Did you know that silica exposure is the second-most dangerous hazard faced by construction workers? But, that’s not the only industry in which workers must grapple with the dangerous substance.
Silica dust is produced while drilling or cutting rocks, sand, and construction materials. Miners, constructions workers, and those in the engineered stone industry are most vulnerable to silica dust exposure.
And yet, it gets even worse.
An alarming 2.3 million workers are exposed to silica at work annually, in the United States. Silica exposure leads to the development of lung cancer, silicosis, kidney disease and chronic obstructive heart disease. There are about 234,580 new cases of lung cancer and 125,070 resultant deaths, in 2024 in the United States alone.
In a recent development that highlights the urgent need for effective occupational health measures, OSHA federal safety inspectors discovered alarming conditions at a countertop manufacturing company in Chicago.
This investigation was prompted by the acute health situation of a 31-year-old employee who required a double lung transplant due to accelerated silicosis, an incurable lung disease caused by inhaling silica dust. This incident serves as a wake-up call for businesses about the critical importance of safeguarding worker health.
Here, we’ll take a look at OSHA’s response to one company’s complete lack of safety precautions, the dangers of silica dust exposure, and how you can protect your workers from the harmful effects of silica dust.
Let’s break it down.
Related Article: New OSHA Initiatives to Combat Silica Exposure in Engineered Stone Industry.
Related Article: Is Silica the New Asbestos?
Understanding Silicosis and The Risks of Silica Dust
Silicosis is a progressive lung disease that results from the inhalation of crystalline silica, a common component found in materials like granite and engineered stone.
The Centers for Disease Control and Prevention (CDC) estimates that individuals diagnosed with silicosis may experience a reduction in life expectancy by approximately 11 years.
Moreover, the survival rate for lung transplants in patients with silicosis is alarmingly low, with less than 11 percent surviving 15 years post-surgery.
The dangers of silica exposure are not limited to one individual; they can affect entire teams of workers.
In this case, OSHA discovered that not only was a 31-year-old employee suffering, but his 59-year-old father, also a co-worker, was awaiting a lung transplant related to silicosis.
Sadly, an additional 47-year-old employee had been grappling with unresolved work-related lung disease for over three years.
OSHA’s Investigation and Findings
When OSHA inspectors arrived at the counter-top production site in February 2024, they were met with a concerning sight.
Workers were laboring in a dense haze of dust, and many were using respirators incorrectly. The air sampling conducted by OSHA revealed that employees were exposed to silica levels nearly six times higher than permissible limits.
This shocking discovery prompted immediate action from OSHA, as the health and safety of workers were clearly at risk.
Further investigation revealed that the company, had failed to implement a safety program to protect its six employees from silica exposure.
In fact, the safety situation was so bad that two workers’ compensation insurance carriers had refused to insure the company in 2022 and 2024 due to the lack of air sampling and obvious overall failures to protect workers.
The Consequences of Negligence
OSHA’s findings led to serious repercussions for the company. The agency cited the company for 8 egregious willful violations, 4 willful violations, and 20 serious safety and health violations, proposing penalties exceeding $1 million.
These violations included:
– Failing to establish a baseline of employees’ medical health to monitor silica exposure.
– Not performing medical surveillance to track exposure levels.
– Lacking engineering and administrative controls to reduce silica dust to safe levels.
– Exposing workers to unsafe levels of silica dust.
– Not having a respiratory protection program in place.
The consequences of these violations are profound, especially for the workers affected. Many of the employees, including the two suffering from silicosis, had limited English proficiency and received no information about the dangers of silica exposure or training on how to properly use personal protective equipment (PPE).
The company has 15 business days from the receipt of these citations and penalties to comply, request an informal conference with OSHA’s area director, or contest the finding of the investigation before the independent Occupational Safety and Health Review Commission.
The Importance of Workplace Safety Programs
This incident underscores the critical need for comprehensive workplace safety programs that prioritize employee health. Employers must take proactive steps to ensure that their workers are protected from hazardous materials, including silica.
Here are some actionable steps businesses can take:
- Conduct Regular Risk Assessments
Regularly evaluate your work environments for potential hazards, including silica exposure. This includes air quality testing and monitoring dust levels to ensure compliance with safety regulations.
- Implement Training Programs
Training employees on the proper use of PPE and the dangers associated with silica exposure is essential. This training should be accessible to all employees, regardless of their language proficiency.
- Establish Health Monitoring Protocols
Implement medical surveillance programs to monitor the health of employees who may be exposed to silica. Establishing a baseline for employees’ health can help detect any issues early on.
- Create a Safety Culture
Fostering a workplace culture that prioritizes safety can encourage employees to speak up about hazards and participate in safety initiatives. Employers should lead by example and demonstrate a commitment to worker health.
– See DOL’s Final Rule Reducing Silica Dust Exposure, Better Protecting Miners’ Health From Irreversible Workplace Illnesses
– View MSHA’s Final Rule- Lowering Miners’ Exposure to Respirable Crystalline Silica and Improving Respiratory Protection.
– See DOL’s Enforcement, Compliance Initiative to Protect Workers from Silica Exposure In Engineered Stone Fabrication & Installation
Bringing it Together
The case of this company serves as a stark reminder of the potential dangers lurking in workplaces where silica exposure is a risk. It highlights the necessity to take your responsibilities seriously, and to implement effective health and safety measures.
By prioritizing worker safety, you can not only comply with regulations but also protect the health and well-being of their employees. The stakes are high, and the lives of workers depend on it.
Stay In Compliance With Worksite Medical
To protect your team and remain in compliance with OSHA, you need to find a medical provider in your area that specializes in occupational health.
In the case of Worksite Medical, we make that easier with mobile medical testing that reaches across the US.
With Worksite Medical, you can get all the resources of a lab brought directly to your worksite, minimizing your workers’ downtime.
We’ll tailor a comprehensive medical surveillance program to your specific needs. Our services include silica exams, physical testing, heavy metal labs, PPE fit-testing, x-rays, audiometric exams, and much more. We safely maintain all of your team’s medical records, and provide you with quick access.
You’ll keep your employees at work, and stay ahead of OSHA inspections.
Protect your team and your workplace now with Worksite Medical. Not sure what you need? Try our medical testing wizard here.
Give us a call at 1-844-622-8633, or complete the form below to schedule an on-site visit or to get your free quote.
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