Many times, in industries involving cutting, grinding, or drilling silica-containing materials, such as stone, concrete, or glass, an inhalable dust gets released into the air, resulting in a serious workplace hazard called respirable crystalline silica (RCS), sometimes better known as silica dust. This story examines a real-life silica dust exposure incident resulting in life-altering illness. Together, we explore what happened, the impact of not taking precautions, and key lessons that will prevent it from happening to others.
What Happened?
A group of workers at a concrete plant were assigned to cut and shape concrete slabs for an upcoming project. Due to rushed deadlines, workers proceeded without putting sufficient dust exposure control measures in place beforehand, wearing only smiles while working.
Roughly three months after completing the project, one of the workers, Don, began to experience a persistent cough and shortness of breath. After many doctor visits and diagnostic tests, Don was diagnosed with silicosis, a restrictive lung disease caused by prolonged silica dust exposure. A medical evaluation confirmed that Don’s silicosis was in an advanced stage, forcing him to retire early with a permanent disability.
The Consequences
Because the manufacturing facility took shortcuts in critical industrial hygiene control measures, Don suffered a permanent, life-threatening illness. Silica dust is one of the many chemical hazards that may seem insignificant because of its fine, invisible-like powdery appearance. Still, even trace amounts can have a big impact on your health. Generally, silicosis develops after 5-20 years of continued exposure, but it can occur after only a few months of very heavy exposure.
The manufacturing facility faced fines and penalties for non-compliance with workplace safety standards, and occupational health authorities scrutinized it more closely, leading to mandatory corrective actions. In addition to possible compensation claims from Don, this incident has had a resounding negative impact on employee morale and trust in workplace safety protocols.
Lessons Learned
Soon after Don’s diagnosis, the manufacturing facility partnered up with a health and safety consulting firm, like Cardinal Compliance Consultants, and began to work on six key tactics to make sure this doesn’t happen again and that there was a much bigger emphasis on prioritizing safety as a company value.
Key Tactics to Control Silica Dust Exposure:
- Implement Effective Dust Control Measures – Use wet methods, local exhaust ventilation, and enclosures to reduce airborne silica dust.
- Enforce the Use of Respiratory Protection – Provide and mandate the use of properly fitted respirators when dust levels exceed permissible exposure limits.
- Conduct Regular Air Monitoring – Continuously assess air quality to ensure exposure remains within safe limits.
- Adhere to Regulatory Compliance – Follow OSHA and industry standards to mitigate silica dust exposure risks.
- Provide Comprehensive Worker Training – Educate employees on silica hazards, exposure limits, and proper protective measures.
- Encourage a Culture of Safety – Empower workers to report unsafe conditions and halt work, if necessary, safety controls are not in place.
In addition, potentially exposed workers were enrolled in an extensive medical surveillance program which included pulmonary function tests and x-ray imaging.
Silica Dust Exposure Safety Assessment
This real-life respirable crystalline silica incident highlights the often devastating health effects of prolonged exposure to silica dust and the critical importance of implementing proper safety controls. By following these lessons, employers can create safer work environments and protect workers from preventable occupational diseases.
If your company commonly works with material(s) containing silica, or is exposed to silica dust, contact Cardinal Compliance Consultants to understand what exposure risk your workers are facing, how to implement appropriate control measures, and to make sure employee training is exceeding standards. Remember, we’re here, not just for compliance, but for peace of mind.