Introduction
A growing number of serious and life-changing health cases linked to engineered stone dust exposure have prompted the Health and Safety Executive (HSE) to strengthen its guidance on how this material must be worked with.
Engineered stone is widely used in modern construction, particularly for kitchen and bathroom worktops. However, investigations into worker illness and enforcement action have highlighted that poor control of dust during cutting and fabrication can result in severe and often irreversible health conditions.
Incident and Enforcement Overview
HSE enforcement activity has already demonstrated the consequences of failing to manage silica dust risks effectively.
In one case, a stone worktop manufacturer was fined £60,000 after repeatedly failing to protect workers from exposure to hazardous dust. Inspectors identified widespread accumulation of stone dust across the workshop, alongside a lack of effective control measures and poor health and safety management.
The company was prosecuted for breaching the Health and Safety at Work Act and the Control of Substances Hazardous to Health (COSHH) Regulations. This case reinforces that inadequate control of exposure to respirable crystalline silica (RCS) is not only a health risk—but a clear legal failure.
More broadly, HSE research and international evidence have identified cases of workers developing serious lung disease, including accelerated silicosis, after relatively short exposure periods. These findings have been a key driver behind the changes to guidance.
Why the Risk is So Serious
Engineered stone can contain up to 95% crystalline silica, which is significantly higher than many natural materials. When it is cut, ground or polished, fine respirable dust is released that can penetrate deep into the lungs.
Exposure to this dust can lead to serious diseases, including:
- Silicosis
- Chronic obstructive pulmonary disease (COPD)
- Lung cancer
Unlike traditional silica-related illness, which may develop over decades, exposure from engineered stone has been linked to faster-developing or “accelerated” silicosis, sometimes occurring within just a few years.
What Has Changed?
In response to this evidence, HSE issued updated guidance in May 2026 which significantly strengthens expectations for controlling dust exposure.
The key changes include:
- Dry cutting of engineered stone is now considered unacceptable
- Water suppression must be used during cutting and fabrication
- Employers should consider using lower-silica materials where possible
- Effective control of airborne dust and mist is required
- Suitable respiratory protective equipment (RPE) must be provided
- Health surveillance must be in place for exposed workers
These expectations are framed as legal requirements under COSHH rather than optional best practice.
Regulatory Focus and Inspections
Alongside the updated guidance, HSE has launched a targeted inspection programme across the engineered stone sector.
Inspectors are carrying out more than 1,000 inspections nationally to assess how well businesses are controlling silica dust risks, with enforcement action expected where standards are not met.
This forms part of HSE’s wider approach to ensuring that businesses understand and comply with their legal duties to protect worker health.
HSE campaign and inspection programme
Alongside the new guidance, HSE has launched a nationwide inspection programme targeting the engineered stone sector. As part of this initiative, inspectors are carrying out more than 1,000 inspections across Great Britain over a 12‑month period.
This campaign is part of HSE’s wider “Work Right” approach, focusing on ensuring that businesses understand and meet their legal responsibilities. Inspectors are specifically looking at how effectively employers control silica dust risks, and enforcement action will be taken against those who do not comply.
The regulator has made it clear that expectations are now explicit, and non-compliance will not be tolerated.
Summary
The changes to engineered stone guidance have been driven by real-world cases of serious illness and enforcement action highlighting failures to control exposure to silica dust.
The message from HSE is clear: businesses must take a proactive approach to eliminating or controlling dust risks and ensure that robust, effective controls are in place.
Failure to do so not only puts workers at risk of life-changing disease but exposes organisations to significant legal and financial consequences.
Brainbox + Question
Is water suppression really needed when manufacturing stone worktops?
Yes, water suppression is essential when manufacturing stone worktops, particularly those made from engineered stone, to control the generation of respirable crystalline silica (RCS) dust. This is a critical health and safety requirement due to the significant risks associated with silica dust exposure.
Here’s why water suppression is necessary:
- Dust Control: Cutting, grinding, or shaping engineered stone produces extremely fine silica dust particles that can be easily inhaled. Water suppression effectively reduces the amount of dust released into the air by wetting the material during these processes, making it less likely for the dust to become airborne.
- Health Protection: Exposure to RCS dust can cause severe and irreversible health conditions such as silicosis, chronic obstructive pulmonary disease (COPD), lung cancer, and other respiratory diseases. Water suppression minimises workers' exposure to these harmful particles.
- Regulatory Compliance: Employers are legally required to eliminate or control exposure to hazardous substances, such as silica dust, under health and safety legislation. Water suppression is a key engineering control measure to ensure compliance with these requirements and reduce risks to workers.
- Effectiveness Compared to Other Methods: Water suppression is considered more effective than dry cutting or grinding, especially when combined with other controls like local exhaust ventilation. It can significantly reduce the concentration of respirable dust in the work environment.
- HSE Expectations: The Health and Safety Executive (HSE) has emphasised the importance of using water suppression systems as part of its revised guidance on working with engineered stone. Failure to implement such measures may result in enforcement action.
In practice, water suppression systems should be well-maintained, use an adequate water supply, and ensure that workers are trained in their proper use. Additionally, employers must implement further measures such as local exhaust ventilation, personal protective equipment (PPE), and regular housekeeping to manage silica dust risks effectively.
