Case Study: Kitchen Worktops & Silica Exposure: An In-Depth Occupational Health Risk Assessment

Background

In the kitchen and untility worktops industry, one of the most concerning occupational health hazards is exposure to Respirable Crystalline Silica (RCS). Silica is a natural substance found in varying amounts in most rocks, sand and clay, and in products such as bricks and concrete. In the stonemasonry sector, operations such as sanding, cutting, grinding, or polishing stone materials can generate fine dust containing RCS.

Respirable crystalline silica is a particular concern due to its ability to be inhaled deeply into the lungs. Once in the respiratory system, these tiny particles are difficult to clear, and over time, they can cause significant health problems. Long-term exposure to RCS can lead to the development of severe and debilitating diseases. One of the most significant of these is silicosis, an irreversible and sometimes fatal lung disease. Continued exposure to RCS can also lead to lung cancer and has been associated with other diseases, such as tuberculosis, kidney disease, and autoimmune disorders.

Given the severe health effects of RCS, it is classified as a Group 1 carcinogen by the International Agency for Research on Cancer (IARC), indicating sufficient evidence to show it can cause cancer in humans.

Due to this, the exposure to RCS is subject to stringent regulatory controls. In the United Kingdom, the Health and Safety Executive (HSE) enforces stringent standards for occupational exposure to respirable crystalline silica. The Control of Substances Hazardous to Health (COSHH) Regulations 2002 (as amended) has established Workplace Exposure Limits (WELs) that should not be exceeded.However, companies need to aim for more than just compliance with these limits. The focus should be on minimising the exposure of their employees to RCS as far as reasonably practicable.
 
In this context, the stonemasonry company in question has developed a robust occupational exposure monitoring programme. This programme not only ensures that exposure to RCS stays within regulated limits but also promotes proactive measures to mitigate risks, keeping the exposure as low as reasonably possible, recognising the severity of potential health implications.

Methodology

 
The chosen sampling methodology for the company's occupational exposure monitoring programme is in alignment with the methods prescribed by the Health and Safety Executive (HSE) in the United Kingdom. Specifically, it follows the guidance outlined in the HSE's Methods for the Determination of Hazardous Substances (MDHS).
 
For the detection and quantification of respirable crystalline silica (RCS), the company adopts the MDHS 101 method. According to this procedure, personal air samples are collected via a cyclone separator attached to the worker's breathing zone, trapping the respirable dust fraction on a pre-weighed filter. Post-sampling, the filters are sent to a lab, where they are analysed for RCS content using Fourier-transform infrared spectroscopy (FTIR) or X-ray diffraction (XRD). This method enables precise measurement of RCS concentration in the air, thereby ensuring worker exposure is kept within the defined Workplace Exposure Limits (WELs).
 
Regarding Volatile Organic Compounds (VOCs), the company employs the methodology stated in the MDHS 96. Personal air samples are collected in specially prepared containers known as Tenax tubes, which are designed to absorb VOCs present in the air. These samples are then analysed using Thermal Desorption Gas Chromatography-Mass Spectrometry (TD-GC-MS). This technique allows for the identification and quantification of a wide range of VOCs, including those generated in stone finishing processes.
 
By adhering to these MDHS methods, the company ensures that it's accurately assessing the exposure of its employees to RCS and VOCs, and thereby, effectively protecting their health and safety in compliance with regulatory requirements.
 

Observations

 
In the onsite observations, it was noted that the company had various processes in place to reduce the risk of exposure to harmful substances. For instance, the company had established controlled work zones to limit the spread of dust generated from cutting and polishing activities. Ventilation systems were also in place to remove dust particles from the work areas. In terms of personal protective equipment (PPE), workers were observed wearing dust masks and other appropriate gear to further reduce the potential for exposure.
 
However, certain areas for improvement were identified. First, it was observed that the ventilation systems, although functional, were not optimally designed to capture and remove all dust particles. Some systems were inadequately sized for the operations they were meant to serve, leading to potential areas where dust accumulation could occur.
 
Second, it was found that while workers were wearing PPE, the masks provided were not always the appropriate type for the nature of the dust produced, specifically when dealing with respirable crystalline silica.
 
The observations also highlighted that while measures to mitigate exposure to volatile organic compounds (VOCs) were in place, such as using low VOC materials and keeping containers sealed when not in use, the consistency of these practices varied across the site. Overall, the observation phase emphasised the need for continual improvement and regular review of implemented control measures.

Value Delivered and Recommendations

 
The comprehensive assessment delivered considerable value to the customer. The primary value proposition was the detailed and scientific analysis of the potential health risks associated with respirable crystalline silica and volatile organic compounds exposure. This analysis shed light on areas of the company's operations that required immediate attention and areas where they were effectively managing risks.
 
The assessment also provided a basis for strategic decision-making. By identifying shortcomings in the ventilation systems and PPE, the customer was able to re-evaluate and upgrade these critical components of their workplace safety protocol. Our recommendations for redesigning ventilation systems and providing suitable PPE led to immediate actions, enhancing the safety of the work environment and potentially reducing the risk of occupational diseases.
 
Moreover, we emphasized the importance of consistency in implementing safety practices to limit exposure to VOCs. The company agreed to ensure regular training and compliance checks, leading to improved work practices and a reduction in potential health risks.
 
The comprehensive report also served as a reminder for the company about the importance of continuous improvement and regular review of safety measures. By adhering to these practices, the company can better ensure the health and safety of its employees while minimizing potential liabilities related to occupational health and safety.
 
In conclusion, our thorough investigation, detailed analysis, and practical recommendations provided the company with the necessary information and guidance to enhance its safety protocols, reinforcing its commitment to employee health and safety.