In stone fabrication, precision and quality are key, but beyond the hum of saws and CNCs, one critical thing often gets missed – dust.
Everyone in the stone industry should be aware of the threat to health that dust poses. The risks and consequences of silicosis and respirable crystalline silica (RCS) are well publicised by now and experienced fabricators will be all too familiar with the damage that dust, wet and dry, can cause to machinery.
Effective dust extraction and collection systems are not just a legal duty of the employer, they are essential in maintaining a safe work environment, ensuring the long life of machinery and protection of fabricators.
In this article, as part of our Safe in Stone campaign, we explore why organising proper dust management is crucial for all stone fabrication workshops. We’ll explore the methods and benefits of dust extraction and collection, as well as water suppression, PPE, factory hygiene and the consequences of taking this topic lightly.
Why is it important to extract and collect dust?
There are many reasons why extraction and collection of dust is vital in any stone workshop.
Firstly, the protection of workers. Stone dust generated through fabrication of materials contains harmful RCS. Long exposure to this dust can lead to very serious respiratory conditions, such as silicosis. Installing proper dust extraction systems reduces the number of particles in the air, limiting the risk of workers inhaling the hazardous substances, and maintaining compliance with safety regulations.
Gradual accumulation of dust can also cause a great deal of problems with machinery and tools. Fine dust particles can access the smallest of areas, including internal components of saws, grinders, polishers and other fabrication equipment, leading to wear and tear occurring quicker than usual. Generally, a build-up of dust in machines causes overheating and general failures, leading to costly repairs and downtime.
Not only is a dusty workshop not pleasant for workers, but it can also reduce productivity. When dust settles, it can reduce visibility, ruin accuracy and create a dirty atmosphere in general. Washing your factory down with clean water every morning and night means that any dried dust that has settled is then dampened and once you start work it won’t be reagitated into the air.
How can I reduce dust levels in my factory?
Depending on the size of your factory, what machines you are using and your way of working, there are a number of ways you can address the levels of dust in your factory. For the safest working conditions, we’d advise using a combination of the below methods.
The most effective way to extract dust is with a fixed extraction system, such as dust benches or water walls, which are designed to cover a particular area of a workshop – like where hand finishing is done. Water walls are very effective as they extract the dust from the atmosphere using powerful vacuums and collect it using running water. This prevents it from re-entering the workshop and, if a water filtration system is being used, it is then removed entirely and turned into sludge.
Another popular method to reduce dust levels is the use of wet dust suppression techniques, where water is sprayed onto stone during cutting, polishing or grinding. The use of water keeps the dust particles together, and helps prevent them from diffusing into the atmosphere, reducing the risk of the operator inhaling it.
Using Personal Protective Equipment and Respirable Protective Equipment is another way to help prevent over exposure to dangerous dusts such as RCS. Check out the full range of PPE that we supply, including full face masks such as the very popular Optrel Swiss Air Mask.
Good practice and the right systems
Maintaining your factory to a good standard is also key to limiting the amount of dust present. As previously mentioned, it’s good practice to wash down your entire factory with water at the beginning and end of every day, to prevent any dry settled dust from becoming reagitated. You could also look at providing a laundry service for your employees, to protect them from wearing clothing covered in stone dust and transferring it into an enclosed environment like their car or their home.
If you are washing down your factory every morning and night, make sure you do so with clean or filtered water. Filtering your water effectively extracts the stone dust, and this is important to keep your factory at a good, clean standard. Water filtration systems, like the Dal Prete Mini Compact range, separate foreign particulates from your factory water cycle before compressing and dry disposing of it, preventing it from re-entering the workshop environment.
Another method some fabricators use to limit the amount of dust entering the atmosphere is a dust control cowl with a vacuum attachment for use with power tools. This ensures the dust is extracted at source, and safely removed using rubber, plastic or polycarbonate fittings. Cowls are available in clear polycarbonate which ensures the cowl doesn’t obstruct visibility during cutting.
If you’re looking to actively monitor the dust levels in your factory, dust monitoring systems, like the Trolex range, can give you real time monitoring of the dust levels in your factory. These devices allow you to stay updated and if the levels reach an alarming level you can quickly identify the areas at risk and act quickly to mitigate against that risk. It’s important to be aware that the levels of dust will vary at different times in different areas of your factories, so you should seek advice on how best to use the dust monitoring system to keep your staff as safe as possible.
Putting health at the forefront of everything you do
Extraction and collection of stone dust in your workshop is crucial – primarily for the health of your workers, but also for the optimisation of your machinery, and cleanliness of your factory. As an employer, you have a responsibility to look after the welfare of your team, and do what is necessary to keep them happy, comfortable and safe in what they are doing. We recommend ensuring your employees have access to regular health check-ups to help monitor potential health risks like silicosis, but also other issues like Hand Arm Vibration Syndrome (HAVS) and Musculoskeletal Disorders (MSDs).
Check out our blog on dust safety and solutions for other methods of managing dust in your workshop, and how to deal with it: https://stonegatetooling.com/knowledge-base/dust-safety-awareness-and-solutions/
For a full range of blogs, videos and articles, visit our Safe In Stone campaign.
For further information, or enquiries, contact our team on +44 (0) 1482 620400 or [email protected]. Or, book to visit the Innovation Hub at Stonegate House, where you can see dust management systems in action.
