SAFE USAGE GUIDEMeasures to prevent Health Hazards Related to Silica Dust
Stone products like CoPA Surfaces surfaces pose no hazards during transportation, shipping, or consumer use. They are entirely safe for both domestic and commercial applications.
However, during fabrication processes, respirable crystalline silica (RCS) is generated, posing health risks to fabrication workers and others exposed to it continuously when safety protocols are not followed.
Hence, all fabrication of CoPA Surfaces surfaces must adhere to carefully controlled safety conditions. Fabrication processes may include cutting, grinding, chipping, sanding, drilling, polishing, installing, dismantling, and other tasks.
WHAT IS SILICA?
Crystalline silica commonly exists in nature as the mineral quartz and is present in granite, sandstone, quartzite, various rocks, and sand. It comprises silicon and oxygen (silicon dioxide; SiO2). It's also a component of everyday manufactured products like glass, pottery, countertops, and construction materials such as bricks, blocks, tiles, slabs, cement, ceramic, and concrete.
HAZARDS OF RESPIRABLE CRYSTALLINE SILICA
RCS particles are small enough to enter the lungs, leading to irreversible damage and potentially causing silicosis. Workers without proper protection are at risk of:
- Silicosis, an incurable lung disease that can lead to disability and death.
- Lung cancer.
- Chronic obstructive pulmonary disease (COPD); and
- Kidney disease.
Cutting stone, as pictured, generates dangerous crystalline silica dust that can become trapped in lung tissue and cause silicosis.
WHAT IS SILICOSIS?
Silicosis is an occupational lung disease affecting workers in stone fabrication and construction industries, among others. It's an incurable, progressively disabling, and sometimes fatal lung condition caused by prolonged exposure to RCS particles smaller than 10 microns. These particles get trapped in lung tissue, causing inflammation and scarring, reducing the lungs' oxygen intake capacity. Symptoms include progressive shortness of breath, cough, and fatigue. Silicosis has chronic, accelerated, and acute clinical forms, largely depending on exposure intensity and duration.
CALIFORNIA PROPOSITION 65
WARNING: This product contains chemicals, including silica and titanium dioxide, which become airborne and respirable during fabrication and are classified by the State of California as carcinogens and reproductive toxins. For more information, visit www.p65warnings.ca.gov.
PERMISSIBLE EXPOSURE LIMIT, ACTION LEVEL & THRESHOLD LIMIT VALUES
The Permissible Exposure Limit (PEL) is the legally allowable safety limit
set by each state or geographic region, above which RCS exposure is
prohibited. The Action Level (AL) is typically half the PEL value and
triggers certain mandatory activities like RCS monitoring and medical
surveillance. Threshold Limit Values (TLVs®) are recommendations by
the American Conference of Governmental Industrial Hygienists
(ACGIH®).
ACGIH® suggests that exposure at or below the TLV® level
doesn't pose an unreasonable risk of disease or injury, assuming an
8-hour daily time-weighted average exposure over a working lifetime.
The ACGIH® TLV® for RCS is 0.025 mg/m3. PELs for RCS are under
review worldwide.
As of March 25, 2016, the USA Occupational Safety
and Health Administration (OSHA) revised the PEL for RCS in the USA to
0.05 mg/m3 with an AL of 0.025 mg/m3. Consult occupational health
and safety experts to minimize exposure levels in your workplace.
AIRBORNE DUST MONITORING
Employers must assess the RCS exposure of workers if it's at or above the Action Level averaged over an 8-hour day. Assess the RCS level in the workplace through air sampling and analysis in collaboration with occupational health and safety experts. Ensure monitoring covers areas beyond fabrication sites, such as offices and storage areas, exposed to RCS. Share results with employees to encourage compliance with safety protocols.
| STONE | AVERAGE % SÍLICA |
|---|---|
| Engineered stone | ≥93 |
| Quartzite | 95 |
| Quartzitic sandstone | 90 |
| Sandstone | 60 |
| Granite | 10 - 45 |
| Marble | 5 - 30 |
| Slate | Varies |
| Soapstone | Varies |
Sources: Silica Hazards from Engineered Stone Countertops, NIOSH Science Blog, March 2014; ASTM C616, Standard Specification for Quartz-Based Dimension Stone; American Geological Institute, Dictionary of Geological Terms
REDUCING RESPIRABLE CRYSTALLINE SILICA
Water-integrated Machinery & Tools
Dry cutting, grinding, or polishing CoPA Surfaces surfaces generates RCS. Properly designed water-integrated tools and machinery significantly reduce RCS levels and should be used for all cutting, grinding, and shaping tasks. It's crucial to note that water-integrated rotating tools produce RCS-contaminated water mist, which can be dispersed and inhaled. Hence, Respiratory Protective Equipment (RPE) may be necessary even when using water-integrated tools.
CNC Machines
CNC machines, such as waterjet cutters and automated sawing machines, offer faster, safer, and more accurate operations compared to manual saws. Always use safety doors to prevent dust dispersal and maintain a safe distance between the operator and the dust source.
Manual Tools
When using manual tools, the operator's breathing zone is close to the dust source, leading to high RCS levels. Implement the following safety procedures:
- Use water-integrated manual tools whenever possible.
- Prevent RCS-contaminated water mist dispersion by using guards, plastic flaps, or brush guards.
- Adjust air and water pressure to ensure optimal water usage on the slab, preventing dry RCS or RCS-contaminated water mist dispersion.
- Wear a half-face respirator when using manual tools.
VENTILATION SYSTEM
Proper ventilation is essential for a safe and healthy workspace for you and your employees.
General Workspace Ventilation
Ventilation systems introduce fresh air and dilute contaminants in the workplace, aiming for at least six air exchanges per hour. Ensure extracted air is released safely away from doors and windows according to local regulations
Local Exhaust Ventilation
Local Exhaust Ventilation (LEV) captures RCS at the source, transporting it away from the worker's breathing zone to prevent inhalation and minimize workplace air contamination. Install LEV systems connected to dust extraction units like bag filters or cyclones at all workstations.
Manual Tools Dust Collection
When dry manual tools must be used, employ a dedicated dust collection attachment connected to the tool and a high-efficiency particulate air (HEPA) vacuum. This is critical as the operator's breathing zone is close to the dust source.
Standing Fans
Avoid using standing fans as they can disperse settled or airborne dust, contaminating clean areas or the work environment.
Isolating Workers from Dust-Generating Processes
Maintain distance from the work process to reduce RCS exposure whenever possible. Ensure workers using powered hand tools are separated from others to prevent exposure to RCS generated by their activities. Use physical barriers between workstations to prevent RCS-contaminated water mist from spreading.
PERSONAL PROTECTIVE EQUIPMENT (PPE)
PPE should be used to protect workers in all fabrication plant, installation sites, and related work areas. This includes general PPE and RPE, all meeting regulatory standards.
Mandatory Use
Employers must provide PPE to workers in hazardous workplaces and ensure its use. Access to hazardous areas should be restricted to authorized workers equipped with the necessary PPE, clearly marked with appropriate signage.
Equipment Compliance & Maintenance
Follow manufacturer instructions and regulations for the use, checking, cleaning, maintenance, and storage of PPE.
Training
Provide training to employees and outsourced workers on the fitting, selection, adaptation, use, and maintenance of all PPE.
Record Keeping
Maintain records of all PPE used, training, and maintenance checks to demonstrate compliance with safety requirements. The following equipment should be worn in the fabrication plant and installation sites:
- Hair covering to contain long hair
- Safety helmet during handling and transporting
- Nonslip, steel-capped safety shoes.
- Dust mask.
- Safety glasses or approved eye protection.
- Earplugs in noisy areas.
- Gloves for chemical or rough material protection.
- In wet areas, aprons and steel-capped rubber boots in addition to the above.
Isolating Workers from Dust-Generating Processes
Maintain distance from the work process to reduce RCS exposure whenever possible. Ensure workers using powered hand tools are separated from others to prevent exposure to RCS generated by their activities. Use physical barriers between workstations to prevent RCS-contaminated water mist from spreading.
DISAPOSABLE MASK
HALF FACE RESPIRATOR
Respiratory Protective Equipment (RPE)
In hazardous areas with RCS, RPE should be used to enhance worker protection. Various types of RPE are available for different materials and exposure levels. An occupational health and safety professional should determine the appropriate RPE based on RCS concentrations and other considerations.
However, the use of RPE does not exempt the employer from keeping RCS levels as low as reasonably practicable, ideally below the required PEL, by employing water-integrated tools, LEV, and other engineering controls. Implement and enforce policies for all workers to wear RPE in areas with potential hazardous dust exposure.
Types of (RPE)
Three common types of RPE include Powered Air Purifying Respirators (PAPR), half face respirators, and disposable dust masks. PAPR and half face respirators offer higher protection levels than disposable dust masks.
The manufacturer's instructions specify the appropriate level of RCS protection, fitting procedures, and duration of use. Consult with experts for guidance if instructions are unavailable.
When to Use Each Type of RPE (RPE)
Use a half face respirator:
- During wet manual tool fabrication in the plant.
- When near locations generating RCS.
- At installation sites during dust-producing modifications.
Use a disposable mask:
- In areas far from RCS generation, such as during floor and machinery washing with running water or near CNC machines connected to exhaust ventilation systems.
Use PAPR:
- In cases of unknown exposure levels or extreme RCS levels.
- If the worker has facial hair.
- Ensure RPE compliance with local regulations.
Replacing Disposable Dust Masks
Masks marked "NR" (not reusable) are for single-shift use, while "R" (reusable) masks can be used for multiple shifts per manufacturer instructions. Ensure disposable dust masks conform to standard EN 149:2001.
| FILTER | PROTECTION FROM AIRBORNE PARTICLES |
|---|---|
| P1 | 80% |
| P2 | 90% |
| P3 | 99.95% |
| N95 | 95% |
| N99 | 99% |
| N100 | 99.97% |
Replacing Filters in Half Face Respirators
Typically, replace filters every 6 months following the manufacturer's instructions.
Filter Specifications
RPE filters are classified as P1, P2, and P3, or N95, N99, and N100, indicating increasing filtration efficiency. Use P3 or N95 filters for disposable masks and half face respirators, or higher (N99, N100) for better protection.
Fitting
Fit test each worker with a half face respirator before initial use and check the seal each time they wear it. Workers with facial hair should use PAPR or other suitable alternatives as facial hair can compromise the seal.
Medical Evaluation
Workers should undergo medical evaluations to determine their suitability for wearing RPE. Consult with occupational health and safety professionals to meet local evaluation requirements.
Storage
Follow manufacturer instructions for storing RPE. Storing RPE improperly increases the risk of exposure to RCS and deteriorates the equipment.
Cleaning & Dust Disposal
Regular cleaning methods minimize RCS spread and contribute to a safer work environment. Establish a daily cleaning schedule, and employ low-pressure wet hosing, wet sweeping, or HEPA vacuum systems for cleaning. Promptly clean wet or dry sludge to prevent airborne dust. Provide adequate vacuum and water connection points for effective cleaning and maintain drainage systems. Dispose of wet sludge in sealed containers to prevent drying and airborne dispersion, adhering to state-specific waste disposal regulations. Contact relevant environmental agencies for further guidance on construction waste disposal, particularly dust containing silica.
GENERAL SAFETY
CoPA Surfaces prioritizes creating a safe work environment and expects distributors, fabricators, and installers to uphold the same commitment to safety and comply with local occupational health regulations. Fabricating CoPA Surfaces produces respirable dust that poses health risks. For detailed information and protective measures, refer to the CoPA Surfaces Safe Usage Guide - Measures to Prevent Health Hazards Related to Crystalline Silica Dust at: CoPA Surfaces.com.
Housekeeping
Regularly maintain cleanliness in the workspace to prevent hazards from arising due to untidiness.
Keep Well Ventilated
Ensure proper ventilation and lighting in work areas to maintain a conducive working environment.
Authorized Personnel Only
Limit access to the work area to authorized personnel and workers.
Proper Footing
Maintain balance and proper footing to avoid accidents.
First-Aid Kit
Always have a fully equipped first-aid kit suitable for the tasks conducted onsite.
Read Instructions
Familiarize yourself with the instruction manuals of tools used, understanding their applications, maintenance, limitations, and potential hazards.
Use Appropriate Tools
Use tools and attachments according to manufacturer recommendations, avoiding misuse or improvisation.
Maintain Tools
Ensure all tools are in good working condition and serviced per manufacturer recommendations.
Protective Apparel
Wear the following protective gear when fabricating CoPA Surfaces:
Helmet & Hair Covering:
Use a helmet and hair covering to contain long hair during handling and transportation.
Hearing Protection:
Wear appropriate hearing protection in noisy areas.
Respiratory Protective Equipment (RPE):
Use a disposable dust mask with P3/N95 filter, fit-tested half face respirator with P3/N95 filters or higher, or a Powered Air Purifying Respirator (PAPR) suitable for working conditions.
Safety Goggles:
Use safety glasses or approved eye protection.
Gloves:
Wear gloves for protection against chemicals or rough materials.
Safety Shoes:
Use nonslip, steel-capped safety shoes; in wet areas, wear steel-capped rubber boots in addition to safety shoes.
Required Equipment
Ensure the availability of the following equipment:
- General ventilation system.
- Local exhaust ventilation.
- Water recycling system.
- Forklift or other lifting device.
- Fabrication workbenches in various sizes.
- Stone carts/dollies.
- Storage racks or A-frame.
Wet Cutting Machinery
Use one of the following for cutting slabs:
- Combined waterjet and diamond blade saw (CNC)
- Waterjet (CNC).
- Automated bridge saw (CNC).
Disclaimers
This Guide is intended for use by individuals with expertise, professional
experience, and technical skills, at their discretion and risk. CoPA Surfaces assumes
no responsibility and disclaims all liability for any harmful effects resulting from
the fabrication and installation of our products.
The information and recommendations in this Guide are based on data
believed to be correct as of the publication date, relying on our knowledge,
experience, and that of our professional partners. While every precaution has
been taken in its preparation, we assume no responsibility for errors or
omissions, or for damages resulting from the use of information contained
herein.
Professional judgment should be applied before performing any actions based
on the instructions in this Guide, and a prior trial should be conducted before
performing any actions for the first time. CoPA Surfaces representatives are
available to address any questions.
This Guide should not be considered a comprehensive list, interpretation, or
summary of any laws, standards, rules, orders, or safety requirements.
Fabricators and installers of CoPA Surfaces slabs must be familiar with relevant local
laws and standards, including Occupational Health and Safety laws and
environmental protection laws.
No guarantee or warranty of any kind, express or implied, is made regarding
merchantability, fitness for a particular purpose, or otherwise.
NOTICE - HAZARDOUS SILICA DUST
CoPA Surfaces products contain crystalline silica (up to 90%). Processing these products generates crystalline silica dust, which, when inhaled over prolonged periods, can cause silicosis and other serious lung diseases. Implement all safety measures before processing this product.
For more information about product characteristics, risks, and safety measures, refer to CoPA Surfaces's Safety Data Sheet and Safe Usage Guide - Measure to Prevent Health Hazards Related to Crystalline Silica Dust at: copasurfaces.com