Where does silica dust come from?
Silica dust is released when materials containing crystalline silica are cut, drilled, ground or otherwise disturbed. Common sources include concrete, brick, stone, tile, and mortar – all of which are frequently used in construction and manufacturing. Tasks like demolition, sanding or crushing of these materials can send fine silica particles into the air, where they can be easily inhaled by workers nearby.
What health complications can silica dust cause?
Breathing in silica dust over time can lead to a range of serious and irreversible health issues. The most well-known is silicosis – a lung disease that causes scarring and reduces the lungs’ ability to take in oxygen. But exposure can also contribute to chronic obstructive pulmonary disease (COPD), lung cancer, and even kidney disease. These conditions often develop slowly, making early prevention and control measures essential.
Who is at risk of exposure to silica dust?
Workers across a wide range of industries can be exposed to silica dust, particularly those in construction, demolition, mining, quarrying, and manufacturing. Anyone involved in tasks like cutting stone, sanding concrete, or handling materials that generate dust is at risk. Even those not directly performing these tasks can be affected if controls like ventilation and dust suppression aren’t in place.
How much silica dust is harmful?
Even small amounts of silica dust can be dangerous when inhaled regularly. It’s not just high concentrations that pose a risk – repeated exposure to low levels over time can still lead to serious health issues. That’s why it's so important for employers to monitor dust levels, assess the risks, and implement effective control measures to reduce exposure as much as possible.
What is the exposure limit for silica dust in the UK?
In the UK, the Workplace Exposure Limit (WEL) for respirable crystalline silica is 0.1 mg/m³, averaged over an eight-hour period. This limit is legally enforceable and is intended to minimise the risk of long-term harm. However, many experts argue that even this level may not offer full protection. An Imperial College London meta‑analysis of nearly 66,000 workers found halving current UK limits (to 0.05 mg/m³) could reduce silicosis cases by 77%4, highlighting serious risk even at 'permissible' levels. This is why best practice often goes beyond compliance to prioritise worker safety.
Can you get silicosis from a single exposure?
While silicosis typically develops after prolonged exposure, in rare cases, extremely high levels of silica dust inhaled over a short period can cause what's known as acute silicosis. This form of the disease can appear within weeks or months and can be rapidly life-threatening. In extreme scenarios, such as cutting engineered stone slates, workers have developed severe silicosis within just a few years; some progressed so quickly they required transplants or died, even in their twenties and thirties.5
Common silica dust pitfalls for SMEs
Many small businesses still rely on masks as their primary defence against silica dust, but this reactive approach falls short. The focus should be on stopping dust at the source using extraction systems, water suppression, and effective cleaning methods. NFP has seen first-hand the serious consequences of poor silica dust management – including cases where employees developed silicosis due to historic failings, and in one tragic instance, an employee died, triggering a coroner’s investigation. Many of these issues stem from outdated practices 25–30 years ago, when awareness was limited. Educating today’s workforce is essential to prevent history from repeating itself.
Misconceptions about the dangers of silica dust
Despite the serious health risks, many businesses still underestimate the dangers of silica dust due to widespread misconceptions and a lack of visible symptoms. NFP has identified several common misunderstandings that contribute to poor control measures:
- “If I can’t see it, it’s not a problem.” Silica dust is invisible and doesn’t cause immediate discomfort, workers and employers often fail to take it seriously.
- “It won’t happen to me.” Many workers assume they’re not personally at risk of silicosis, leading to resistance around wearing masks or using other protective equipment.
- Short-term thinking – Some employers hesitate to invest in proper monitoring or dust control systems due to cost concerns, overlooking the long-term health risks and potential legal consequences.
- Lack of urgency – Without early warning signs, there’s often no perceived need to act until it’s too late – by which point irreversible damage may have already occurred.
Addressing these misconceptions is key to changing behaviours and ensuring effective, long-term protection for workers.
High-profile failures in silica dust management
Silica dust isn’t just a UK issue – it’s a global one. Many stone worktops used in construction and manufacturing here are imported from countries like India and China, where safety standards can vary. A recent case in Spain brought international attention to the issue when the owner of Cosentino – a major producer of quartz worktops – admitted to concealing the risks of silicosis from workers.
Nearly 1,900 employees are believed to have been affected, with some developing life-threatening illnesses. The case led to a suspended prison sentence and over €1 million in compensation, highlighting the serious consequences of ignoring silica dust risks.6
