities and processes in a quarrying environment can be regularly monitored, allowing for effective control measures to be introduced for excess silica dust. 

Silica is a naturally occurring mineral found in many types of rocks and stones. When working in stonemasonry, natural minerals are regularly cut into, generating high levels of RCS, exposing workers to potential lung and respirable illnesses. 

Shaping, cutting and crafting natural and engineered stone involves chiselling, grinding and polishing of stone, which can contain up to 90% silica content. Once disturbed it often becomes airborne further increasing the risk of illness. 

Without effective and regular control measures, suitable for the material on the job, such as wet methods and dust extraction workers may put themselves and other workers at risk. Real-time silica monitoring can help to support this. 

Real-time silica monitoring with AIR XS provides a valuable insight to the entire workplace, which can be used for introducing the correct control measures to ensure that workers aren’t overexposed to high silica content. 

As part of our ongoing testing programme in real-world scenarios, we recently visited a local company manufacturing specialist refractory materials.

During the visit, Joe Morais, our in-house Occupational Hygienist, conducted personal exposure monitoring using traditional techniques as stipulated in MDHS 101/2 – Crystalline silica in respirable airborne dust, alongside our AirX range of real-time monitoring instrumentation. 

Among other things, personal sampling was conducted on one of the Mill Operators as he filled bags with product containing crystalline silica.

2 x AIR XS units were positioned either side of the operator’s work area, and the resultant respirable crystalline silica levels were recorded in real time. 

In line with standard Occupational Hygiene practice, the personal samplers were retrieved from the operatives, processed, and submitted to an external accredited laboratory for analysis of both respirable dust and respirable crystalline silica exposure concentrations. 

The analytical results indicated that the operative was exposed to 0.101 mg/m³ respirable crystalline silica during bagging activities. At the same time, the AIR XS units returned average respirable crystalline silica results of 0.118 mg/m³ and 0.079 mg/m³ respectively.

The data provided valuable insights into the operative’s behaviours based on exposure profiles during the assessment period. 

This comparative result not only demonstrates how AIR XS performs in line with traditional monitoring techniques but also highlights its importance in interpreting operative behaviours, the impact of resting periods, and the design of control measures.