Effectiveness of dust control methods for crystalline silica and respirable suspended particulate matter exposure during manual concrete surface grinding

From Engineered Stone Slab to Silicosis: A Synthesis of Exposure Science and Medical Evidence

Engineered stone (ES) is a popular building product, due to its architectural versatility and generally lower cost. However, the fabrication of organic resin-based ES kitchen benchtops from slabs has been associated with alarming rates of silicosis among workers. In 2024, fifteen years after the first reported ES-related cases in the world, Australia became the first country to ban the use and importation of ES. A range of interacting factors are relevant for ES-associated silicosis, including ES material composition, characteristics of dust exposure and lung cell-particle response. In turn, these are influenced by consumer demand, work practices, particle size and chemistry, dust control measures, industry regulation and worker-related characteristics. This literature review provides an evidence synthesis using a narrative approach, with the themes of product, exposure and host. Exposure pathways and pathogenesis are explored. Apart from crystalline silica content, consideration is given to non-siliceous ES components such as resins and metals that may modify chemical interactions and disease risk. Preventive effort can be aligned with each theme and associated evidence.

The Evaluation of Worker Exposure to Airborne Silica Dust During Five OSHA Table I Construction Tasks

Fifty-one (51) personal silica air samples were collected over 13 days on 19 construction employees while they performed five different construction tasks found in the Occupational Safety and Health Administration's (OSHA) respirable crystalline silica standard for construction, Table 1, which specifies engineering, work practice, and respiratory protection controls that employers can use in lieu of exposure monitoring to adhere to the standard. The average construction task time was 127 min (range: 18-240 min) with a mean respirable silica concentration of 85 μg m-3 (standard deviation [SD] = 176.2) for all 51 measured exposures. At least one OSHA-specified silica dust control measure was used during all 51 samples collected. The mean silica concentrations for the five tasks were: core drilling 11.2 μg m-3 (SD = 5.31 μg m-3), cutting with a walk-behind saw 126 μg m-3 (SD = 115 μg m-3), dowel drilling 99.9 μg m-3 (SD = 58.7 μg m-3), grinding 172 μg m-3 (SD = 145 μg m-3), and jackhammering 23.2 μg m-3 (SD = 5.19 μg m-3). Twenty four of 51 (47.1%) workers were exposed above the OSHA Action Level (AL) of 25 μg m-3 and 15 of 51 (29.4%) were exposed above the OSHA Permissible Exposure Limit (PEL) of 50 μg m-3 when exposures were extrapolated to an 8-h shift. When silica exposures were extrapolated to 4 h, 15 of 51 (29.4%) of workers sampled were exposed over the OSHA AL and 8 of 51 (15.7%) were exposed over the OSHA PEL. A total of 15 area airborne respirable crystalline silica samples were collected on days where the personal task-based silica samples were taken, with an average sampling time of 187 min. Of the 15 area respirable crystalline silica samples, only four were greater than the laboratory reporting limit of 5 μg m-3. The four area silica samples with reportable concentrations revealed background silica concentrations of 23 μg m-3, 5 μg m-3, 40 μg m-3, and 100 μg m-3. Odds ratios were used to analyze the apparent association between dichotomous background construction site exposures to respirable crystalline silica (detectable or not detectable), and personal exposure category (over or not over the OSHA AL and PEL) when exposure times were extrapolated to 8 h. The associations were strongly positive and significant between detectable background exposures and personal overexposures for workers conducting the five Table 1 tasks with engineering controls in place. The results of this study suggest that exposure to hazardous levels of respirable crystalline silica may be present even when OSHA-specified engineering controls are implemented. The current study findings also suggest that background construction site silica concentrations may potentially cause task-based overexposures, even when the OSHA Table 1 control methods have been put in place.

A systematic review of the effectiveness of dust control measures adopted to reduce workplace exposure

The recent increase in silicosis cases in several countries casts doubt on dust control practices and their effectiveness in preventing respirable crystalline silica (RCS) exposure. Apart from silicosis, RCS may lead to other illnesses, health-related quality of life losses for workers and their families, and economic losses for companies. Thus, this systematic literature review examined the effectiveness of interventions employed to prevent exposure to RCS and increase the use of dust control measures. The review used keywords related to dust control interventions to search seven databases. Search results were screened and extracted for synthesis. The narrative synthesis showed the extent of research investment in China. In several designs and combinations, the interventions utilized water, surfactant, foam, and air currents to reduce dust exposure. These interventions offer varying degrees of dust control effectiveness against RCS and respirable dust. Although evidence indicates that interventions significantly decrease dust concentration levels, the control measures in place may not effectively prevent workplace overexposure to RCS. The review found that education and training interventions are employed to improve dust controls and respiratory protective equipment (RPE) use. Also, marketing strategies promote the use of RPE. These interventions can increase the frequency of use of RPE and the adoption of best practice dust control measures. Interventions increase knowledge, awareness, and attitudes about RPE usage and generate positive perceptions while reducing misconceptions. However, the benefits obtained from an intervention may diminish after its implementation, indicating that the interventions may not continually motivate workers to adopt control measures or use RPE.

Occupational Dust Exposure and Respiratory Protection of Migrant Interior Construction Workers in Two Chinese Cities

Migrant interior construction workers are increasing in China. Construction workers are at an increased risk of work-related illness (WRI) due to prolonged exposure to and inhalation of dust. Dust concentrations in the air can be reduced significantly with effective respiratory protection measures. We assessed the dust exposure and factors associated with respiratory protection of migrant interior construction workers. The total dust concentration in the workplace ranged from 0.07 to 335.27 mg/m³, with a total dust exceedance rate of 50.00%. The respiratory dust loading ranged from 0.03 to 220.27 mg/m³, with a respiratory dust exceedance rate of 71.42 %. The highest total dust concentration occurred when masons were polishing cement walls. We performed a questionnaire survey of 296 persons in two cities in China, in which 87.84% had no respiratory protection or only one protection measure. Gender, workplace, respiratory disease, and protective attitude all had an effect on the level of respiratory protection. The dust exposure in most jobs exceeds hygiene standards. The respiratory protection of migrant interior construction workers in China is inadequate.

Respiratory symptoms and use of dust-control measures in New Zealand construction workers – A cross-sectional study

Dust-exposed construction workers have an increased risk of respiratory symptoms, but the efficacy of dust-control measures remains unclear. This study compared respiratory symptoms, using a modified European Community Respiratory Health Survey questionnaire, between construction workers (n = 208) and a reference group of bus drivers and retail workers (n = 142). Within the construction workers, we assessed the effect of collective (on-tool vacuum/’wet-cut’ systems) and personal (respirators) exposure controls on symptom prevalence. Logistic regression assessed differences between groups, adjusted for age, ethnicity, and smoking status. Construction workers were more likely to cough with phlegm at least once a week (OR 2.4, 95% CI 1.2–4.7) and cough with phlegm ≥3 months/year for ≥2 years (OR 2.8, CI 1.2–7.0), but they had similar or fewer asthma symptoms. Construction workers who had worked for 11–20 years reported more cough/phlegm symptoms (OR 5.1, 1.7–15.0 for cough with phlegm ≥3 months/year for ≥2 years) than those who had worked <10 years (OR 1.9, 0.6–5.8), when compared to the reference group. Those who used ‘wet-cut’ methods reported less cough with phlegm, although the evidence for this association was weak (OR 0.4, CI 0.2–1.1 for cough with phlegm at least once a week); use of on-tool extraction showed a similar trend. No associations between respiratory protective equipment-use and symptoms were found. In conclusion, construction workers reported more symptoms suggestive of bronchitis, particularly those employed in the industry for >10 years. Use of collective dust exposure controls might protect against these symptoms, but this requires confirmation in a larger study.

Break-even Analysis of Respirable Crystalline Silica (RCS) Exposure Interventions in the Construction Sector

OBJECTIVE

We investigated long-term economic impacts of respirable crystalline silica (RCS) removal interventions in the construction at the societal level.

METHODS

We estimated costs and benefits of two RCS exposure interventions, use of "respirators" and "wet method," over a 30-year time period. We identified economic impacts of the interventions under four different scenarios.

RESULTS

Under current practices, we estimated that approximately 125 lung cancer cases attributable to RCS exposure would arise in 2060. Under the full exposure removal scenario, we estimated there would be 53 new cases. Over the 30-year time period, the estimated cumulative averted cases are 787 and 482 for respirators and wet method, respectively, which amount to net benefits of $422.13 and $394.92 million.

CONCLUSIONS

Findings provide important information for policymakers seeking to reduce the economic burden of occupational lung cancer in society.

Control of Dust Dispersion From an Enclosed Renovation Site Into Adjacent Areas by Using Local Exhaust Ventilation

OBJECTIVE

In real-world applications, implementation of an enclosure and negative pressurization is not always adequate to prevent the dispersion of dust from renovation sites. This study aimed to quantify the effect of local exhaust ventilation (LEV) in controlling the dust concentration within an enclosed renovation site to reduce the dust dispersion into adjacent areas.

METHODS

The concentrations of inhalable and respirable dust were measured in 16 cases during renovation projects. Filter samples and time-resolved dust concentration data were collected simultaneously from the renovation site and adjacent areas to assess the efficacy of LEV in limiting the dust dispersion.

RESULTS

The dispersion of dust outside of the enclosed renovation sites was limited significantly with using LEV. The estimated dust removal efficiency of LEV was 79% for inhalable dust concentration in the renovation site and 62% in the adjacent area. The use of LEV reduced the concentration of respirable dust by 33‒90% in the adjacent area and 80-87% within the renovation site.

CONCLUSIONS

Using LEV was found to play a substantial role in dust containment, particularly when the enclosure failed to maintain the negative pressure. The study provides data-driven recommendations that are of practical importance as they promote healthier workplaces and policy improvements. In conclusion, dust dispersion into adjacent areas is prevented with an airtight enclosure (including airlocks) and continuous negative pressure. Dust containment was also obtained by having target dust concentration at the enclosed renovation site to below 4 mg m-3 for inhalable dust and below 1 mg m-3 for respirable dust, even though the enclosures not being continuously under negative pressure. The suggested target concentrations are achievable by using on-tool LEV during the most dust-producing tasks.

A probabilistic approach for economic evaluation of occupational health and safety interventions: a case study of silica exposure reduction interventions in the construction sector

BACKGROUND

Construction workers are at a high risk of exposure to various types of hazardous substances such as crystalline silica. Though multiple studies indicate the evidence regarding the effectiveness of different silica exposure reduction interventions in the construction sector, the decisions for selecting a specific silica exposure reduction intervention are best informed by an economic evaluation. Economic evaluation of interventions is subjected to uncertainties in practice, mostly due to the lack of precise data on important variables. In this study, we aim to identify the most cost-beneficial silica exposure reduction intervention for the construction sector under uncertain situations.

METHODS

We apply a probabilistic modeling approach that covers a large number of variables relevant to the cost of lung cancer, as well as the costs of silica exposure reduction interventions. To estimate the societal lifetime cost of lung cancer, we use an incidence cost approach. To estimate the net benefit of each intervention, we compare the expected cost of lung cancer cases averted, with expected cost of implementation of the intervention in one calendar year. Sensitivity analysis is used to quantify how different variables affect interventions net benefit.

RESULTS

A positive net benefit is expected for all considered interventions. The highest number of lung cancer cases are averted by combined use of wet method, local exhaust ventilation and personal protective equipment, about 107 cases, with expected net benefit of $45.9 million. Results also suggest that the level of exposure is an important determinant for the selection of the most cost-beneficial intervention.

CONCLUSIONS

This study provides important insights for decision makers about silica exposure reduction interventions in the construction sector. It also provides an overview of the potential advantages of using probabilistic modeling approach to undertake economic evaluations, particularly when researchers are confronted with a large number of uncertain variables.

The Evaluation of Short-Term Water Misting of Room Air in Reducing Airborne Dust after Renovation Work

OBJECTIVE

To shorten the time for airborne dust concentration to be reduced to a lower level after a renovation task has been completed, a short-term water misting method was assessed. A short-term water misting method is based on low water consumption to avoid harmful wetting of materials. The method is considered similar to a general ventilation method that dilutes work-generated airborne dust concentrations. Thus, short-term misting is not intended to replace the source control measures.

METHODS

Airborne dust removal by the short-term water misting performed after dust generation was evaluated in a controlled laboratory settings by comparing PM10 decay and inhalable dust concentrations between a control and misting tests (average water flow = 0.22 l min-1) of 2 and 4 min. A portable handheld misting device was used. The practicability and effectiveness of the misting technique as a supplementary control measure was verified in the three field cases.

RESULTS

In laboratory tests, reductions in airborne PM10 and inhalable dust were 30% and 28%, avoiding condensation of water to surfaces. In the field, inhalable dust concentrations were reduced by 86-95% after an hour from the misting, whereas ventilation alone was calculated to dilute dust concentrations by 18-39%. Average clean air delivery rates varied from 0.03 to 0.07 m3 s-1.

CONCLUSIONS

Short-term misting after a dust-generating task is an effective measure to control the airborne dust after dust-producing tasks in environments where an effective air exchange for dust removal is not a feasible alternative. The information obtained from the study is beneficial to construction and renovation project management personnel and field practitioners.

Control Dust Pollution on Construction Sites: What Governments Do in China?

Dust pollution is a key issue that contractors ought to address in the sphere of sustainable construction. Governments on behalf of the public assume part of the responsibilities for minimizing dust emissions on construction sites. However, the measures that are useful for governments to fulfill such a responsibility have not been explored explicitly in previous studies. The aim of this research is to map out China’s practices in this area with the intention of filling the knowledge gap. Using a combination of research methods, five categories of governmental measures are proposed: technological, economic, supervisory, organizational, and assessment-based. Data from 37 major cities in China are collected for analysis. While the proposed categories of measures are demonstrated in China, the data analysis results show that governments prefer technological and organizational measures, and institutional guarantees and technological innovation are a prerequisite for dust-free construction. This research provides a comprehensive examination of construction dust control from the perspective of governments, and it can assist governments in improving the performance of dust management in the construction context.

A New Test Bench System for Hammer Drills: Validation for Handle Vibration

Workers' can be exposed to high levels of hand vibration when drilling into concrete or rock using hammer drills; exposures that can cause hand arm vibration syndrome. Exposure levels may be reduced by different drill and bit designs and drilling methods, but these interventions have not been systematically evaluated. The purpose of this project was to develop a robotic test bench system for measuring handle vibration on drills in order to compare differences in drill designs, power sources, bit designs and drilling methods. The test bench is a departure from the ISO method for measuring drill handle vibration (ISO 28927-10), which requires drilling by humans. The test bench system was designed to repeatedly drill into concrete blocks under force control while productivity and handle vibration were measured. Handle vibration levels with different drills and bit sizes were similar to those collected following ISO methods. A new robotic test bench system for measuring handle vibration is presented and validated against ISO methods and demonstrates dynamic properties similar to human drilling.

Experimental Evaluation of Respirable Dust and Crystalline Silica Controls During Simulated Performance of Stone Countertop Fabrication Tasks With Powered Hand Tools

OBJECTIVES

Workers who fabricate stone countertops using hand tools are at risk of silicosis from overexposure to respirable crystalline silica. This study explored the efficacy of simple engineering controls that can be used for dust suppression during use of hand tools by stone countertop fabricators.

METHODS

Controlled experiments were conducted to measure whether wet methods and on-tool local exhaust ventilation (LEV) reduced respirable dust (RD) exposures during use of various powered hand tools on quartz-rich engineered stone. RD samples collected during edge grinding with a diamond cup wheel and a silicon carbide abrasive wheel were analyzed gravimetrically as well as by X-ray diffraction to determine silica content. A personal optical aerosol monitor was used simultaneously with the RD samples and also for rapid assessment of controls for polishing, blade cutting, and core drilling.

RESULTS

On-tool LEV and sheet-flow-wetting were effective in reducing exposures, especially when used in combination. Sheet-flow-wetting with LEV reduced geometric mean exposures by as much as 95%. However, typical water-spray-wetting on a grinding cup was less effective when combined with LEV than without LEV. Mean silica content of RD samples from grinding operations was 53%, and respirable mass and silica mass were very highly correlated (r = 0.980). Optical concentration measures were moderately well correlated with gravimetric measures (r = 0.817), but on average the optical measures during a single trial using the factory calibration were only one-fifth the simultaneous gravimetric measures.

CONCLUSIONS

Sheet-flow-wetting combined with on-tool LEV is an effective engineering control for reducing RD exposures during engineered stone edge grinding and blade cutting. On the other hand, addition of LEV to some water-spray-wetted tools may reduce the effectiveness of the wet method.

Effective dust control systems on concrete dowel drilling machinery

Rotary-type percussion dowel drilling machines, which drill horizontal holes in concrete pavement, have been documented to produce respirable crystalline silica concentrations above recommended exposure criteria. This places operators at potential risk for developing health effects from exposure. United States manufacturers of these machines offer optional dust control systems. The effectiveness of the dust control systems to reduce respirable dust concentrations on two types of drilling machines was evaluated under controlled conditions with the machines operating inside large tent structures in an effort to eliminate secondary exposure sources not related to the dowel-drilling operation. Area air samples were collected at breathing zone height at three locations around each machine. Through equal numbers of sampling rounds with the control systems randomly selected to be on or off, the control systems were found to significantly reduce respirable dust concentrations from a geometric mean of 54 mg per cubic meter to 3.0 mg per cubic meter on one machine and 57 mg per cubic meter to 5.3 mg per cubic meter on the other machine. This research shows that the dust control systems can dramatically reduce respirable dust concentrations by over 90% under controlled conditions. However, these systems need to be evaluated under actual work conditions to determine their effectiveness in reducing worker exposures to crystalline silica below hazardous levels.

An evaluation of on-tool shrouds for controlling respirable crystalline silica in restoration stone work

OBJECTIVES

The task of grinding sandstone with a 5-inch angle grinder is a major source of exposure to respirable crystalline silica (RCS), known to cause diseases such as silicosis and lung cancer among workers who work with these materials. A shroud may be a suitable engineering control for this task. The objectives of this study were to evaluate the effectiveness of four commercially available shrouds at reducing respirable dust and RCS levels during the task of grinding sandstone using tools and accessories typical of restoration stone work.

METHODS

The task of grinding sandstone with a 5-inch angle grinder, equipped with different grinding wheels, was carried out over three trials at a restoration stone masonry site. Photometric and RCS data were collected when a 5-inch grinder, equipped with different grinding wheels, was used to grind sandstone with and without a shroud. A total of 24 short duration samples were collected for each no shroud and with shroud combination. Worker feedback on the practicalities of each shroud evaluated was also collected.

RESULTS

Respirable dust concentrations and RCS were both significantly lower (P < 0.001) when the grinders were equipped with a shroud compared with grinders without a shroud. Total geometric mean (GM) photometric respirable dust levels measured when grinding with a shroud were 0.5 mg m(-3), a reduction of 92% compared to grinding without a shroud (7.1 mg m(-3)). The overall GM RCS concentrations were reduced by the use of a shroud by 99%. GM photometric exposure levels were highest when using the Hilti 5-inch diamond grinding cup and Diamond turbo cup and lowest when using the Corundum grinding point.

CONCLUSIONS

Concentrations of respirable dust and RCS can be significantly reduced by using commercially available shrouds while grinding sandstone with a 5-inch angle grinder in restoration stonework. The short-term photometric respirable dust and RCS measurements collected with and without a shroud indicate that dust and RCS concentrations are reduced by between 90 and 99%. Supplemental exposure controls such as respiratory protective equipment would be required to reduce worker 8-h time-weighted average RCS exposure to below the Scientific Committee on Occupational Exposure Limits recommended occupational exposure limit value of 0.05 mg m(-3) and the American Conference of Governmental Industrial Hygienists threshold limit value of 0.025 mg m(-3).

Silica exposure during construction activities: statistical modeling of task-based measurements from the literature

Many construction activities can put workers at risk of breathing silica containing dusts, and there is an important body of literature documenting exposure levels using a task-based strategy. In this study, statistical modeling was used to analyze a data set containing 1466 task-based, personal respirable crystalline silica (RCS) measurements gathered from 46 sources to estimate exposure levels during construction tasks and the effects of determinants of exposure. Monte-Carlo simulation was used to recreate individual exposures from summary parameters, and the statistical modeling involved multimodel inference with Tobit models containing combinations of the following exposure variables: sampling year, sampling duration, construction sector, project type, workspace, ventilation, and controls. Exposure levels by task were predicted based on the median reported duration by activity, the year 1998, absence of source control methods, and an equal distribution of the other determinants of exposure. The model containing all the variables explained 60% of the variability and was identified as the best approximating model. Of the 27 tasks contained in the data set, abrasive blasting, masonry chipping, scabbling concrete, tuck pointing, and tunnel boring had estimated geometric means above 0.1mg m(-3) based on the exposure scenario developed. Water-fed tools and local exhaust ventilation were associated with a reduction of 71 and 69% in exposure levels compared with no controls, respectively. The predictive model developed can be used to estimate RCS concentrations for many construction activities in a wide range of circumstances.

Silicosis

Silicosis is a fibrotic lung disease caused by inhalation of free crystalline silicon dioxide or silica. Occupational exposure to respirable crystalline silica dust particles occurs in many industries. Phagocytosis of crystalline silica in the lung causes lysosomal damage, activating the NALP3 inflammasome and triggering the inflammatory cascade with subsequent fibrosis. Impairment of lung function increases with disease progression, even after the patient is no longer exposed. Diagnosis of silicosis needs carefully documented records of occupational exposure and radiological features, with exclusion of other competing diagnoses. Mycobacterial diseases, airway obstruction, and lung cancer are associated with silica dust exposure. As yet, no curative treatment exists, but comprehensive management strategies help to improve quality of life and slow deterioration. Further efforts are needed for recognition and control of silica hazards, especially in developing countries.

Alpha-1-antitrypsin deficient man presenting with lung function decline associated with dust exposure: a case report

Introduction

People with α₁-antitrypsin deficiency are at increased risk for the development of chronic obstructive pulmonary disease. Previous retrospective epidemiologic studies have found that exposure to occupational dust among those with α₁-antitrypsin deficiency is a risk factor at the group level for poorer lung function, but on an individual clinical basis, a causal attribution can be difficult to establish.

Case presentation

We describe the case of a 68-year-old Caucasian man with a 25 pack-year smoking history who presented with new-onset dyspnea on exertion in the setting of workplace dust exposure. During his evaluation, he was found to have α₁-antitrypsin deficiency with evidence of development of pulmonary emphysema. Workplace spirometric monitoring over 10 years of surveillance for an on-the-job respirator fit program demonstrated a sharp downward slope in forced expiratory volume in one second, or FEV₁, during his periods of most significant dust exposure, which was attenuated after discontinuation of his workplace exposure.

Conclusion

Patients with α₁-antitrypsin disease should be assessed for occupational exposures and closely monitored for work-accelerated progression of lung function decline. More generally, this case report supports the biological plausibility of occupationally associated chronic obstructive pulmonary disease, underscoring that work-associated pulmonary disease can be multi-factorial.