Protecting Stone Workers from Harmful Silica Dust: Essential Guidance for Worktop Installers

Protecting Stone Workers from Harmful Silica Dust: Essential Guidance for Worktop Installers

Stone worktop installation might seem like a routine task, but the risks associated with respirable crystalline silica (RCS) in stone dust make it one of the most hazardous jobs in the construction industry. Whether cutting, chiselling, or polishing natural or engineered stone, workers are exposed to fine silica dust particles that, when inhaled, can lead to severe, life-altering lung diseases.

The Health and Safety Executive (HSE) has introduced new guidance to help stone worktop installers understand how to stay safe and minimise exposure to silica dust. In this blog, we’ll break down the risks, key safety measures, and the legal responsibilities of both employers and self-employed workers.

Why Silica Dust Exposure is a Serious Threat

Silica is a naturally occurring substance found in stone, sand, concrete, and other construction materials. When stone is cut, sanded, carved, or ground, it generates fine dust particles that can be inhaled deep into the lungs. Over time, exposure to RCS can cause irreversible, and often fatal, lung conditions, including:

  • Silicosis – A lung disease caused by prolonged inhalation of silica dust, leading to scarring and breathing difficulties.
  • Chronic Obstructive Pulmonary Disease (COPD) – A long-term, progressive condition that restricts airflow and causes severe respiratory distress.
  • Lung Cancer – Prolonged exposure to RCS is a known cause of lung cancer, making workplace dust control a critical health priority.

With hundreds of workers diagnosed each year, taking action to prevent exposure is essential to protect both health and livelihoods.

New HSE Guidance: Protecting Stone Workers on the Job

To reduce the risks associated with silica dust, the HSE has worked with industry experts to produce new guidance that outlines key safety measures for stone worktop installers. The advice focuses on three main areas:

1. Competent Staff & Effective Processes

  • Ensuring workers are properly trained and that work processes are designed to minimise silica exposure is vital. Employers must:
  • Provide training on silica dust risks and control measures.
  • Ensure workers use respiratory protective equipment (RPE) such as FFP3 masks with an Assigned Protection Factor (APF) of at least 20.
  • Make sure extraction and dust suppression systems are properly maintained.

2. Pre-Installation Actions

  • Before arriving on-site, the following steps should be taken:
  • Minimise cutting on-site – Pre-cut sink and tap holes, drainage grooves, and edge shaping before delivery.
  • Use accurate measurements – Obtain specifications using templates, contractor-provided dimensions, or infrared measuring devices to reduce last-minute cutting.
  • Remove dust before transportation – Use wet cleaning methods or an M-class vacuum to clean worktops before they leave the workshop.

3. On-Site Installation: Working Safely

Once on-site, installers must take extra precautions to limit silica exposure:

  • Use water suppression or on-tool extraction with an M-class vacuum.
  • Ensure an adequate water supply for dust suppression.
  • Segregate cutting areas – If cutting must be done on-site, it should be in a well-ventilated, restricted access area (ideally outdoors).
  • Shut down heating and air-conditioning systems to prevent dust from spreading.
  • Wear the right protective equipment – This includes FFP3 masks, coveralls, and appropriate gloves.
Qualitative Face Fit Testing: Ensuring RPE is Effective

Wearing a mask is only effective if it fits properly, creating a secure seal that prevents silica dust from being inhaled. Employers must ensure that anyone using tight-fitting respiratory protective equipment (RPE) undergoes face fit testing to confirm an adequate fit.

Why Face Fit Testing Matters

  • Prevents leaks – A poorly fitted mask will not provide full protection against fine silica dust.
  • Ensures compliance – The HSE requires workers using tight-fitting RPE to have a face fit test.
  • Improves worker confidence – Employees can work knowing they are properly protected.

Train Your Own Face Fit Tester

Instead of relying on external providers, businesses can train their own in-house Face Fit Tester, allowing them to:

  • Conduct qualitative face fit tests for employees on-site.
  • Ensure ongoing compliance without external costs.
  • Keep workers safe with regular mask fit checks.

At Acadame, we offer Face Fit Testing and Train the Tester courses to help businesses take control of their RPE compliance. Get in touch to book your training today!

Safe Clean-Up Practices: Reducing Residual Dust Risks

Even after the work is done, dust remains a significant hazard. Cleaning up properly is essential to prevent further exposure. Installers should:

  • Use wet cleaning methods – Avoid dry sweeping, which can send silica particles back into the air.
  • Wear RPE during clean-up to avoid inhaling residual dust.
  • Use M-class vacuums instead of compressed air or dry brushing to remove dust from tools, surfaces, and clothing.
  • Dispose of stone waste carefully – Wet slurry and collected dust should be bagged and disposed of correctly to prevent further exposure.
Legal Responsibilities: What the Law Says

Employers and self-employed stone workers must comply with legal regulations to control silica dust exposure under the Control of Substances Hazardous to Health Regulations (COSHH). This means:

  • Assessing risks  Conducting workplace risk assessments to identify exposure risks.
  • Implementing control measures – Using water suppression, extraction systems, and PPE to minimise exposure.
  • Providing training – Ensuring all workers understand silica dust hazards and how to work safely.

Even self-employed workers are legally responsible for protecting themselves and others from dust exposure. Failing to comply with COSHH regulations can result in legal action and serious health consequences.

The Future of Silica Safety in Stone Working

The HSE is continuing to increase awareness and enforcement around silica dust exposure in the construction and stone industries. Stricter regulations, improved PPE, and better training are key to protecting workers from preventable diseases.

By following best practices, using effective dust control measures, and staying informed on industry updates, stone workers and employers can play a crucial role in creating safer work environments.

Take Action Now: Protect Yourself & Your Team

If you work with stone, take silica dust exposure seriously. Follow the new HSE guidance, ensure proper dust control, and invest in Face Fit Testing and COSHH Awareness training to keep your team safe.

📢 Acadame now offers Face Fit Testing, Train the Tester courses, and COSHH Awareness training – available in the classroom or as e-learning. Ensure your team is protected, compliant, and fully trained in hazardous substance management. Contact us today to book your training!

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At Acadame, we’re not just another training provider—we’re your partners in safety excellence. With a commitment to innovation, relevance, and engagement, we deliver high-quality training programs designed to exceed your expectations at a competitive price. From industry-leading trainers and assessors to cutting-edge learning technologies, we offer an unmatched learning experience that equips you with the knowledge, skills, and confidence to thrive in your career. Choose Acadame and unlock your full potential in the realm of health and safety.

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