The Health and Safety Executive (HSE) has introduced significant new measures aimed at reducing the risks associated with working with engineered stone. This follows growing concern around cases of silicosis affecting workers, including younger individuals exposed to hazardous dust during fabrication activities.
At the centre of this update is a clear message to the industry: dry cutting of engineered stone is no longer considered acceptable practice, and suitable dust control methods must be implemented as a legal requirement.
Why Engineered Stone Dust Presents a Serious Risk
Engineered stone, widely used for kitchen and bathroom worktops, often contains high levels of crystalline silica. When cut, ground, or polished, it releases fine airborne particles known as respirable crystalline silica (RCS).
According to the COSHH guidance, these particles are small enough to penetrate deep into the lungs, where they can lead to serious and irreversible health conditions including:
- Silicosis
- Chronic obstructive pulmonary disease (COPD)
- Lung cancer
A key concern is that damage can occur before symptoms appear, making early exposure particularly dangerous and difficult to detect.
Dry Cutting vs Wet Cutting: What the Evidence Shows
Research underpinning the HSE’s position shows that dry cutting generates significantly higher levels of hazardous dust compared to wet methods.
Water suppression systems, which introduce water directly at the cutting point, are proven to reduce airborne dust and are now considered essential for compliance. The COSHH guidance reinforces this by explicitly recommending:
- Use of on-tool water suppression systems
- Measures to control airborne mist containing silica
- Adequate ventilation systems to prevent build-up
These controls are not new in principle, but the expectation for consistent, enforced adoption across the industry has now been strengthened.
Legal Duties Under COSHH Regulations
The Control of Substances Hazardous to Health Regulations 2002 (COSHH) require employers to either prevent exposure to hazardous substances or reduce it to a level that is as low as reasonably practicable.
The updated guidance makes expectations clearer, outlining essential steps for employers working with engineered stone:
- Select materials with lower silica content where possible
- Implement water suppression controls during cutting and polishing
- Provide suitable respiratory protective equipment (RPE)
- Carry out health surveillance for exposed workers
- Maintain effective cleaning and dust control procedures
Regular review of control measures is also required to ensure their effectiveness over time.
Increased HSE Inspections Across Great Britain
To support compliance, HSE has launched a nationwide inspection campaign targeting stone fabrication businesses. These visits will focus on assessing whether appropriate dust control measures are in place and whether legal duties are being met.
Inspectors will be taking enforcement action where standards fall short. This initiative reflects a broader effort to ensure consistency across the sector and to address concerns that some businesses may be cutting corners at the expense of worker safety.
Practical Control Measures for Employers
The guidance provides detailed, practical controls that organisations should adopt as standard. These include:
Engineering Controls
- On-tool water suppression systems
- Local exhaust ventilation (LEV) to extract mist
- Segregation of high-risk activities to minimise exposure
Personal Protection
- Powered air-purifying respirators (PAPR) or equivalent RPE
- Appropriate protective clothing that does not retain dust
Housekeeping and Maintenance
- Regular cleaning using wet or vacuum methods
- Avoidance of dry sweeping or compressed air
- Routine maintenance of equipment and control systems [st3a | PDF]
The guidance also emphasises that poor housekeeping can reintroduce dust into the air, increasing exposure risks even after cutting has stopped. [st3a | PDF]
Protecting Workers Through Awareness and Training
In addition to engineering controls, employers must ensure that workers:
- Understand the risks associated with silica dust
- Are trained in the correct use of control measures
- Know how to identify faults or failures in systems
- Participate in health surveillance programmes where required [st3a | PDF]
Clear communication and supervision are essential to ensure that controls are used correctly and consistently.
What This Means for Your Business
The HSE’s latest intervention is a clear signal that expectations have changed. Businesses involved in engineered stone fabrication should urgently review their current practices to ensure they align with the updated guidance.
Failure to comply could result in enforcement action, but more importantly, it places workers at serious risk of life-changing illness.
Final Thoughts: A Preventable Risk That Requires Immediate Action
Silicosis and other silica-related diseases are entirely preventable with the right controls in place. The latest guidance reinforces that responsibility sits firmly with employers to protect their workforce.
With inspections underway and expectations clarified, now is the time for businesses to address any gaps in their control measures and demonstrate a proactive approach to health and safety.
Need support reviewing your COSHH assessments or dust control measures?
Green Hat Consulting can provide expert guidance, site audits, and practical solutions to help you stay compliant and protect your workforce.
See HSE Press Release: HSE says no dry cutting of engineered stone
