In May 2026, HSE updates to COSHH guidance for stone fabricators in the UK led to a ban on the dry cutting and polishing of engineered stone worktops. This places a greater focus than ever on factory processes and day-to-day workflows in stone fabrication environments, including the production of countertops. If changes haven’t been made already, then it is wise to start looking at it now. Not just for the fabrication of quartz worktops but as a best practice for working with any type of stone. It is not only essential for protecting workers from silica dust exposure and risks such as silicosis, but also for maintaining an efficient, productive and profitable stone fabrication factory, as well as looking after costly machinery.
Following the guidance change, the HSE announced a series of spot inspections across stone fabrication factories in the UK. No notice is given for these visits, and if your factory is deemed to be in breach of their guidance, you will be subject to immediate and severe enforcement action.
In this blog, we outline 14 key housekeeping practices to help protect both your employees and your business from the risks associated with dust exposure, including Respirable Crystalline Silica (RCS) Dust.
1. Basic housekeeping
A clear area without clutter is easier to keep clean and promotes good standards, as opposed to a messier work environment. Employ good processes like “Red Tag” systems and don’t allow work, remnants, spare parts and consumables to be left on one side. Everything in the factory should have a home. This simplifies cleaning down, stops dust gathering and limits slips, trips and fall risks.
2. Wash down the factory
All work areas and equipment should be cleaned daily. Less frequently-used equipment and additional workspaces should be cleaned at weekly, at the least. When cleaning down machinery, do not dry brush or use compressed air – these methods can agitate the dust, including silica dust, and it enters the air again. Instead, use wet cleaning methods and wash down with water. You need to make sure you have the correct drainage system in place in your factory, consisting of channels in which you can sweep the dirty water where it will then be collected in your pit or tank. You should then consider an efficient water treatment system which will collect your sludge safely and allow you to dispose of it responsibly, while providing you with a constant flow of clean, filtered water.
3. Never dry sweep
Dry sweeping must not happen in the factory. It causes silica dust to become airborne and increases exposure to risk. Where washing down with water is not possible, a H-Class vacuum should be used to collect dust safely and efficiently. Responsible factory practice is constituted of dust suppression and dust capture.
4. Monitor RCS exposure levels
Regular, professional, monitoring of silica dust levels is a requirement and helps identify high risk areas within the factory. The readings will allow you to implement measures in the correct locations to improve your overall dust management. External specialists can, and should, be employed to carry out this work. Alongside this it’s even possible to purchase mobile and wearable devices that monitor the levels of dust in the air surrounding you whilst you fabricate quartz, and other surface material, kitchen worktops.
5. Mitigate against spray
Even when working wet, water spray is a huge risk to fabricators. Dust-filled spray lands and dries, and the next movements in that area can reagitate it up into the air – making it a respiratory hazard once more.
To reduce this risk, ensure water is suppressed and collected during stone cutting and polishing. Baffle systems, splashguards or containment barriers can be used to close off certain areas, and tools should be fitted with suitable cowls and hoods to limit how much spray enters the air.
Again, monitoring of air quality helps identify areas of risk and can help you understand what plans and actions you will need to consider.
6. Keep your fabricators at full health
Regular health monitoring of your workers is important as an early warning measure, that can help protect against the long-term effects of silica dust exposure and diseases such as silicosis. Health surveillance can identify issues early on, and ensures your business is meeting its responsibilities. Some fabrication companies work with specialist occupational health providers to carry out regular checks and assessments. Bringing in external specialists also ensures that monitoring is carried out professionally and in line with HSE guidance. This doesn’t just help mitigate against the threat of silicosis either, identifying other occupational health risks in a stone workshop such as HAVS (Hand-Arm Vibration Syndrome), tinnitus, heart conditions and diabetes.
7. Decontaminate your fabricators
Regular decontamination throughout the day and at the end of shifts is essential. Consider providing special protective work clothing, that remains on site wherever possible. Many stone fabricator factories now are investing in laundry systems to ensure clean clothing is provided daily.
Clean and dirty changing areas should be kept separate to prevent dust from entering areas where risk mitigation has not been put in place, like the showroom, office and canteen. It is important that fabricators do not take dusty and contaminated clothing into vehicles or homes, due to the risk of spreading RCS dust to environments where others are present.
8. Maintain your dust collection and extraction systems
Dust extraction systems must be properly maintained, as they are constantly in use. Regular Local Exhaust Ventilation (LEV) inspections should be scheduled to ensure that your dust collection systems are in good working condition.
To assist with this, carry out regular cleaning of the ductwork and monitor the condition of the filters to ensure you aren’t putting too much pressure on the system, or overworking a full duct or filter.
9. Implement effective water suppression
Following updated HSE guidance, wet working is now compulsory when fabricating any kind of engineered stone or quartz due to risks posed by RCS Dust. As a result, working wet is now becoming a regular practice both in the factory and in the factory. Effective water suppression isn’t about just using water, it’s about controlling how the water is used and subsequently collected to prevent fine silica particles and mist from becoming airborne during countertop fabrication. Ensure you are using the right volume of water and directing it towards the cut or polish area.
10. Create zones to promote dust level awareness
Clear zoning within the factory helps reduce the spread of dust. This includes clearly separating and marking areas where dust will be more prominent (such as the factory), from spaces such as canteens, offices, and changing rooms where staff are less likely to be so conscious of the risk of dust inhalation.
Processes should be in place to ensure dust is not transferred between these areas.
11. Manage your water systems and slurry disposal
Water and slurry systems must be carefully managed. Once sludge dries up, it can break down and re-enter the air as RCS, increasing risk of exposure to conditions such as silicosis. Once sludge does dry, you must have a safe process in place to handle, remove and dispose of the dry blocks. Consider who you are using for your sludge disposal, to ensure they too are acting responsibly and protecting both your workers and their employees too.
12. Monitor the condition of your tools and equipment
Regular maintenance of tools and machinery is essential. Stone, natural or man-made, is highly abrasive, and this causes tool wear over time. Check that on-tool water suppression and mist control systems are working correctly and make sure you report any damage before use.
Often, blunt blades, routers and drills can increase dust and heat – even in wet working conditions. So, well-maintained tools not only promote safety but also increase overall efficiency and finish.
13. Control who enters your building
You should strictly manage access to your factory. All visitors, contractors, maintenance engineers and temporary workers should be checked before entering to check they do not bring any dust from other sites. They will also need to be inducted into your factory, so they know the rules, “go” or “no-go” areas.
14. Report dust incidents and near-misses
Dust related incidents and near misses should be recorded and investigated thoroughly – this includes failures in extraction systems, water supply issues, or non-compliance with RPE or PPE.
Keeping accurate records is essential for compliance and to assist with improving your processes.
There is a lot of difference guidance on these areas, and we know it may seem overwhelming to understand and implement. Every factory is set up in a different way and follows different processes for worktop fabrication, so we encourage you to reach out for support. Our team of specialists are on hand to offer support and guidance where needed. In addition to this, you can access a hub of resources, articles and videos on our Safe in Stone page on the website. Alternatively, contact us on info@stonegatetooling.co.uk or +44 (0) 1482 620400, for further guidance on how to ensure your factory is compliant with the recent HSE guidance.
