What the ban on engineered stone means for mining
By now, you’ve probably heard of Australia’s groundbreaking move: the world’s first ban on engineered stone, which took effect on January 1, 2024.
This historic moment made headlines, but let’s peel back the layers and understand what’s really going on.
First off, what is engineered stone? It’s an artificial material created by combining a high percentage of finely crushed stone particle with a binding resin. The mixture is then put under a vacuum to remove air, catalysed and subject to vibration and pressure to form the final product.
The ban applies to engineered stone containing more than one per cent respirable crystalline silica. But wait, the replacement products are now labelled “zero silica” engineered stone. Sounds fancy, right? Well, here’s the twist: these new products still contain silica. The difference? The harmful respirable crystalline silica has been swapped out for recycled glass—amorphous silica, which is less hazardous to our lungs.
Now, why the fuss? Silica hazards have been on our radar for centuries, but the engineered stone industry’s silicosis surge caught us off guard. Silicosis, typically thought of as a slow-brewing disease over decades, was found in one in four engineered stone workers in one study. That’s a rate significantly higher than what we see in mining and many of these were younger workers with less than a decade in the industry.
But here’s where Australia shines. Remember the re-identification of black lung cases in Queensland? That wake-up call led to the development of top-notch health surveillance systems. Chest x-rays and spirometry became the norm. Silicosis, though, can be hard to spot – it shows up as tiny pinpoints which can be difficult to see on a regular x-ray. So, many workers were sent for CT scans, revealing silicosis more clearly.
Now, let’s talk danger. High quartz engineered stone is a perfect storm of health hazards. These contained very small particle sizes, hefty silica content, a range of metals, and resins. VOCs, or volatile organic compounds, have also been found in workplace exposure measurements which could come from a range of sources including the resins, glues and solvents – it’s a toxic cocktail. The very small particle sizes in engineered stone don’t help either, which in many cases are crushed to a size much smaller than normally found in natural stones.
Many workers were unaware of the risks. Unfortunately, dry cutting was routinely performed. This created not only an exposure for the worker doing the cutting, but created a dusty environment where workers would continue to breathe in the particles as long as they were in the area. Dry cutting has now been banned.
So why was Australia so quick to go for a ban? Engineered stone benchtops are vanity products. Alternatives abound, and manufacturers hold the reins. The industry has complete control over what goes into their products and will survive with the quartz ban. Some of the larger engineered stone suppliers had their alternative products ready to launch as soon as the ban was announced.
So what does this mean for mining? With its robust silica monitoring and control requirements, mining is ahead of the curve. We have a much better understanding of our silica risks and exposures. New legislation for Australia came into effect 1 September 2024, which now includes a ban on uncontrolled crystalline silica processing, requirements for silica risk control plans, and the reporting of workplace exceedance over the workplace limits. And it’s not just about engineered stone—it extends to construction and beyond.
But we as an industry must remain vigilant. As we chase critical minerals, new mines and processing facilities must silica-proof their processes. Some spodumene ores? Silica-rich. So, let’s mine smarter, breathe easier, and keep our lungs crystal-clear.
Further reading
Engineered stone is now banned. But how safe are the alternatives? (The Conversation)
Silica Resources Hub with more information on how to monitor and control silica dust (Australian Institute of Occupational Hygienists)