Health and safety experts are warning that many UK workplaces are unknowingly exposing staff to dangerous levels of silica dust — a material responsible for an irreversible and sometimes fatal lung disease.
According to Peninsula UK, a provider of employment law and health and safety services, silica dust is present in countless industrial and domestic settings, from construction sites to kitchen worktops. Artificial stone, which can contain over 90 percent silica, poses the highest risk, while natural materials such as marble and granite contain far less.
At least 45 cases of silicosis have been recorded in the UK, with two deaths already confirmed this year. Experts say the disease is entirely preventable if employers follow their legal responsibilities under the Control of Substances Hazardous to Health Regulations (COSHH).
A Preventable Occupational Hazard
Silica dust is produced when materials such as concrete, brick, stone, tiles and mortar are cut, drilled or polished — common in construction, manufacturing and fabrication. Toni Houghton, health and safety advice and content manager at Peninsula, said the danger lies in the particle’s microscopic size.
“Silica dust and silicosis are intrinsically linked,” she said. “Respirable crystalline silica is released during routine work and can lodge deep in the lungs, where it causes inflammation and scarring. This process leads directly to silicosis, a progressive and irreversible lung disease of which there is no cure.”
Houghton said silicosis can develop in three forms — chronic, accelerated and acute — depending on exposure levels and duration. “Chronic silicosis results from long-term exposure at lower levels. Accelerated silicosis arises from higher exposures over shorter periods, while acute silicosis can develop within months following intense exposures and may be rapidly fatal,” she explained. “All three are preventable. None are reversible.”
Employer Duties Under UK Law
The Health and Safety Executive (HSE) classifies respirable crystalline silica as a hazardous substance under COSHH, requiring employers to assess risks and eliminate exposure wherever possible. Houghton said too many organisations still treat compliance as a paperwork exercise rather than a matter of life and death.
“UK law does not treat silica exposure as a grey area,” she said. “Employers must assess the risk, eliminate exposure and implement effective controls where elimination is not possible. Engineering controls come first. Wet cutting, on-tool extraction, local exhaust ventilation and controlled work methods are fundamental. Respiratory protective equipment is a last line of defence, not a primary control, and must be supported by face-fit testing, training and supervision.”
Houghton warned that failures to manage dust properly can have devastating consequences. “Silicosis does not indicate bad luck; it indicates failed systems, weak enforcement or deliberate shortcuts. Silica dust management is not about compliance optics; it is about preventing a predictable, permanent disease.”
Workplace Wellbeing and Long-Term Health Risks
Occupational health professionals are increasingly concerned that the risks of silica dust extend beyond traditional heavy industry. Fabrication plants, property maintenance firms and even home improvement workshops can expose workers to the same dangers if proper ventilation and dust control systems are not in place.
Medical experts link silicosis to a heightened risk of chronic obstructive pulmonary disease (COPD), lung infections and cancer. Once symptoms appear — such as breathlessness, fatigue or persistent coughing — the damage is usually irreversible.
Workplace wellbeing managers are being urged to treat silica control as part of wider employee health strategies, ensuring early education, training and medical monitoring for at-risk staff. Health surveillance is mandatory for employees exposed to silica dust, including regular lung function tests and medical assessments.
Building a Culture of Prevention
The HSE says thousands of UK workers could be inhaling dangerous levels of dust every day, despite existing regulations. Recent inspections have found widespread failures to maintain dust extraction systems, provide suitable respiratory protection or monitor exposure levels.
Experts recommend that employers carry out detailed risk assessments and invest in modern dust suppression equipment. Worker engagement is also critical, and employees should be trained to recognise risks and empowered to report unsafe practices.
Houghton said long-term prevention depends on leadership accountability. “Employers must treat silica dust as seriously as any other occupational hazard,” she said. “Engineering controls, proper supervision and consistent health monitoring save lives. Silicosis is entirely preventable, but only if we stop treating it as an invisible risk.”