GRANITE HOUSE MONITOR FOR POTENTIALLY HAZARDOUS AIRBORNE SILICA DUST

Customer / End User

Granite House

Application

Interior surfacing

Industry

Worktop fabrication

Country

United Kingdom

Product(s) used

AIR XS Silica Monitor

Challenge

Granite House, who deliver bespoke granite and quartz work surfaces, based in Preston, United Kingdom, wanted to determine exactly how much Respirable Crystalline Silica (RCS) they were exposed to, when undertaking specific activities such as cutting stone and using heavy duty machinery. 

Outcome

Despite regularly using wet cutting methods and ensuring staff are always following correct protocol and best practice, AIR XS Silica Monitor was deployed to ensure workers were regularly best protected from risk. The ability to move the unit around site and nearby specific processes ensured risk was reduced throughout the day. 

Company & Application 

Based in Preston, Lancashire, Granite House by Stone Masters is in their 22nd year of providing and delivering bespoke worktops and services, whether locally or nationally across the entire UK. 

From initiating first templates of designs, to manufacturing, servicing and installing finalised granite worktops, Granite House does it all, meaning workers are regularly in contact with marble, porcelain, quartz and granite materials. 

The Challenge 

Working with such materials including marble, porcelain, quartz and granite materials, workers are often at risk of airborne RCS when cutting or drilling, as the material is ground down into fine, respirable particulates. 

Whilst materials such as marble and porcelain have low silica content (between 5% to 25%), materials such as quartz can contain up to 90% silica content, making it seriously dangerous for anyone who may be exposed to airborne RCS. 

The AIR XS plan 

An AIR XS unit was deployed nearby processes which involved cutting and other heavy-duty processes using silica containing materials, such as quartz and granite. Even though most processes undertaken by Granite House, such as sawing granite and quartz, are completed using wet methods and water suppression, in order to ensure all their staff are always protected from silicosis risks, the AIR XS was seen as a necessary tool to use. 

One staff member at Granite House commented:

Obviously silicosis is a big thing in our industry and AIR XS helps to make sure that our whole team is safe. So, we’re going to make sure we monitor everything to monitoring everything to keep our team safe.

We took it all the way around the factory but even around the saws where we’re cutting we’ve got to be careful, because even though everything’s cut under water, that the stone silica dust is not going into aerosol and then drying and affecting the air that’s around us.

Silicosis is one of the most serious risks in our industry, and it’s one we take incredibly seriously. AIR XS offers a layer of protection that keeps our whole team safe, and it’s the kind of standard every fabricator should be holding.”

Employee

Granite House

The process of using AIR XS was seen as a success by Granite House and its staff members, not only to protect their workforce but to determine whether their water suppression and water usage during cutting is effective in reducing silica levels. 

 We’re always keen to collaborate with workplaces where employees could be exposed to harmful particulates in the workplace. Reach out to our dedicated team of experts who can discuss how to deploy AIR X real-time particulate monitoring in your workplace today. 

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    INDUSTRY RISKS
    Open Pit + Overground Mining

    The International Council of Mining and Metals (ICMM) report occupational diseases contribute to nearly 2.5 million annual deaths in mining + metallurgy industries. Exposure to hazardous particulates + gases play a major role in this.

    What are the risks?

    • Asbestos particulates
    • Copper powder
    • Diesel Engine Exhaust Emissions (DEEE)
    • Respirable Crystalline Silica (RCS)
    • Gold + other mataliferous dusts
    • Other airborne dusts + mists
    • Carbon Dioxide
    • Hydrogen Sulphide
    • Sulphur Dioxide
    • Mercury vapour
    • Methane

    Why may these risks occur?

    • Blasting rock + other raw materials
    • Crushing rock + other raw materials
    • Demolition of rock structures
    • Use of certain machinery
    • Blasting rock + other raw materials
    • Decay of organic matter
    • Processing rocks + raw materials
    • Use of certain machinery
    • Use of diesel vehicles

    PRODUCT SOLUTIONS

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          INDUSTRY RISKS
          · STONE INDUSTRY

          An estimated 600,000 workers are exposed to silica in the UK each year according to the British Safety Council, which is generated in various different ways across multiple occupational environments, including stonemasonry and worktop manufacturing.

          What are the risks?

          • Construction dust
          • Fine engineered stone
          • Respirable dusts
          • Respirable Crystalline Silica (RCS)

          Why may these risks occur?

          • Drilling + chiselling stone
          • Grinding + cutting stone
          • Lack of wet methods
          • Polishing stone
          • Poor ventilation
          • Use of engineered stone over natural stone

          PARTICULATE MONITORING

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                INDUSTRY RISKS
                · QUARRYING + AGGREGATES

                World Green Building Council reports every year about 100 billion tonnes of hard rock and other raw materials are extracted in quarrying for use across industrial sectors globally. When demolished, drilled into or blasted, these fine materials can become respirable and airborne, posing serious health risks to workers.

                What are the risks?

                • Construction dust
                • Diesel Engine Exhaust Emissions
                • Quarry + aggregate dust
                • Respirable Crystalline Silica (RCS)
                • Hard rock
                • Carbon Monoxide
                • Hydrogen Sulphide
                • Formaldehyde
                • Flammable gases
                • Methane

                Why may these risks occur?

                • Cutting into hard rocks
                • Drilling into hard rocks
                • Demolition of hard rocks
                • Use of certain machinery
                • Transportation of hard rocks
                • Blasting rock + other raw materials
                • Handling hard rocks
                • Processing rocks + raw materials
                • Transportation of materials
                • Use of explosives
                • Use of diesel vehicles

                PRODUCT SOLUTIONS

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                      5 quarrying scenarios where respirable dust is generated

                      Crushing + screening

                      Breaking down all types and sizes of rocks in quarrying, through crushing and screening processes generate high levels of respirable dust. When the rocks are crushed and then screened, large volumes of both visible and invisible dust becomes airborne and travels across the entire quarry site, presenting a risk for all workers. 

                      Drilling + blasting

                      As in mining, quarrying also involves a large amount of drilling, blasting and other methods to break down rocks and spaces for processing and extracting. These processes lead to rocks, clay and other natural materials becoming very small and making them airborne and easily inhaled, leading to severe health risks for workers. 

                      Storage of minerals + natural materials

                      Once all materials have been extracted and processedthey’re stored in designated areas after collection. Herenatural materials are stored in stockpiles, where they grind against other materials and minerals, creating more and more respirable dust. When these minerals are used, the settled dust becomes disturbed and airborne. 

                      Maintenance + handling processes

                      Maintenance of all types of machinery, vehicles and minerals, such as rock and sand in quarrying can generate respirable dust. If dust from screening, drilling and even in stockpiles isn’t correctly maintained it becomes dormant. Poor maintenance and handling processes like dry sweeping can spread dust, presenting health issues. 

                      Transport of goods

                      Heavy-duty vehicles used in quarrying such as haul trucks and conveyors often involve moving large volumes of natural minerals which have been processed and are fine and small in size. This can present risk of airborne dust across all areas of the site, as well as other dust which may be trapped in wheels and cabs of the vehicle. 

                      PARTICULATE MONITORING

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                        5 stone working scenarios where respirable dust is generated

                        Chiselling + non-power tools

                        Smaller, non-power tools such as chisels can generate high levels of respirable dust, such as silica, in stone works. A vital job for creating features and designs within stone, this process requires chipping and breaking down part of the stone into fine dust as a byproduct, which becomes airborne and poses significant risk to workers. 

                        CNC machines

                        CNC machines use a computerised operation to cut and shape large slabs of marble and other materials in stone works, often generating dust as a byproduct. Without proper dust control measures, such as water to damp down the dust or dust extraction units added on the machine, it can become airborne and easily inhalable. 

                        Handheld power tools

                        Dust can be generated from handheld drills, grinders and other power tools used in stone works. The high intensity from the automation of these tools means stones are ground and broken down faster, leading to higher levels of airborne dust, especially in and around the breathing zone of those using the power tools. 

                        Lack of water-controlled processes

                        It’s not just on CNC machinery where water-controlled processes are essential to limiting dust control. Any large machinery jobs involving polishing, cutting and finishing generates high levels of respirable dust which, and without effective water-control to dampen the dust making it heavier, dust subsequently becomes airborne. 

                        Ineffective maintenance processes

                        As there are various different ways respirable dust can be generated in stone work industriesit’s essential that maintenance is as effective in relation to the workplace you’re in to prevent further dust generation. Dry sweeping, lack of dust extraction and general ignorance of the issue can lead to dormant dust not being dealt with properly. 

                        PARTICULATE MONITORING

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                          5 health risks linked to occupational dust exposure

                          1. Occupational lung diseases

                          Arguably the most well-known and common risk associated with exposure to hazardous dusts in the workplace relate to occupational lung diseases. Diseases such as Silicosis, Chronic Obstructive Pulmonary Disease (COPD), Black Lung Disease and occupational lung cancer all are associated with dust inhalation in the workplace. 

                          2. Respiratory illness and irritation

                          Whilst long-term exposure to breathing in dust can lead to lung diseases, initial, short-term exposure to hazardous dusts can lead to respiratory illness and irritation. Breathing in dust such as Respirable Crystalline Silica (RCS) and wood dust can cause serious respiratory diseases; the NHS claim it’s the third biggest cause of death in England. 

                          3. Cardiovascular diseases

                          Exposure to breathing in hazardous dust can lead to cardiovascular diseases and other heart and blood vessel issues. Dust and hazardous particulates can easily travel through your bloodstream and deep into your lungs, damaging your blood vessels in the process. This can increase blood pressure and make it more likely to give you blood clots. 

                          4. Occupational asthma

                          The British Thoracic Society reports that occupational asthma is responsible forroughly 1/6 cases of adult-onset asthma. Occupational asthma can be caused by various types of dust in multiple different industries, such as flour dust, wood dust, grain dust and various fumes from metals.  

                          5. Long-term health concerns

                          There have been examples of various other health concerns relating to workplace exposure to hazardous dust. Skin, eye and nose irritation, as well as some rare examples of kidney disease have all been linked to examples where workers have failed to protect themselves against hazardous dust. 

                          PARTICULATE MONITORING

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                            UK URGED TO FOLLOW AUSTRALIAN STONE BAN

                            There have been recent calls for the UK government to follow in the steps of the Australia and introduce a ban of manufacturing engineered stone in an attempt to combat rising cases of silicosis.

                            SILICA DUST EXPOSURE WITH ENGINEERED STONE

                            This news comes after cases of silicosis linked to engineered stone exposure recently came to light globally. Workers who have been exposed to engineered stone quartz and dust are now being affected by and diagnosed with severe lung problems, linked to inhaling such dust. Earlier in the year, it had prompted the Australian government to act and ban the use, manufacturing, and production of engineered stone across the entire country. 

                            Now the UK is being urged to do the same, with the first cases of occupational silicosis related to engineered stone production have now been reported in the country. Various medical staff who have treated workers diagnosed with these cases of silicosis are calling for similar action to be taken in the UK as in Australia. 

                            SILICOSIS CASES IN THE UK

                            According to British newspaper i the first 8 cases of silicosis linked to engineered stone use have been confirmed, all of which are men. The average age of the 8 men is 34, with the youngest to be diagnosed just 27 years old. Of the 8 cases, 1 man has died, and 2 others have been referred for lung transplant assessments. 

                            The article from i features an interview with one of the diagnosed workers, Malik al-Khalil, a stonemason who is just 31. After working with engineered stone for 5 years, Malik was diagnosis with silicosis, contracted after cutting engineered stone slabs in a small London workshop. Malik said, “I want to let all the people working in this work know what’s happening from this material” and believes the only solution to this growing problem is a nationwide ban of the product; “Of course [it should be banned] because the silicosis is coming from this material.” 

                            A MEDICAL CONCERN

                            It’s not just Malik and fellow diagnoses patients who are calling for engineered stone to be banned in the UK. Dr Johanna Feary, a respiratory consultant from the Royal Brompton Hospital where Malik al-Khalil is being treated, and lead author for ‘Thorax’, has also highlighted her concerns over exposed to the product. Dr Feary told i “We’ve been anticipating that we would start seeing cases in the UK at some point. That moment has arrived now.” 

                            The team of doctors writing in ‘Thorax’, who highlighted the first 8 cases, have also called for a legal requirement to report cases of silicosis, as well as calling for the implementation of health and safety regulation for both small companies and national guidelines to treat and monitor for silicosis. 

                            AIR X PARTICULATE MONITORING

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