Silica dust might seem harmless (just tiny particles floating in the air) but for workers in industries like construction, mining, and countertop manufacturing, it’s a silent killer.
Crystalline silica, a mineral found in materials like sand, stone, and concrete, becomes dangerous when workers cut, grind, or polish these materials, releasing fine dust into the air.
According to OSHA, an estimated 2.3 million workers in the U.S are exposed to respirable crystalline silica (RCS) dust in their workplaces.
Recent OSHA citations against a Georgia countertop manufacturer highlight a persistent issue: many employers still fail to protect workers from silica exposure. This negligence can lead to severe lung diseases, both in the short and long term.
In this article, we’ll break down what silica exposure is, short-term and long-term lung diseases caused by silica, OSHA and CDC guidelines for protection, and best practices to reduce workplace risks.
Let’s dive in…
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OSHA Fines Georgia Countertop Maker for Silica Dust Exposure
Recently, OSHA cited a Georgia-based countertop manufacturer for exposing workers to hazardous levels of crystalline silica, a known respiratory hazard linked to lung disease and cancer. OSHA’s inspection found that the company failed to implement adequate controls (such as engineering measures or PPE) to limit silica dust exposure during stone cutting and polishing.
The company was cited with seven serious violations, including lack of proper respiratory protection, failure to monitor air quality, and insufficient employee training. Proposed penalties totaled $33,000.
OSHA emphasizes the importance of compliance with silica standards (29 CFR 1926.1153) to protect workers in high-risk industries like stone fabrication.
What Is Silica Exposure?
Crystalline silica is a common mineral in sand, gravel, stone, concrete, brick, industrial abrasives, and countertops (quartz, granite, and engineered stone).
When workers cut, drill, or crush these materials, tiny silica particles become airborne. Without proper protection, workers inhale these particles, which can lodge deep in the lungs, causing inflammation and scarring over time.
How Are Workers Exposed?
Common high-risk jobs include construction workers (cutting concrete or brick), countertop fabricators (polishing stone surfaces), miners and sandblasters, and foundry workers.
OSHA estimates that about 2.3 million U.S. workers face silica exposure on the job, with many unaware of the risks.
Short-Term Effects of Silica Exposure
While silica-related diseases often develop over years, some short-term symptoms can appear quickly, especially with high levels of exposure.
- Silicosis (Acute Form): This is caused by extremely high silica exposure in a short period. Symptoms include severe cough, fever, difficulty breathing, and fatigue. Acute silicosis can develop within weeks or months of exposure. Unfortunately, it can result in rapid lung damage, which is sometimes fatal if left untreated.
- Respiratory Irritation: Even without full-blown silicosis, workers may experience; chronic coughing, wheezing, throat and nasal irritation. These symptoms are warning signs that exposure levels are too high.
Long-Term Effects of Silica Exposure
The most severe consequences of silica exposure take years to develop but are often irreversible.
- Chronic Silicosis: This is caused by moderate to high exposure of over 10 years. Symptoms include; progressive shortness of breath, persistent cough, and chest pain. It can result in permanent lung scarring, leading to disability or death.
- Progressive Massive Fibrosis (PMF): PMF is an advanced form of silicosis where lung scarring becomes so severe that breathing is extremely difficult. It often requires oxygen therapy or lung transplants.
- Lung Cancer: The International Agency for Research on Cancer (IARC) classifies silica as a Group 1 carcinogen. Workers exposed to silica have a higher risk of lung cancer, especially if they smoke.
- Chronic Obstructive Pulmonary Disease (COPD): Silica exposure contributes to COPD, a progressive disease that obstructs airflow. Symptoms include chronic bronchitis and emphysema.
- Kidney Disease & Autoimmune Disorders: Emerging research links silica exposure to kidney damage and autoimmune diseases like rheumatoid arthritis.
OSHA Guidelines for Silica Safety
To combat these risks, OSHA has strict silica exposure standards.
OSHA’s Permissible Exposure Limit (PEL) for General Industry & Construction (29 CFR 1926.1153):
– 50 micrograms per cubic meter (µg/m³) of air over an 8-hour shift.
– Action Level: 25 µg/m³ (requires exposure monitoring).
Required Employer Protections
- Engineering Controls: Use water sprays or vacuum systems to suppress dust. Instillation of local exhaust ventilation may also be required.
- Respiratory Protection: When engineering controls aren’t enough, provide NIOSH-approved respirators (N95 or higher).
- Medical Surveillance: Employers must offer lung function tests and chest X-rays for exposed workers.
- Training & Hazard Communication: Training workers on silica risks and proper PPE use is essential for their health and safety.
– See OSHA’s Publication on TIPS FOR WORKERS EXPOSED TO CRYSTALLINE SILICA.
CDC Recommendations
The National Institute for Occupational Safety and Health (NIOSH) recommends employers:
– eliminate silica use where possible,
– provide regular air monitoring to ensure compliance, and
– encouraging smoking cessation, since silica dust drastically increases cancer risk in smokers.
See more: CDC/NIOSH’s Publication on Silica & Safe Work Practices.
How Workers Can Protect Themselves
While employers must follow OSHA rules for silica protection, workers should also take precautions, e.g.:
– Wear proper respirators when cutting or grinding silica materials.
– Use wet methods to reduce dust.
– Change clothes & shower after work to avoid bringing silica dust home.
– Report unsafe conditions to OSHA if employers fail to provide protection.
Key Takeaways
The recent OSHA citation in Georgia proves that silica exposure remains a serious issue. With both short-term and long-term health effects (from acute silicosis to lung cancer) employers must prioritize worker safety.
By following OSHA’s silica standard and implementing engineering controls, PPE, and medical monitoring, workplaces can prevent unnecessary suffering.
If you work with silica-containing materials, demand proper protection—your lungs depend on it!
Stay In Compliance With Worksite Medical
In most cases, OSHA requires medical surveillance testing, and at no cost to employees.
Worksite Medical makes that program easier with mobile medical testing.
Worksite Medical’s on-site testing services ensure compliance with MSHA and OSHA’s silica and respiratory protection regulations by providing the necessary medical surveillance exams and documentation required for worker protection.
This includes chest X-rays and pulmonary function tests, essential for early detection of silica-related lung diseases and ensuring workers are fit to wear respirators.
With Worksite Medical, a mobile medical testing unit — we can bring all the resources of a lab to you. Our certified lab technicians can perform both qualitative and quantitative respirator tests to ensure a perfect fit.
You’ll keep your employees at work, and stay ahead of OSHA and MSHA 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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